基于同质设备多台配置的独立生产单元构建决策

单元化生产作为一种较好实现生产柔性与生产效率融合的先进生产方式,在变种变量需求环境下它已被大量生产企业特别是装配式生产企业所采用。生产单元构建问题是单元化生产系统设计的关键问题和首要问题,也是单元化生产研究领域的一个热点。本文研究设备易复制情形下,通过配置多台同质设备来实现生产单元间无物料移动,并保证生产单元间工作量均衡的独立生产单元构建问题。本文在综合考虑换装时间、加工顺序、设备生产能力、产品需求量等多个实际生产要素的基础上,建立了以平均总流程时间和各生产单元总流程时间与平均总流程时间偏差最小为目标的数学模型,并开发了一个启发式算法来求解数学模型,最后通过数值算例验证了模型和算法的有效性。     

Semi-interchangeable machines: implications for workload control

Workload control (WLC) is developed as a production planning and control concept for make-to-order job shops. Effective WLC requires a profound decision regarding order release to allow balancing the workload across capacity groups. WLC design has to reflect the company characteristics, especially machine characteristics. In practice, machines that perform the same type of operations are generally not completely identical but semi-interchangeable. The importance of the load balancing function requires careful consideration of semi-interchangeability within WLC. This paper develops different control alternatives to deal with semi-interchangeability and tests them in a simulation study. The results of the study indicate that the most intuitive control option—grouping semi-interchangeable machines into a single capacity group and making the routeing decision at dispatching—does not give the best performance, despite the advantages of pooling synergy. For a low degree of interchangeability it is more attractive to place semi-interchangeable machines in separate capacity groups and to make a routeing decision at order release. This enables more detailed load balancing resulting in shorter throughput times. More generally, it is shown to be advantageous to postpone the final routeing decision until dispatching, though considering separate capacity groups for a preliminary routeing decision at the time of release.     

Workload Balancing Through Recurrent Subcontracting

We model a situation where a firm wishes to balance workload requirements by creating a portfolio of recurrent insourcing and outsourcing contracts. We use harmonic analysis to decompose an input workload profile into a portfolio of insourcing and outsourcing contracts using rectangular‐wave basis functions to better achieve some desired constant workload level. However, this initial selection of contracts may result in impractical options. Therefore, we also develop mathematical programs using principles from goal programming and integer programming to refine the portfolio of contracts to more accurately reflect a realistic environment by placing constraints on the available contracts and explicitly considering operational costs. We consider several modeling extensions including the ability to hold limited amounts of inventory and the use of one‐shot contracts to supplement our portfolio of recurrent contracts.     

A decision support system for modelling and implementing the supply network configuration and operations scheduling problem in the machine tool industry

This paper presents a decision support system to simultaneously solve the supply network configuration problem and the operations scheduling problem for the machine tool industry. A novel database structure, which is able to consider alternative operations and alternative bills of material, has been used. An algorithm for complete enumeration to determine all the feasible solutions using stroke graphs is introduced. A multiagent-based simulator evaluates the different key performance indicators that the supply network deals with for each alternative solution (e.g. workload, profits, delivery times, etc.) to determine that ‘satisficed’ by the collaborative decision-making among its members. A case study based on a Spanish company that assembles highly customised machines and tools in several European plants is considered. From the experiments results based on data linked to this industry, it will be demonstrated that the tool is potentially useful for stakeholders and for the central decision-maker to make decisions collaboratively in a multisite context case.     

Review and reappraisal of modelling and predicting mental workload in single- and multi-task environments

The concept of mental workload has long been recognized as an important factor in individual performance within complex systems. It is documented that either overload or underload may degrade performance, and further affect the efficiency of the whole system. Therefore, systems designers need some explicit models to predict the mental workload imposed on individuals by the system at an early design phase so that alternative system designs can be evaluated. In examining mental-workload literature, it is found that few predictive mental-workload models have considered factors specific to individuals. This research aims to develop a practical framework for predicting mental workload in both single- and multi-task environments considering such individual factors. In order to describe mental workload more precisely and more completely, a framework for mentalworkload definitions, which contains instantaneous workload, average workload, accumulated workload, peak workload and overall workload, is proposed. In order to model individual factors, two new variables, i.e. effective workload and ineffective workload, are introduced to model the taskgenerated workload and individual-generated workload. The extension of the model to multi-task environments is also discussed. The proposed conceptual models are domain-independent and could be used to guide the development of operational models for different specific tasks.     

Job route selection model for workload balancing between workstations in flexible flow line

A flexible flow line (FFL) consists of several groups of identical machines. All work-orders flow along the same path through successive machine groups. Thus, the balancing of workloads between machine groups in order to maximize total productivity is emphasized. On the other hand, many different types of work-orders, in varying batch or lot sizes, are produced simultaneously. The mix of work-orders, their lot sizes, and the sequence in which they are produced affect the workload. However, the work-orders and their lot sizes are pre-fixed and cannot be changed. Because of these reasons, an optimal route selection model has been developed using heuristic search and a min-max algorithm for balancing the workload between machine groups in the FFL.     

Computer-aided development of flexible batch production recipes

In this paper an approach to model-based batch process quality control and optimization using flexible production recipes is presented. Unlike the fixed recipes traditionally used in process industries, a flexible recipe depends on externally provided data from the process as well as the market. In order to manipulate a flexible recipe in a proper and convenient way, the information system FRIS—containing modules for experiment design, recipe initialization and correction, on-line process and off-line experiment evaluation, model development and recipe improvement—is being developed. Each of these functions will be discussed further.     

Integration between flow scheduling and personnel allocation in a parallel line system in automotive industry

A state-of-the-art review over fifty years of flow shop scheduling research, written by Gupta and Stafford (2006), comes to the conclusion that the mathematical theory of flow shop scheduling “suffers from too much abstraction and too little application”. In this paper we will develop an extended mathematical model for flow shop scheduling with parallel lines and simultaneously a worker assignment to machines as well as a solution concept for practical use. Such production systems are realized by applying the BTO-(Build to order) concept, as can be found in the automotive or computer industry, which allows customers to make any changes to their vehicles or hardware configuration within a few days before final assembly. In these cases late configuration is an important task for the producer and a complex scheduling problem arises in this context.     

基于DNA遗传算法的表面贴装生产线负荷优化分配

印制电路板组装任务的负荷优化分配包含设备约束、工艺约束等大量约束,是电子行业表面贴装生产线中的一类重要优化问题。其优化目标是在生产节拍给定和一定约束条件下,使得不同贴装机负荷均衡,任务分配达到最优。首先,根据不同表面贴装机、不同吸嘴及多种类型元件匹配的的复杂性,提出贴装机任务分配组合优化的问题;然后分析设备和元件的参数、组装可行性、贴装时间,以及贴装优化关系等因素,并提出假设条件,建立了平衡率最大化条件下的负荷分配组合优化的数学模型;最后,针对贴装生产线负荷分配问题的复杂性与特殊性,通过改良编码方式后的DNA遗传算法来优化组合数学模型,计算适应度,并借助MATLAB进行仿真求解,进而找到最优解。结果表明：本文提出的贴装生产线负荷分配方法可以解决带复杂约束的印制电路板组装负荷优化分配问题,提高设备的平衡率和生产效率,促进生产线的优化运行。     

Route‐Independent Analysis of Available Capacity in Flexible Manufacturing Systems

In a job shop, because of large setup times, each operation is assigned to only one machine. There is no alternative routing. In a flexible manufacturing system, each manufacturing operation can often be performed on several machines. Therefore, with automated equipment, the capacity of a machine to perform certain operations is not independent of the capacity of other machines. Often, however, operations managers can use a route‐independent answer to production planning questions. For example, how much can be produced of a certain part type and when are important capacity questions in business negotiations, when the detailed routing and scheduling are not yet of interest or cannot be known. This paper provides a mathematical model for the route‐independent analysis of the capacity of flexible manufacturing systems based on a concept of operation types. An example is provided both to illustrate the use of operation types and to highlight the differences between the traditional route‐dependent and the proposed route‐independent formulations of capacity constraints. Some computational results are also given. Finally, a sensitivity analysis is developed to analyze the feasibility of production plans when production requirements and machine capacities can change.     

A routine-based framework implementing workload control to address recurring disturbances

Abstract

This research focuses on responsiveness in high variety manufacturing environments. To achieve it, the article proposes to develop Dynamic Response Capabilities (DRCs) of the manufacturing system defined as the abilities to readjust the planned operating parameters of workload, capacity, and lead time, in the wake of disturbances. To inform their development, built on the Workload Control theory, a routine-based framework is proposed. The framework supports an integrated approach for the implementation of adaptive decision-making routines for workload, capacity, and lead time readjustments at different stages in the order fulfilment process. Findings from two empirical cases show the appropriateness of the framework to develop and utilise DRCs in different settings of disturbances. Results of a simulation study, with one of the case companies, also shows the effectiveness of the framework to drive performance improvements in presence of recurring disturbances leading to demand variability.     

A proposed methodology for the prediction of mental workload, based on engineering system parameters

In the design of engineering systems, mental workload is one of the most important factors in the allocation of cognitive tasks. Current methods of task allocation have criteria that are defined in only general terms and are thus not very useful in aiding detailed decision-making in system design. Whilst there are many quantitative criteria available to determine the physical space in human-machine interaction, system designers really require an explicit model and specific criteria for the following identification of the mental workload imposed by the system; prediction of both human and system performance; evaluation of the alternatives of system design; and the design of system components. It is argued that the available methods of workload or performance are either too domain-dependent to apply to the design of other systems, or subject-dependent and thus do not reflect the objective workload imposed by the system. The presented research adopts a new approach to cognitive task analysis in dynamic decision-making systems. Based on the characteristics derived from task analysis, a general conceptual model of the prediction of mental workload in system design is proposed. In the new model, workload is represented by a set of system parameters—task arrival rate, task complexity, task uncertainty, and performance requirements—which are considered to be the main sources of workload. In this context, workload becomes an objective demand of engineering systems, independent of any subjective factors. Whether an individual or population is overloaded depends upon their workload threshold with respect to the specified task and environment. It is hoped that this new model, after both laboratory and industrial validation, could be used by system designers to predict the workload imposed on people by systems.     

Manufacturing cycle time reduction using balance control in the semiconductor fabrication line

In semiconductor manufacturing, wafer fabrication is the most complicated and important process, and is composed of several hundred process steps and involves several hundred machines. The productivity of the manufacturing process depends mainly on controlling the balance of WIP (work-inprogress) flow to achieve maximum throughput under short manufacturing cycle times. This paper discusses how to determine the proper WIP level for operations, against which balance status can be measured. Balance measurement can be applied in mathematical modelling for bottleneck scheduling and operations management of the fabrication line. Performances are evaluated through computational experiments to show that balance driven management leads to 15-33% more production in 21% shorter manufacturing cycle time than production driven management.     

Healthy lower backs in the construction industry in Sweden

This corss-sectional study exmaines the relationship between healthy lower and psychosocial and physical factors in a random sample of 1773 male construction workers. Infoamtion on lower back status, lifestyle habits, stress, psychosomatic and psychological symptoms, psychosocizal demands and resoruces and physical workload were collected by means of a postal questionnaire. Measures of psycholocial and physical factors were based on factor analysis of the data. The criterion variable 'healthy lower back' (HLB)—no lifetime history of low back pain—proved to be valid compared with an interview and a physical examination. A total of 216 workers (12%) reported HLB. The prevalance rate decreased significantly with increasing age. The prevalence rate of HLB was 6% among workers reporting high stress levels. It was postively influenced when there was a balance between demands and resoruces. A low level of physical workload also increased the prevalence rate of HLB. When age, lifestyle and physical factors were kept constant in a multivariate analysis high scores on the discretions index and low scores on eh psychosomatic, psychological and stress indices cosntributed significantly to an increase prevalence rate of HLB.     

Modeling Pathology Workload and Complexity to Manage Risks and Improve Patient Quality and Safety

Anatomic pathology (AP) laboratories provide critical diagnostic information that help determine patient treatments and outcomes, but the risks of AP operations and their impact on patient safety and quality of care remain poorly recognized and undermanaged. Hospital-based laboratories face an operational and risk management challenge because clinical work of unknown quantity and complexity arrives with little advance notice, which results in fluctuations in workload that can push operations beyond planned capacity, leading to diagnostic delays and potential errors. Modeling the dynamics of workload and complexity in AP offers the opportunity to better use available information to manage risks. We developed a stock-and-flow model of a typical AP laboratory operation and identified key exogenous inputs that drive AP work. To test the model, we generated training and validations data sets by combining data from the electronic medical records and laboratory information systems over multiple years. We demonstrate the implementation of 10-day AP work forecast generated on a daily basis, and show its performance in comparison with actual work. Although the model somewhat underpredicts work as currently implemented, it provides a framework for prospective management of resources to ensure quality during workload surges. Although full implementation requires additional model development, we show that AP workload largely depends on few and accessible clinical inputs. Recognizing that level loading of work in a hospital is not practical, predictive modeling of work can empower laboratories to triage, schedule, or mobilize resources more effectively and better manage risks that reduce the quality or timeliness of diagnostic information.     

Competitive analysis of online machine rental and online parallel machine scheduling problems with workload fence

In this paper, we introduce the concept of “workload fence" into online machine rental and machine scheduling problems. With the knowledge of workload fence, online algorithms acquire the information of a finite number of first released jobs in advance. The concept originates from the frozen time fence in the domain of master scheduling in materials management. The total processing time of the jobs foreseen, corresponding to a finite number of jobs, is called workload fence, which is irrelevant to the job sequence. The remaining jobs in the sequence, however, can only become known on their arrival. This work aims to reveal whether the knowledge of workload fence helps to boost the competitive performance of deterministic online algorithms. For the online machine rental problem, we prove that the competitiveness of online algorithms can be improved with a sufficiently large workload fence. We further propose a best online algorithm for the corresponding scenario. For online parallel machine scheduling with workload fence, we give a positive answer to the above question for the case where the workload fence is equal to the length of the longest job. We also show that the competitiveness of online algorithms may not be improved even with a workload fence strictly larger than the largest length of a job. The results help one manager to make a better decision regarding the tradeoff between the performance improvement of online algorithms and the cost caused to acquire the knowledge of workload fence.

     

基于随机权重多目标遗传算法的多目标动态单元构建方法

考虑多变的市场需求环境下单元生产系统在多个计划期具有多个目标的动态构建决策问题。通过对单元生产构建过程中的总费用、设备负载与能力之间最大偏差以及零部件跨单元移动的总次数3个目标进行权衡,建立了非线性多目标动态单元构建的数学模型。采用自适应小生境技术、惩罚技术、双轮盘赌法和精华选择策略,提出了基于精华保留策略的随机权重多目标遗传算法求解该组合优化问题。结合实例对模型和算法进行了仿真分析,结果显示了算法对解决多目标动态单元构建问题的有效性。     

An asymptotically optimal algorithm for large-scale mixed job shop scheduling to minimize the makespan

This paper considers the large-scale mixed job shop scheduling problem with general number of jobs on each route. The problem includes ordinary machines, batch machines (with bounded or unbounded capacity), parallel machines, and machines with breakdowns. The objective is to find a schedule to minimize the makespan. For the problem, we define a virtual problem and a corresponding virtual schedule, based on which our algorithm TVSA is proposed. The performance analysis of the algorithm shows the gap between the obtained solution and the optimal solution is O(1), which indicates the algorithm is asymptotically optimal.     

Task and Relationship Orientation of Pakistani Managers and Working Professionals: The Interaction Effect of Demographics in a Collective Culture

This study focused on identifying the task and relationship orientations of respondents working in various Pakistani organizations. To explore their orientations, respondents in Khyber Pakhtunkwa (KPK) and Punjab provinces of Pakistan were surveyed. The data were analyzed by Univariate General Linear Model considering age, qualification and managerial experience as independent variables. Pakistani managers seem to use both styles in moderation. While they are more relationships focused, they demonstrate an overall balance between the two styles. In the task orientation, no individual factor showed any significant main effect. But the interaction of age by academics, and academics by management experience has a significant effect on task orientation. In the case of relationship orientation, academics seem to be a statistically significant factor and the interaction of age by academics has a significant effect as well. After the multiple comparisons of sub-classes of independent variables by Tukey Post Hoc test, the common trend of both styles found is that getting advancement in all three independent variables has a significant effect on both orientations.     

MRP in a job shop environment using a resource constrained project scheduling model

One of the most difficult tasks in a job shop manufacturing environment is to balance schedule and capacity in an ongoing basis. MRP systems are commonly used for scheduling, although their inability to deal with capacity constraints adequately is a severe drawback. In this study, we show that material requirements planning can be done more effectively in a job shop environment using a resource constrained project scheduling model. The proposed model augments MRP models by incorporating capacity constraints and using variable lead time lengths. The efficacy of this approach is tested on MRP systems by comparing the inventory carrying costs and resource allocation of the solutions obtained by the proposed model to those obtained by using a traditional MRP model. In general, it is concluded that the proposed model provides improved schedules with considerable reductions in inventory carrying costs.