Simulation of the machine loading decision in flexible manufacturing cell based on FlexSim environment

  • Authors

    • H. T.Nguyen
    • Q. N.Tran
    • A. P. Rifai
    • H. N.Huynh
    • Siti Zawiah Md Dawal
    https://doi.org/10.14419/ijet.v7i4.36.29372
  • FMC, FlexSim, simulation, machine loading, machine assignment.
  • This paper presents a simulation study to understand the behavior of flexible manufacturing cell (FMC) based on the optimal machine loading decision obtained from analytical approach. The machine loading model considered the allocation of machine and operation of each part in its batch in manufacturing environment. The simulation experiment is utilized to evaluate the effects of the most suitable combination of machines and operations in FMC, in relation to the system unbalance, makespan and total flow time based on two experimental scenarios, with 4 machines and 5 part types/8 part types. Results highlighted the competitive performance of obtained optimal loading solution and confirmed the reasonableness of the designed cell. Moreover, the comparison of performance indicators also confirmed that the FlexSim is a helpful and powerful tool to validate the optimal solutions from analytical approach. Finally, the machine loading decision of FMC is effective to be applied in real system at the manufacturing small and medium enterprises (SMEs).

     

  • References

    1. [1] A. Atmani, R. Lashkari, “A model of machine-tool selection and operation allocation in FMS,†International Journal of Production Research 36 (5), 1339-1349 (1998).

      [2] F. T. Chan and R. Swarnkar, “Ant colony optimization approach to a fuzzy goal programming model for a machine tool selection and operation allocation problem in an FMS,†Robotics and Computer-Integrated Manufacturing 22(4), 353-362 (2006).

      [3] N. Kumar and K. Shanker, “A genetic algorithm for FMS part type selection and machine loading,†International Journal of Production Research 38(16), 3861-3887 (2000).

      [4] M. Tiwari, B. H. Rika, N. V. Rthi, P. Jaggi and S. Mukhopadhyay, “A heuristic solution approach to the machine loading problem of an FMS and its Petri net model,†International Journal of Production Research 35(8), 2269-2284 (1997).

      [5] A. Prakash, N. Khilwani, M. K. Tiwari and Y. Cohen, “Modified immune algorithm for job selection and operation allocation problem in flexible manufacturing systems,†Advances in Engineering Software 39(3), 219-232 (2008).

      [6] M. P. Groover, Automation, Production Systems, and Computer-Integrated Manufacturing, 4th Edition. Prentice Hall (2010).

      [7] H. Yang and Z. Wu, “GA-based integrated approach to FMS part type selection and machine-loading problem,†International Journal of Production Research 40(16), 4093-4110 (2002).

      [8] A. Kumar, M. Tiwari, R. Shankar, and A. Baveja, “Solving machine-loading problem of a flexible manufacturing system with constraint-based genetic algorithm,†European Journal of Operational Research 175(2), 1043-1069 (2006).

      [9] R. Rai, S. Kameshwaran, M. Tiwari, “Machine-tool selection and operation allocation in FMS: solving a fuzzy goal-programming model using a genetic algorithm,†International Journal of Production Research 40(3), 641-665 (2002).

      [10] A. M. Abazari, M. Solimanpur, and H. Sattari, “Optimum loading of machines in a flexible manufacturing system using a mixed-integer linear mathematical programming model and genetic algorithm,†Computers & industrial engineering 62(2), 469-478 (2012).

      [11] K. E. Stecke and J. J. Solberg, “Loading and control policies for a flexible manufacturing system,†International Journal of Production Research 19(5), 481-490 (1981).

      [12] A. Negahban and J. S. Smith, “Simulation for manufacturing system design and operation: Literature review and analysis,†Journal of Manufacturing Systems 33(2), 241-261 (2014).

      [13] J. S. Smith, “Survey on the use of simulation for manufacturing system design and operation,†Journal of Manufacturing Systems 22(2), 157-171 (2003).

      [14] E. Lavery, M. Beaverstock, A. Greenwood, W. Nordgren and S. Warr, Applied Simulation: Modeling and Analysis Using FlexSim, 3rd Edition. FlexSim Software Products (2011).

      [15] D. Chan, FlexSim Basic Training. Workshop materials on FlexSim (2014).

      [16] A. Carrie, Simulation of Manufacturing Systems: John Wiley & Sons Ltd (1988).

      [17] H.-H. Huang, P. Sung, C. Huang, C.-H. Li, “A Research on the Mixed-Line Production Scheduling Problem of a Flow-shop System,†the third International Conference on Engineering, Project and Production Management, Brighton, United Kingdom (2012).

      [18] C. Song, H. Luo, T. Qu, H. Lv, and G. Q. Huang, “A simulation approach to hybrid flowshop scheduling using dispatching rules,†Proceedings of the 6th CIRP-Sponsored International Conference on Digital Enterprise Technology, Volume 66 of the series Advances in Intelligent and Soft Computing, pp. 877-884 (2010), Springer Berlin Heidelberg.

      [19] N. Selvaraj, “Application of Simulation Model for Distributed Scheduling Problems in FMS,†The Proceedings of the World Congress on Engineering, Vol. I (WCE 2011), July 6-8, 2011, London, U.K.

      [20] L. Yao, W. Zhu, “Visual simulation framework of iron and steel production scheduling based on flexsimâ€, The IEEE Fifth International Conference on the Bio-Inspired Computing: Theories and Applications (BIC-TA), 23-26 Sept. 2010, Changsha, China.

      [21] G. Zhou and L. Mao, “Design and simulation of storage location optimization module in AS/RS based on FLEXSIM,†International Journal of Intelligent Systems and Applications (IJISA), Vol. 2, No. 2, 33-40 (2010).

      [22] Z. Guiliang and C. Weihong, “Optimization and Simulation of Storage Location Assignment in AS/RS Based on FLEXSIM,†International Conference on the Logistics Engineering and Intelligent Transportation Systems (LEITS), 26-28 Nov. 2010, Wuhan, China.

      [23] J. Peng, “Optimal Allocation in Automatic Storage & Retrieval System Based on Flexsim Simulation,†The 2010 IEEE International Conference on Internet Technology and Applications (pp. 1-5), 20-22 Aug. 2010, Wuhan, China.

      [24] J. Peng, “Optimal Allocation of Resources in Production Line Based on Flexsim Simulation,†The IEEE International Conference on the Management and Service Science (MASS), 24-24 Aug. 2010, Wuhan, China. DOI: 10.1109/ICMSS.2010.5576372.

      [25] L.-H. Chen, D.-W. Hu and T. Xu, “Highway freight terminal facilities allocation based on flexsim,†Procedia-Social and Behavioral Sciences 96, 368-381 (2013).

      [26] P. Pawlewski, K. Rejmicz, K. Stasiak and M. Pieprz, “Just in sequence delivery improvement based on Flexsim simulation experiment,†The IEEE Proceedings of the Winter Simulation Conference (pp. 1-12) (2012), Berlin, Germany.

      [27] H. C. Cheng, D. Y. K Chan, “Simulation optimization of part input sequence in a flexible manufacturing system,†IEEE Proceedings of the 2011 Winter Simulation Conference, Phoenix, AZ.

      [28] C. Srinivas, B. Satyanarayana, K. Ramji and N. Ravela, “Determination of buffer size in single and multi row flexible manufacturing systems through simulation,†International Journal of Engineering Science and Technology, 3(5), 3889-3899 (2011).

      [29] A. Tripathi, M. Tiwari, F. Chan, “Multi-agent-based approach to solve part selection and task allocation problem in flexible manufacturing systems,†International Journal of Production Research 43(7), 1313-1335 (2005).

      [30] A. K. Kaban, Z. Othman and D. S. Rohmah, “Comparison of Dispatching Rules in Job-Shop Scheduling Problem using Simulation: A Case Study,†International Journal of Simulation Modelling 11(3), 129-140 (2011).

      [31] O. Al-Araidah, A. Boran and A. Wahsheh, “Reducing Delay in Healthcare delivery at Outpatients Clinics using Discrete Event Simulation, International Journal of Simulation Modelling 11(4), 185-195 (2012).

      [32] R. Zhao, “Simulation-based Environment Cost Analysis for Work-in-Progress,†International Journal of Simulation Modelling 11(4), 211-224 (2012).

      [33] D. Gracamin, B. Lalic, I. Beker, D. Lalic and B. Buchmeister, “Cost-Time Profile Simulation for Job Shop Scheduling Decisions,†International Journal of Simulation Modelling, 12(4), 213-224 (2013).

      [34] A. Singh, “Minimization of Mean Tardiness in a Flexible Job Shop,†International Journal of Simulation Modelling 12(3), 190-204 (2013).

      [35] W. B. Nordgren, “FlexSim simulation environment,†The IEEE Proceedings of the Winter Simulation Conference, pp. 250-252, Vol. 1 (2003).

      [36] J. Banks, J. S. Carson, B. L. Nelson and D. M. Nicol, Discrete-Event System Simulation, 5th Edition. Prentice Hall (2009).

      S. K. Mukhopadhyay, S. Midha, V. M. Krishna, “A heuristic procedure for loading problems in flexible manufacturing systems,†International Journal of Production Research 30(9), 2213-2228 (1992).
  • Downloads

  • How to Cite

    T.Nguyen, H., N.Tran, Q., P. Rifai, A., N.Huynh, H., & Zawiah Md Dawal, S. (2018). Simulation of the machine loading decision in flexible manufacturing cell based on FlexSim environment. International Journal of Engineering & Technology, 7(4.36), 15558-1563. https://doi.org/10.14419/ijet.v7i4.36.29372