Robotic assembly of printed circuit boards with component feeder location consideration

The use of industrial robots for the assembly of printed circuit boards (PCB) is fast gaining popularity. Minimization of the time required for board assembly while maintaining production quality is the process planner's main task. This task involves the specification of the insertion sequence of components in their respective locations and the assignment of component types to feeders or dispensing magazine slots. The time taken by a robot to fetch a component for insertion is dependent on the location of the feeder that holds the component type. Similarly, board assembly lime is dependent on the order of component insertion on the board and the fetch time of components between insertions. In this paper, models to minimize the total assembly time for a board are developed and studied. Factors considered in the analysis of the assembly time are the component assignment to magazine     

A heuristic approach for component scheduling on a high-speed PCB assembly machine

The collect-and-place machine is one of the most widely used placement machines for assembling electronic components on the printed circuit boards (PCBs). Nevertheless, the number of researches concerning the optimisation of the machine performance is very few. This motivates us to study the component scheduling problem for this type of machine with the objective of minimising the total assembly time. The component scheduling problem is an integration of the component sequencing problem, that is, the sequencing of component placements; and the feeder arrangement problem, that is, the assignment of component types to feeders. To solve the component scheduling problem efficiently, a hybrid genetic algorithm is developed in this paper. A numerical example is used to compare the performance of the algorithm with different component grouping approaches and different population sizes.     

Multiple criteria approach for solving feeder assignment and assembly sequence problem in PCB assembly

The feeder assignment and assembly sequence problem in printed circuit board (PCB) assembly with the twin objectives of minimizing magazine travel time and minimizing board travel time is presented in this study. The problem uses Dynamic Pick-and-Place (DPP) model where robot arm, board and magazine move together with different speeds based on relative coordinates between consecutive assembled points. The difficulty of the problem is that the feeder assignment depends on assembly sequence and vice versa. A new approach is proposed to improve the existing approaches. The trade-off between two strategies, assembly by area and assembly by component types, can give better results. The numerical experiments proved the efficiency of the new algorithm.     

Scheduling in an assembly-type production chain with batch transfer

This paper addresses a three-machine assembly-type flowshop scheduling problem, which frequently arises from manufacturing process management as well as from supply chain management. Machines one and two are arranged in parallel for producing component parts individually, and machine three is an assembly line arranged as the second stage of a flowshop for processing the component parts in batches. Whenever a batch is formed on the second-stage machine, a constant setup time is required. The objective is to minimize the makespan. In this study we establish the strong NP-hardness of the problem for the case where all the jobs have the same processing time on the second-stage machine. We then explore a useful property, based upon which a special case can be optimally solved in polynomial time. We also study several heuristic algorithms to generate quality approximate solutions for the general problem. Computational experiments are conducted to evaluate the effectiveness of the algorithms.     

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。     

A mathematical model for job shop scheduling with multiple process plan consideration per job

In this paper, a mixed integer programming model is formulated for scheduling a set of jobs through a shop when each job is supplied or provided with multiple process plans or process routings. Simultaneous selection of a process plan for each job and the sequencing of the jobs through the machines in the shop based on the set of selected process plans is addressed. The procedure developed seeks to integrate the selection of machines for each job and the sequencing of jobs on each machine based on the objective of minimizing production makespan. the application of the procedure is demonstrated with an example problem. The following conclusions were drawn as a result of the research: (1) the procedure developed produces optimal or near optimal solution; (2) the benefit from the developed approach is that it allows a shop to adaptively select process plans for jobs to optimize on production makespan. By combining solution quality with scheduling flexibility and efficiency, the productivity of a shop can be greatly enhanced.     

印刷电路板组装生产线调度优化问题建模

印刷电路板(printed circuit board,PCB)组装是电子制造的基础,其核心生产过程包括电子元器件的表面贴装。分别基于典型的表面贴装机(CM402)、以及由高速贴片机(CM402)与多功能贴片机(DT401)组成的流水线的机械特征与生产特性,对上述组装机及组装流水线的调度问题建立优化模型,为进一步的算法开发以及电子制造生产调度的智能化提供理论支持。     

Scheduling a single semi-continuous batching machine

This paper addresses a new problem, called semi-continuous batch scheduling, which arises in the heating-operation of tube-billets in the steel industry. Each heating furnace can be regarded as a semi-continuous batching machine, which can handle up to C jobs simultaneously. The jobs in the same batch enter and leave the machine semi-continuously, which differs from the traditional batching machine scheduling where the jobs in same batch have a starting time and a finishing time. In this paper the processing time of a batch depends on the capacity of the semi-continuous batching machine, the longest processing time of jobs in the batch and its size. The objectives are to schedule jobs on the machine so that the makespan and the total completion time are minimized. A schedule for a semi-continuous batching machine consists of a batching and sequencing for the batches. We propose the optimal properties of two different objective functions and present the different dynamic programming algorithms with a running time of O(n²), respectively.     

Single machine scheduling with general positional deterioration and rate-modifying maintenance

We present polynomial-time algorithms for single machine problems with generalized positional deterioration effects and machine maintenance. The decisions should be taken regarding possible sequences of jobs and on the number of maintenance activities to be included into a schedule in order to minimize the overall makespan. We deal with general non-decreasing functions to represent deterioration rates of job processing times. Another novel extension of existing models is our assumption that a maintenance activity does not necessarily fully restore the machine to its original perfect state. In the resulting schedules, the jobs are split into groups, a particular group to be sequenced after a particular maintenance period, and the actual processing time of a job is affected by the group that job is placed into and its position within the group.     

PRODUCT/PROCESS DESIGN IN MASS PLACEMENT PRINTED CIRCUIT BOARD ASSEMBLY

We describe a set of models that are used to manage the product and process design in a mass placement printed circuit board (PCB) assembly cell. Our models can be divided into two categories. First, we characterize the cell design problem and develop models to design an efficient assembly cell. Second, we present models for optimizing the different operational aspects of the assembly cell. These models were developed to assist the managers of a large electronic manufacturing firm in establishing mass placement PCB assembly cells.     

Discrete parallel machine makespan ScheLoc problem

Scheduling–Location (ScheLoc) problems integrate the separate fields of scheduling and location problems. In ScheLoc problems the objective is to find locations for the machines and a schedule for each machine subject to some production and location constraints such that some scheduling objective is minimized. In this paper we consider the discrete parallel machine makespan ScheLoc problem where the set of possible machine locations is discrete and a set of n jobs has to be taken to the machines and processed such that the makespan is minimized. Since the separate location and scheduling problem are both \(\mathcal {NP}\)-hard, so is the corresponding ScheLoc problem. Therefore, we propose an integer programming formulation and different versions of clustering heuristics, where jobs are split into clusters and each cluster is assigned to one of the possible machine locations. Since the IP formulation can only be solved for small scale instances we propose several lower bounds to measure the quality of the clustering heuristics. Extensive computational tests show the efficiency of the heuristics.     

Transforming an MRP plan into a short-term schedule

A new approach for transforming MRP orders, planned periodically, e.g. on a weekly base, into a detailed sequence of jobs is presented. In this model for a single machine environment, the jobs are partitioned into families and a family specific set-up time is required at the start of each period and of each batch, where a batch is a maximal set of jobs in the same family, that are processed consecutively. An integer program is formulated for both the problem of minimizing the number of overloaded periods and the problem of minimizing the total overtime. These programs generate benchmark results for the heuristic approach. A heuristic model is developed that constructs a schedule in which overloaded periods are relieved and set-up time is saved. In this approach, the job sequence is constructed by repeatedly solving a knapsack problem. The weights used in this knapsack problem relate to the preferred priorities of the jobs not yet scheduled and determine the quality of the final sequence. The different features of the heuristic model are compared using a large set of test problems. The results show that the quality of the final sequence depends on an appropriate choice for the weights.     

一种差异工件单机批调度问题的蚁群优化算法

由于在利用蚁群算法构建差异工件(即工件有尺寸差异)单机批调度问题的解时,批的加工时间是不确定的.从而不能类似于经典调度问题的蚁群算法把批加工时间的倒数作为蚁群算法中的启发式信息,引入批的利用率和批的负载均衡率作为蚁群算法中的启发式信息,提出了JACO(ant colony optimization based a job sequence)和BACO(ant colony optimization based a batch sequence)两种蚁群优化算法.在算法JACO中,解的编码为工件序列,它对应着用BF(best fit)分批规则生成的调度方案,信息素代表工件间的排列顺序;在算法BACO中,解的编码为批序列,信息素代表工件间的批相关性,由此信息素通过中间信息素量来构造相应的解,并引入特定的局部优化策略,提高了算法的搜索效率.实验表明,与以往文献中的SA(simula-ted annealing)、GA(genetic algorithm)算法以及FFLPT(first-fit longest processing time)、BFLPT (best-fit longest processing time)启发式规则相比,算法JACO和BACO明显优于它们,且BACO算法比JACO算法效果更好.     

A generalized procedure for minimizing makespan in a CNC environment

This paper presents the problem of scheduling N jobs, each manufactured in a number of settings, in order, on a CNC machine equipped with an automatic tool changer. A generalized procedure to minimize makespan in a CNC environment has been developed and tested on real industrial problems, considering possible constraints. It is worthy of mention that the procedure suggested finds an optimal solution of the problem discussed by Sule in a short and simplified manner. The step-by-step analysis shows the simplicity and flexibility of the proposed approach.     

A bicriteria approach to scheduling a single machine with job rejection and positional penalties

Single machine scheduling problems have been extensively studied in the literature under the assumption that all jobs have to be processed. However, in many practical cases, one may wish to reject the processing of some jobs in the shop, which results in a rejection cost. A solution for a scheduling problem with rejection is given by partitioning the jobs into a set of accepted and a set of rejected jobs, and by scheduling the set of accepted jobs among the machines. The quality of a solution is measured by two criteria: a scheduling criterion, F1, which is dependent on the completion times of the accepted jobs, and the total rejection cost, F2. Problems of scheduling with rejection have been previously studied, but usually within a narrow framework—focusing on one scheduling criterion at a time. This paper provides a robust unified bicriteria analysis of a large set of single machine problems sharing a common property, namely, all problems can be represented by or reduced to a scheduling problem with a scheduling criterion which includes positional penalties. Among these problems are the minimization of the makespan, the sum of completion times, the sum and variation of completion times, and the total earliness plus tardiness costs where the due dates are assignable. Four different problem variations for dealing with the two criteria are studied. The variation of minimizing F1+F2 is shown to be solvable in polynomial time, while all other three variations are shown to be $\mathcal{NP}$ -hard. For those hard problems we provide a pseudo polynomial time algorithm. An FPTAS for obtaining an approximate efficient schedule is provided as well. In addition, we present some interesting special cases which are solvable in polynomial time.     

Non-resumable scheduling on a single bounded parallel-batch machine with periodic maintenance

We consider the problem of scheduling a set of jobs with different processing times and sizes on a single bounded parallel-batch machine with periodic maintenance. Because the machine is in batch-processing model and the capacity is fixed, several jobs can be processed simultaneously in a batch provided that the total size of the jobs in the batch doesn’t exceed the machine capacity. And the processing time of a batch is the largest processing time of the jobs contained in the batch. Meanwhile, the production of each batch is non-resumable, that is, if a batch cannot be completed processing before some maintenance, that batch needs to be processed anew once the machine returns available. Our goal is to minimize the makespan. We first consider two special cases where the jobs have the same sizes or the same processing times, both of which are strongly NP-hard. We present two different approximation algorithms for them and show that these two algorithms have the same tight worst-case ratio of 2. We then consider the general case where the jobs have the arbitrary processing times and arbitrary sizes, for which we propose a 17/5-approximation algorithm.

     

Multi-objective permutation flow shop scheduling problem: Literature review,classification and current trends

The flow shop scheduling problem is finding a sequence given n jobs with same order at m machines according to certain performance measure(s). The job can be processed on at most one machine; meanwhile one machine can process at most one job. The most common objective for this problem is makespan. However, many real-world scheduling problems are multi-objective by nature. Over the years there have been several approaches used to deal with the multi-objective flow shop scheduling problems (MOFSP). Hence, in this study, we provide a brief literature review of the contributions to MOFSP and identify areas of opportunity for future research.     

Multi-agent scheduling on a single machine with a fixed number of competing agents to minimize the weighted sum of number of tardy jobs and makespans

We study the multi-agent scheduling on a single machine with a fixed number of competing agents, in which, the objective function of each agent is either the number of tardy jobs or the makespan, and the goal of the problem is to minimize the weighted sum of agents’ objective functions. In the literature, the computational complexity of this problem was posed as open. By using enumerating, dynamic programming, and schedule-configuration, we show in this paper that the problem is solvable in polynomial time.     

Scheduling with machine cost and rejection

In this paper we consider the scheduling problem with machine cost and rejection penalties. For this problem, we are given a sequence of independent jobs, each being characterized by its processing time (size) and its penalty. No machine is initially provided, and when a job is revealed the algorithm has the option to purchase new machines. Right when a new job arrives, we have the following choices: (i) reject it, in which case we pay its penalty; (ii) non-preemptively process it on an existing machine, which contributes to the machine load; (iii) purchase a new machine, and assign it to this machine. The objective is to minimize the sum of the makespan, the cost for purchasing machines, and the total penalty of all rejected jobs. For the small job case, (where all jobs have sizes no greater than the cost for purchasing one machine, and which is the generalization of the Ski-Rental Problem) we present an optimal online algorithm with a competitive ratio of 2.     

A FRAMEWORK FOR MACHINE SCHEDULING PROBLEMS WITH CONTROLLABLE PROCESSING TIMES

This is a study of single and parallel machine scheduling problems with controllable processing time for each job. The processing time for job j depends on the position of the job in the schedule and is a function of the number of resource units allocated to its processing. Processing time functions and processing cost functions are allowed to be nonlinear. The scheduling problems considered here have important applications in industry and include many of the existing scheduling models as special cases. For the single machine problem, the objective is minimization of total compression costs plus a scheduling measure. The scheduling measures include makespan, total flow time, total differences in completion times, total differences in waiting times, and total earliness and tardiness with a common due date for all jobs. Except when the total earliness and tardiness measure is involved, each case the problem is solved efficiently. Under an assumption typically satisfied in just-in-time systems, the problem with total earliness and tardiness measure is also solved efficiently. Finally, for a large class of processing time functions; parallel machine problems with total flow time and total earliness and tardiness measures are solved efficiently. In each case we reduce the problem to a transportation problem.