Batch sizes and lead-time performance in flexible manufacturing systems

Production lead-time performance in flexible manufacturing systems is influenced by several factors which include: machine groupings, demand rates, machine processing rates, product batching, material handling system capacity, and so on. Hence, control of lead-time performance can be affected through the manipulation of one or more of these variables. In this article, we investigate the potential of batch sizing as a control variable for lead-time performance through the use of a queueing network model. We establish a functional relationship between the two variables, and incorporate the relationship in an optimization model to determine the optimal batch size(s) which minimizes the sum of annual work-in-process inventory and final inventory costs. The nonlinear batch sizing problem which results is solved by discrete optimization via marginal analysis. Results show that batch sizing can be a cheap and effective variable for controlling flexible manufacturing system throughput.     

Work flow control in the flexible flow line

This research involves the development and evaluation of a part flow control model for a type of flexible manufacturing system (FMS) called a dedicated flexible flow line (FFL). In the FFL, all part types flow along the same path between successive machine groups. The specific objective of the part flow control model for the FFL is to minimize makespan for a given set of parts produced in a FFL near-term schedule, given fixed available buffer constraints. The control model developed in this research involved the repeated, real-time execution of a mathematical programming algorithm. The algorithm attempts to release the right mix of parts at the tight time to keep the FFL operating smoothly. The focus of the approach is directed toward managing WIP buffers for each machine group queue. The algorithm specifically incorporates stochastic disturbance factors such as machine failures. Through a limited number of simulation experiments, performance of the control model is shown to be superior to other parts releasing and control methods reported in the literature.     

Cascading flowlines and layout modules: Practical strategies for machine duplication in facility layouts

The standard approach for design of a layout for a high-variety low-volume (HVLV) manufacturing facility has been to use either a from-to chart or a multi-product process chart to design a process layout or a cellular layout, respectively, for the facility. Considerable research has focused on making a go-no go decision to implement any one of these two traditional layouts as the preferred layout for an HVLV manufacturing facility. This paper introduces a variety of Hybrid Cellular Layouts (HCLs) which integrate the attributes of the traditional functional, cellular and flowline layouts. The mathematical models and methods for design of two HCLs—cascading flowline layout and modular layout—are discussed in detail. Unlike the standard models in the literature, the design of the cascading flowline layout introduces a novel string-to-graph aggregation and planar graph embedding method that allows machine duplication in the layout. Similarly, the design of the Modular layout introduces a substring clustering method instead of the standard method of cluster analysis to form part families using the complete routings of the parts. For each HCL, results from an industry project are presented to demonstrate the real-world viability of the concepts, methods and software developed to support the design of HCLs for high-variety low-volume manufacturing facilities.     

An Analytical Queueing Network Model for Flexible Manufacturing Systems with a Discrete Handling Device and Transfer Blockings

In this paper, we study job shop-like flexible manufacturing systems (FMSs) with a discrete material handling system (MHS). In such FMSs, the MHS is a critical device, the unavailability of which may induce transfer blockings of the machines. The FMS devices therefore are hierarchically structured into primary and secondary devices to manage such blocking and avoid deadlocks in these FMSs. For evaluating the quantitative steady-state performance of such FMSs, we propose an analytical queueing network model that relies on an approximate method proposed for analyzing computer systems with simultaneous possessions of resources. Such a model is obtained using the concept of passive resources and by aggregating the FMS workload data so that models are much more tractable. The analytical results are validated against discrete event simulation and shown to be very encouraging. We also show how to increase their robustness, especially under light workload conditions, by modifying an assumption of the method concerning service time distributions.     

Tool addition strategies for flexible manufacturing systems

The allocation of tools to machines determines potential part routes in flexible manufacturing systems. Given production requirements and a minimum feasible set of tools, the decision of how to fill vacant slots in tool magazines to maximize routing flexibility is shown to be a minimum cost network flow problem for the cases when routing flexibility is a function of the average workload per tool aggregated over tool types, or of the number of possible routes through the system. A linear programming model is then used to plan a set of routes for each part type so as to minimize either the material handling requirement or the maximum workload on any machine. The impact of these tool addition strategies on the material handling and workload equalization is investigated and computational results presented. The advantage of the overall approach is computational simplicity at each step and the ability to react to dynamic changes.     

A queueing model for a two-stage stochastic manufacturing system with overlapping operations

This paper presents analytical expressions for estimating average process batch flow times through a stochastic manufacturing system with overlapping operations. It is shown that the traditional queueing methodology cannot be directly applied to this setting, as the use of the overlapping operations principle causes the arrival process of sublots at the second stage to be a non-renewal process. An embedded queueing model is then proposed, which provides a tool to estimate the flow time reductions caused by the use of overlapping operations. Moreover, we provide expressions to estimate the production disruptions occurring at the second stage. The results of our research confirm the general intuition that the overlapping operations principle leads to less congestion, and hence a smoother flow of work through the system. On the other hand however, lot splitting inevitably requires more material handling on the shop floor. The expressions provided in this paper allow the quantification of the trade-off between these two effects, e.g., by gauging them within the scope of a cost model.     

Estimation of Part Waiting Time and Fleet Sizing in AGV Systems

As manufacturing systems have grown in size and complexity, material flow control has become one of the key issues for system efficiency, and determination of the number of vehicles required is an important issue in the design of the AGV (automatic guided vehicle) systems for automated material flow control. In an AGV system, a part issues a delivery request for its transportation, and then an empty vehicle is assigned based on a pre-determined vehicle selection rule and provides delivery service.This research presents a fleet sizing procedure for an AGV system with multiple pickup and delivery stations. A queueing model is used to estimate part waiting times. The fleet sizing procedure estimates the minimum number of vehicles needed to ensure a predefined part waiting time limit. While most stochastic models assume first-come-first-served or random vehicle selection rules for the selection of an empty vehicle, this model considers such additional rules as the nearest vehicle selection rule, which is the most popular among all vehicle selection rules. The performance of the proposed model is examined through computational experiments.     

Vehicle Travel Time Models for AGV Systems under Various Dispatching Rules

The design and evaluation of AGV-based material handling systems are highly complex because of the randomness and the large number of variables involved. Vehicle travel time is a fundamental parameter for solving various flexible manufacturing system (FMS) design problems. This article presents stochastic vehicle travel time models for AGV-based material handling systems with emphasis on the empty travel times of vehicles. Various vehicle dispatching rules examined here include the nearest vehicle selection rule and the longest idle vehicle selection rule. A simulation experiment is used to evaluate and demonstrate the presented models.     

Performance modeling of a manufacturing cell with a single material transporter: An approximation

We consider a flexible manufacturing system with a number of workstations, a single material transporter, and a common storage space of finite capacity. The material handling delay times are explicitly considered in the model and assumed to follow a two-stage Coxian distribution. The material processing times on a workstation also have a two-stage Coxian distribution. The routing of parts within the system follows a Markov chain. An approximate performance model is developed and the results are compared with the exact or simulation results. We also investigate how this performance model compares to a simulation with deterministic routing and processing times. Finally, we study the effect, on the performance measures, of ignoring the material transporter or of modeling the transporter as a central server with aggregation of routing information.     

Task Partitioning in Insect Societies. II. Use of Queueing Delay Information in Recruitment

The collection and handling of colony resources such as food, water, and nest-construction material is often divided into subtasks in which the material is passed from one worker to another. This is known as task partitioning. If tasks are partitioned with direct transfer of material between foragers and receivers, queueing delays can occur as individuals search or wait for a transfer partner. Changes in environmental conditions and relative number of foragers and receivers affect these delays as well as colony ergonomic efficiency. These delays are used in recruitment in both honeybees and Polybia wasps. This study investigates the distribution of queueing delays and the information content and quality of those delays using a stochastic-simulation model. Information quality increases with colony size. When the relative proportions of foragers and receivers are suboptimal, the group in excess has better information. Individuals can increase information quality of delays by two mechanisms: averaging over consecutive trips and averaging over multiple transfers within a trip where direct transfer occurs. We suggest that multiple transfer occurs in the honeybee in order to improve information quality.     

Some problems of industrial scale-up

There are problems associated with all stages of the scaling-up of biological processes developed on a laboratory scale. The large size of industrial fermenters required for commercial viability (up to 100 m³) gives rise to problems of mixing, heat transfer, and control as well as problems in physically handling large volumes of liquids and gases. The concentration of products obtained from biological processes is low (typically 10 per cent), so recovery processes require a large energy input. The optimization and integration of all parts of the process, from the initial fermentation to marketable product, is essential.     

Continuous aqueous two-phase extraction of human antibodies using a packed column

The performance of a pilot scale packed differential contactor was evaluated for the continuous counter-current aqueous two-phase extraction (ATPE) of human immunoglobulin G (IgG) from a Chinese hamster ovary (CHO) cells supernatant (CS) enriched with pure protein. Preliminary studies have been firstly performed in order to select the dispersed phase (phosphate-rich or polyethylene glycol 3350 Da (PEG)-rich phase) and the column packing material. The PEG-rich phase has been selected as the dispersed phase and the stainless steel as the preferred material for the column packing bed since it was not wetted preferentially by the selected dispersed phase. Hydrodynamic studies have been also performed, and the experimental results were successfully adjusted to the Richardson-Zaki and Mísek equations, typically used for the conventional organic-aqueous two-phase systems. An experimental set-up combining the packed column with a pump mixer-settler stage showed to have the best performance and to be advantageous when compared to the IgG batch extraction. An IgG recovery yield of 85% could be obtained with about 50% of total contaminants and more than 85% of contaminant proteins removal. Mass transfer studies have revealed that the mass transfer was controlled by the PEG-rich phase. A higher efficiency could be obtained when using an extra pump mixer-settler stage and higher flow rates.     

A Dynamic Tool Requirement Planning Model for Flexible Manufacturing Systems

Despite their strategic potential, tool management issues in flexible manufacturing systems (FMSs) have received little attention in the literature. Nonavailability of tools in FMSs cuts at the very root of the strategic goals for which such systems are designed. Specifically, the capability of FMSs to economically produce customized products (flexibility of scope) in varying batch sizes (flexibility of volume) and delivering them on an accelerated schedule (market response time) is seriously hampered when required tools are not available at the time needed. On the other hand, excess inventory of tools in such systems represents a significant cost due to the expensive nature of FMS tool inventory. This article constructs a dynamic tool requirement planning (DTRP) model for an FMS tool planning operation that allows dynamic determination of the optimal tool replenishments at the beginning of each arbitrary, managerially convenient, discrete time period. The analysis presented in the article consists of two distinct phases: In the first phase, tool demand distributions are obtained using information from manufacturing production plans (such as master production schedule (MPS) and material requirement plans (MRP)) and general tool life distributions fitted on actual time-to-failure data. Significant computational reductions are obtained if the tool failure data follow a Weibull or Gamma distribution. In the second phase, results from classical dynamic inventory models are modified to obtain optimal tool replenishment policies that permit compliance with such FMS-specific constraints as limited tool storage capacity and part/tool service levels. An implementation plan is included.     

Task Partitioning in Insect Societies. I. Effect of Colony Size on Queueing Delay and Colony Ergonomic Efficiency

The collection and handling of colony resources such as food, water, and nest construction material is often divided into subtasks in which the material is passed from one worker to another. This is known as task partitioning. When material is transferred directly from one individual to another, queueing delays frequently occur because individuals must sometimes wait for a transfer partner. A stochastic simulation model was written to study the effect of colony size on these delays. Queueing delay decreases roughly exponentially with colony size because stochastic fluctuations in the arrival of individuals are lower in larger colonies. These results support empirical studies of Polybia occidentalis and other theoretical studies of honeybees. The effect of the relative number of individuals in the two subtask groups was also studied. There is a unique optimal ratio of the number of workers associated with each of the subtasks that simultaneously minimizes mean queueing delay and maximizes colony nectar-processing rate. Deviations from this optimal ratio, for example, as a result of forager mortality or changes in nectar productivity that affect foraging trip duration, increase mean queueing delays greatly, especially in smaller colonies.     

Life cycle assessment of bio-based products: a disposable diaper case study

Purpose

In this study, a life cycle assessment of a bioplastic based diaper was performed. The product has several innovative elements, due to the implementation of eco-design principles, such as: (1) introduction of biopolymers (namely polylactic acid (PLA) and Mater-bi®), (2) relevant reduction of petrochemical plastics, and (3) minimization of energy consumptions and use of renewable energy in manufacturing. The aim of the study is to evaluate the environmental benefits gained through eco-innovation, while identifying further areas of improvement.

Methods

The bio-based diaper has been evaluated using a “cradle-to-gate” analysis. The functional unit is one diaper, assuming an average size among the different commercial options. A case study of an enterprise in Italy (WIP S.p.A) was carried out to collect as much reliable primary data as possible. In order to highlight potential areas of improvement and to compare the environmental performance of the product, a sensitivity analysis based on three different impact assessment methods (adopting ReCiPe 2008, IMPACT 2002+ and Cumulative Energy Demand (CED)) and a comparison with a standard commercial diaper were performed. Finally, three possible end-of-life scenarios including composting of WIP diaper were hypothesized and tested.

Results and discussion

Contribution analysis suggested that sourcing and production of raw materials used in WIP diaper manufacturing contributed most significantly to the potential environmental impacts. Adopting ReCiPe method, pulp, and sodium polyacrylate present the highest environmental burdens in WIP diaper system. Applying IMPACT2002+ method, PLA relative contribution to the toxicity increases, due to the generation of the electricity used in corn production and in PLA production phases. For both methods, impacts related to energy consumption of the WIP diapers’ production process look to be negligible. WIP diaper performance has room for improvement, since critical points were detected in the life cycle stages of raw materials used. However, the results of the normalization step, according to ReCiPe method, state that WIP diapers can bring environmental benefits, compared to standard ones. Moreover, if composting end-of-life scenario is included in the assessment, there is a significant improvement in WIP diaper environmental performance compared to a standard diaper.

Conclusions

Integrating eco-innovation and eco-design principles in the production of the bio-based diaper leads to a better environmental profile, compared to the standard one. Nevertheless, there are several areas of concerns to be considered in order to further improve its environmental performance. So far, the possible improvements identified from the case study are: (1) the selection of biopolymers suppliers with better production systems from an environmental point of view, (2) the reduction of distances along the supply chain, and (3) the implementation of composting procedures for the end of life. In conclusion, the introduction of biopolymers in diaper composition could lead them to be preferable compared to standard diapers, but criticisms arise, which need to be solved, to avoid the risk of burdens shifting.     

Design,construction, and optimization of a novel,modular, and scalable incubation chamber for continuous viral inactivation

We designed, built or 3D printed, and screened tubular reactors that minimize axial dispersion to serve as incubation chambers for continuous virus inactivation of biological products. Empirical residence time distribution data were used to derive each tubular design's volume equivalent to a theoretical plate (VETP) values at a various process flow rates. One design, the Jig in a Box (JIB), yielded the lowest VETP, indicating optimal radial mixing and minimal axial dispersion. A minimum residence time (MRT) approach was employed, where the MRT is the minimum time the product spends in the tubular reactor. This incubation time is typically 60 minutes in a batch process. We provide recommendations for combinations of flow rates and device dimensions for operation of the JIB connected in series that will meet a 60‐min MRT. The results show that under a wide range of flow rates and corresponding volumes, it takes 75 ± 3 min for 99% of the product to exit the reactor while meeting the 60‐min MRT criterion and fulfilling the constraint of keeping a differential pressure drop under 5 psi. Under these conditions, the VETP increases slightly from 3 to 5 mL though the number of theoretical plates stays constant at about 1326 ± 88. We also demonstrated that the final design volume was only 6% ± 1% larger than the ideal plug flow volume. Using such a device would enable continuous viral inactivation in a truly continuous process or in the effluent of a batch chromatography column. Viral inactivation studies would be required to validate such a design. © 2017 American Institute of Chemical Engineers Biotechnol. Prog., 33:954–965, 2017     

Reliability analysis of flexible manufacturing systems

High productivity is the primary goal of flexible manufacturing systems (FMSs) in which semi-independent workstations are integrated using automated material-transport systems and hierarchical local networks. Availability of various subsystems and of the system as a whole is a prerequisite for achieving functional integration as well as high throughput. An FMS also has inherent routing and operation flexibilities that provide it with a certain degree of fault tolerance. A certain volume of production can thus be maintained in the face of subsystem (i.e., machines, robots, material handling system, etc.) failures. In this article, we propose two reliability measures, namely, part reliability (PR) and FMS reliability (FMSR) for manufacturing systems and present algorithms to evaluate them. We also consider the dynamic or time-dependent reliability analysis as a natural generalization of the static analysis. The methods outlined use an algorithm that generates process-spanning graphs (PSGs), which are used to evaluate the reliability measures.     

Heuristics for the design of part-orienting systems

In many manufacturing systems, parts must be fed to automatic machines in a specific orientation. This is often accomplished by what are known as part-orienting systems (POSs). A POS consists of one or more separate devices that orient parts, usually with multiple orientations. A theoretical analysis along with the development of some heuristic algorithms is carried out in order to treat the problem of efficient selection and ordering of part-orienting devices that make up a POS. It is indicated that the size of such problems can be quite large in the context of flexible manufacturing systems which may require what are known as flexible part-orienting systems for their efficient operation. Computational experiments are performed in order to evaluate the relative performance of the heuristic algorithms.     

An efficient heuristic for scheduling batches of parts in a flexible flow system

Flexible manufacturing systems (FMSs) are a class of automated systems that can be used to improve productivity in batch manufacturing. Four stages of decision making have been defined for an FMS—the design, planning, scheduling, and control stages. This research focuses on the planning stage, and specifically in the area of scheduling batches of parts through the system. The literature to date on the FMS planning stage has mostly focused on the machine grouping, tool loading, and parttype selection problems. Our research carries the literature a step further by addressing the problem of scheduling batches of parts. Due to the use of serial-access material-handling systems in many FMSs, the batch-scheduling problem is modeled for a flexible flow system (FFS). This model explicitly accounts for setup times between batches that are dependent on their processing sequence. A heuristic procedure is developed for this batch-scheduling problem—the Maximum Savings (MS) heuristic. The MS heuristic is based upon the savings in time associated with a particular sequence and selecting the one with the maximum savings. It uses a two-phase method, with the savings being calculated in phase I, while a branch-and-bound procedure is employed to seek the best heuristic solution in phase II. Extensive computational results are provided for a wide variety of problems. The results show that the MS heuristic provides good-quality solutions.     

Superporous agarose monoliths as mini-reactors in flow injection systems

A new type of agarose material, superporous agarose, was used as a support material in an analytical system designed for monitoring of bioprocesses with respect to metabolites and intracellular enzymes. The superporous agarose was used in the form of miniaturised gel plug columns (15×5.0 mM I.D. monolithic gel bed). The gel plugs were designed to have one set of very large pores (about 50 m in diameter) through which cells, cell debris and other particulate contaminants from the bioreactor could easily pass. The material also had normal diffusion pores (300 Å) characteristic of all agarose materials, providing ample surface for covalent attachment of antibodies and enzymes used in the analytical sequence. The superporous agarose gel plug columns were characterised with respect to flow properties and handling of heavy cell loads as well as dispersion of injected samples (a Bodenstein number of about 40 was observed with acetone tracer at a flow rate of 1 ml min^–1). To evaluate the practical performance of the superporous gel plug columns, two applications were studied: (1) on-line determination of glucose in cultivation broth (gel plug with immobilized glucose oxidase) and (2) immunochemical quantification of intracellular -galactosidase in E. coli (gel plug with lysozyme to achieve cell lysis and gel plug with antibodies against -galactosidase).