This paper addresses the scheduling problem in a Permutation Flow Shop (PFS) environment, which is associated with many types of industries such as chemical, petrochemical, automobile manufacturing, metallurgical, textile, etc. Thus, this work intends to solve a PFS scheduling problem in order to minimize the total weighted tardiness, since it is an important sequencing criterion not only for on time delivery jobs but also for customer satisfaction. To solve the problem, GRASP (Greedy Randomized Adaptive Search Procedure) metaheuristic is proposed as a solution, which has shown competitive results compared with other combinatorial problems. In addition, two utility functions called Weighted Modified Due Date (WMDD) and Apparent Tardiness Cost (ATC) are proposed to develop GRASP. These are based on dynamic dispatching rules and also known for solving the problem of total weighted tardiness for single machine scheduling problem. Next, an experimental design was carried out for comparing the GRASP performance with both utility functions and against the WEDD dispatching rule results. The results indicate that GRASP-WMDD could improve the total weighted tardiness in 47.8% compared with WEDD results. Finally, the GRASP-WMDD performance for the PFS total tardiness problem was evaluated, obtaining a relative deviation index of 13.89% and ranking the method over 26 heuristics and metaheuristics.
Optimization of hole-making operations plays a crucial role in which tool travel and tool switch scheduling are the two major issues. Industrial applications such as moulds, dies, engine block etc. consist of large number of holes having different diameters, depths and surface finish. This results into to a large number of machining operations like drilling, reaming or tapping to achieve the final size of individual hole. Optimal sequence of operations and associated cutting speeds, which reduce the overall processing cost of these hole-making operations are essential to reach desirable products. In order to achieve this, an attempt is made by developing an effective methodology. An example of the injection mould is considered to demonstrate the proposed approach. The optimization of this example is carried out using recently developed particle swarm optimization (PSO) algorithm. The results obtained using PSO are compared with those obtained using tabu search method. It is observed that results obtained using PSO are slightly better than those obtained using tabu search method.
Turning experiments were carried out on AA 7075/SiC composite workpiece in dry and spray cooling environments based on L16 Taguchi design of experiments. Multiple performance optimization of process parameters was performed using grey relational analysis. The performance characteristics considered were average surface roughness, cutting tool temperature and material removal rate. Uncoated carbide inserts were used for machining the workpiece in a high speed precision lathe. A grey relational grade obtained from grey relational analysis was used to optimize the process parameters. Optimal combination of process parameters was then determined by the Taguchi method using the grey relational grade as the performance index. Experimental results indicated that the turning in spray cooling environment was beneficial compared to that in dry environment for the quality response characteristics under consideration. Analysis of variance showed that feed was the most significant parameter for the multiple performance characteristics during turning in both the environments.
The theory of constraints is an approach for production planning and control, which emphasizes on the constraints in the system to increase throughput. The theory of constraints is often referred to as Drum-Buffer-Rope developed originally by Goldratt. Drum-Buffer-Rope uses the drum or constraint to create a schedule based on the finite capacity of the first bottleneck. Because of complexity of the job shop environment, Drum-Buffer-Rope material flow management has very little attention to job shop environment. The objective of this paper is to apply the Drum-Buffer-Rope technique in the job shop environment using a Markov chain analysis to compare traditional method with Drum-Buffer-Rope. Four measurement parameters were considered and the result showed the advantage of Drum-Buffer-Rope approach compared with traditional one.
The powder coating is an economic, technologically superior and environment friendly painting technique compared with other conventional painting methods. However large variation in coating thickness can reduce the attractiveness of powder coated products. The coating thickness variation can also adversely affect the surface appearance and corrosion resistivity of the product. This can eventually lead to customer dissatisfaction and loss of market share. In this paper, the author discusses a dual response surface optimization methodology to minimize the thickness variation around the target value of powder coated industrial enclosures. The industrial enclosures are cabinets used for mounting the electrical and electronic equipment. The proposed methodology consists of establishing the relationship between the coating thickness & the powder coating process parameters and developing models for the mean and variance of coating thickness. Then the powder coating process is optimized by minimizing the standard deviation of coating thickness subject to the constraint that the thickness mean would be very close to the target. The study resulted in achieving a coating thickness mean of 80.0199 microns for industrial enclosures, which is very close to the target value of 80 microns. A comparison of the results of the proposed approach with that of existing methodologies showed that the suggested method is equally good or even better than the existing methodologies. The result of the study is also validated with a new batch of industrial enclosures.
In the existing literature of inventory modeling under the conditions of permissible delay in payments, researchers have assumed that the retailers have to settle their accounts at the end of credit period i.e. supplier accept only full amount at the end of the credit period. However in reality, supplier may either accept the partial amount at the end of the credit period and unpaid balance subsequently or the full amount at a fix point of time after the expiry of the credit period, if the retailer finances the inventory from the supplier itself. Further, in the classical deteriorating inventory models, the common unrealistic assumption is that all the items start to deteriorate as soon as they arrive in the system. However, in realistic environment, it is observed that there are several non-instantaneous deteriorating items that have a shelf life and start to deteriorate after a time lag, like dry fruits, potatoes, yams and even some fruits and vegetables etc. Considering the importance of above mentioned facts, the present study formulates a fuzzy inventory model for non-instantaneous deteriorating items under conditions of permissible delay in payments. The paper discusses all the possible cases which may arise and yet not considered in the previous inventory models under permissible delay in payments. Further, this paper also considers price-dependent demand and the possibility of higher interest earn rate than interest payable rate. The objective of this study is to determine the optimal decision policies for the retailer which maximizes the total profit. Finally, the numerical examples are solved by using the proposed algorithm to show the validity of the model followed by the sensitivity analysis.
Resource-Constrained Project Scheduling Problem (RCPSP) is considered as an important project scheduling problem. However, increasing dimensions of a project, whether in number of activities or resource availability, cause unused resources through the planning horizon. Such phenomena may increase makespan of a project and also decline resource-usage efficiency. To solve this problem, many methods have been proposed before. In this article, an effective backward-forward search method (BFSM) is proposed using Greedy algorithm that is employed as a part of a hybrid with a two-stage genetic algorithm (BFSM-GA). The proposed method is explained using some related examples from literature and the results are then compared with a forward serial programming method. In addition, the performance of the proposed method is measured using a mathematical metric. Our findings show that the proposed approach can provide schedules with good quality for both small and large scale problems.
This paper presents the problem of redesigning a supply network of large scale by considering variability of the demand. The central problematic takes root in determining strategic decisions of closing and adjusting of capacity of some network echelons and the tactical decisions concerning to the distribution channels used for transporting products. We have formulated a deterministic Mixed Integer Linear Programming Model (MILP) and a stochastic MILP model (SMILP) whose objective functions are the maximization of the EBITDA (Earnings before Interest, Taxes, Depreciation and Amortization). The decisions of Network Design on stochastic model as capacities, number of warehouses in operation, material and product flows between echelons, are determined in a single stage by defining an objective function that penalizes unsatisfied demand and surplus of demand due to demand changes. The solution strategy adopted for the stochastic model is a scheme denominated as Sample Average Approximation (SAA). The model is based on the case of a Colombian company dedicated to production and marketing of foodstuffs and supplies for the bakery industry. The results show that the proposed methodology was a solid reference for decision support regarding to the supply networks redesign by considering the expected economic contribution of products and variability of the demand.
The present research work investigated the machining of AISI304 austenitic stainless steel in terms of machining force evolution, power consumption, specific cutting force and surface roughness where a factorial experiment design and analysis of variance technique were used and several factors were evaluated for their effects on each level. The case of dry turning process was studied based on design of experiments in order to obtain empirical equations characterizing material machinability according to cutting conditions such as cutting speed, feed rate and depth of cut and the latter ones were put in relationship with the machining output variables (Ra, Fc, Kc and Pc) through the response surface methodology (RSM). Results revealed that feed rate was the most preponderant factor affecting surface roughness (71.04%). However, the depth of cut affects considerably cutting force and cutting power by (60.74% and 67.11%), respectively. In addition, the specific cutting force was found affected significantly by cutting speed with a contribution of 41.43%. The quadratic model of RSM associated with response optimization technique and composite desirability was used to find optimum values of machining parameters (104.54 m/min, 0.08 mm/rev and 0.295 mm).
Laser direct structuring (LDS) is very important step in the MID process and it is a complex process due to different parameters, which influence on this process and its final product. Therefore, it is very important to use a reliable model to predict, analyze and control the performance of the (LDS) process and the quality of the final product. In this work we develop mathematical models by using Artificial Neural Network (ANN) and Response Surface Methodology (RSM) to study this process. The proposed models are used to study the effect of the LDS parameters on the groove dimensions (width and depth), lap dimensions (groove lap width and height) and finally the heat effective zone (interaction width), which are important to determine the line width/space in the MID products and the metallization profile after the metallization step. We also study the relationship between the LDS parameters and the surface roughness which is very important factor for the adhesion strength of MID structures. Moreover these models capable of finding a set of optimum LDS parameters that provide the required micro-channel dimensions with the best or the suitable surface roughness. A set of experimental tests are carried out to validate the developed ANN and the RSM models. It has been found that the predicted values for the proposal ANN and RSM models were closer to the experimental values, and the overall average absolute percentage errors were 4.02 % and 6.52%, respectively. Finally, it has been found that, the developed ANN model could be used to predict the response of the LDS process more accurately than RSM model.