Institute for Systems Research Technical Reports

Permanent URI for this collectionhttp://hdl.handle.net/1903/4376

This archive contains a collection of reports generated by the faculty and students of the Institute for Systems Research (ISR), a permanent, interdisciplinary research unit in the A. James Clark School of Engineering at the University of Maryland. ISR-based projects are conducted through partnerships with industry and government, bringing together faculty and students from multiple academic departments and colleges across the university.

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Subject: search.filters.subject.plant layout

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Now showing 1 - 10 of 17
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    Modeling Separations of Plant Layout Problems
    (2014-08) Herrmann, Jeffrey
    This paper describes the results of a simulation study that evaluated the performance of different separations of the plant layout problem solved by bounded rational decision-makers. Seven problem instances from the literature were studied. We simulated the solution of a problem by a bounded rational decision-maker as a random search over the solution space. The problem was separated by identifying “subsets” of adjacent locations. The subset assignment problem partitioned the departments into subsets corresponding to these subsets of locations. Then, the subset layout problem assigned the locations in the subset to the departments. We considered separations with 2, 3, and 4 subsets. We also considered separations that first aggregated the departments before assigning them to subsets of locations. The results showed that separating the problem can lead to better solutions than solving the problem all-at-once, but some separations lead to worse solutions. Maximizing the flow inside the subsets generated better solutions than maximizing the adjacency of the departments inside the subsets. When fewer subsets are used, minimizing the cost inside each subset generated better solutions than minimizing the total cost. These results show that the quality of the solutions created by a design process is influenced by the choice of subproblems that make up the design process.
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    REU Report: Development of an Agent-Based Factory Shop Floor Simulation Tool
    (1999) Whangbo, Albert J.; Lin, Edward; Herrmann, Jeffrey; ISR
    Manufacturing systems of the future are expected to be agile and failure-tolerant. Current simulation tools are not well equipped to model these dynamically changing systems. Agent-based simulation represents an attractive alternative to traditional simulation techniques. This project aims to develop software for agent-based factory shop floor simulation. The current version of the factory simulation software is implemented in Java. Although the program lacks important features of a decision support tool, it provides a flexible agent-based framework for modeling and testing shop floor configurations.
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    A Genetic Algorithm for Minimax Optimization
    (1997) Herrmann, Jeffrey W.; ISR
    This paper describes a two-space genetic algorithm that finds solutions to minimax optimization problems. The genetic algorithm maintains two populations and searches both simultaneously. Each individual is evaluated with respect to the individuals in the other population. Preliminary experimental results confirm that the algorithm can find good solutions to minimax optimization problems.
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    Integrated Manufacturing Facility Design
    (1995) Ioannou, George; Minis, I.; ISR
    This dissertation addresses for the first time the integrated problem of designing the manufacturing shop layout concurrently with its material handling system. Specifically, this study provides a method to derive shop designs that are economic to set up and efficient to operate. In doing so, it considers the following highly interrelated issues: i) The topology of the material flow network, ii) the transporter fleet size and routing, and iii) the layout of the resource groups on the shop floor. The design problem is modeled by a comprehensive mathematical program which captures critical practical concerns such as investment and operational costs, traffic congestion, and transporter capacities. The model is decomposed into three NP- hard subproblems by fixing and/or aggregating variables and constraints. The first subproblem is the generic multi-commodity fixed charge capacitated network design, for which an improved lower bound is derived based on a dual ascent method. This problem is solved by three heuristics that provide near-optimal network designs. The second subproblem concerns the transporter routing, which is a special case of the distance-constrained vehicle routing problem. For the transporter routing problem near-optimal solutions are derived in polynomial time by two efficient heuristics with bounded worst-case performance. Tight lower bounds are provided by solutions to the assignment problem. An integrated method combines the most effective heuristics for the material handling system design subproblems with a simulated annealing scheme to solve the global shop design problem. Our novel approach addresses simultaneously most major decisions involved in manufacturing shop design, and provides globally near optimal solutions. The method is applied to the redesign of the shop of a large manufacturer, and generates a particularly attractive production system design reducing significantly both investment and operational costs, while providing for smooth system operation.
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    An Integrated Model for Manufacturing Shop Design
    (1995) Ioannou, George; Minis, Ioannis; ISR
    This paper presents an integer programming formulation for the manufacturing shop design problem, which integrates decisions concerning the layout of the resource groups on the shop floor with the design of the material handling system. The model reflects critical practical design concerns including the capacity of the flow network and of the transporters, and the tradeoff between fixed (construction and acquisition) and variable (operational) costs. For realistic industrial cases, the size of the problem prevents the solution through explicit or implicit enumeration schemes. The paper addresses this limitation by decomposing the global model into its natural components. The resulting submodels are shown to be standard problems of operations research. The decomposition approach provides ways to solve the integrated shop design problem in an effective manner.
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    Current Research on Manufacturing Shop and Material Handling System Design
    (1995) Ioannou, George; Minis, Ioannis; ISR
    The importance of the manufacturing shop design in the successful operation of a production system is well known and as a result, significant research has been devoted to this area. This paper reviews important literature in various aspects of manufacturing shop design including layout, material flow path design, and transporter fleet sizing and routing. In addition, the paper focuses on contributions to integration issues such as the design for operation of material handling systems, and the concurrent design of the shop layout and the transportation system. Research studies in these areas are critically examined, and emerging opportunities for research are identified.
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    Minimizing Work-in-Process and Material Handling in the Facilities Layout Problem
    (1995) Fu, Michael C.; Kaku, Bharat K.; ISR
    We consider the plant layout problem for a job shop environment. This problem is generally treated as a quadratic assignment problem with the objective of minimizing material handling costs. In this paper we investigate conditions under which the quadratic assignment solution also minimizes average work-in-process. To get some initial insights, we model the plant as an open queueing network and show that under a certain set of assumptions, the problem of minimizing work-in-process reduces to the quadratic assignment problem. We then investigate via simulation the robustness of this result. We found that the relationship between material handling costs and average work-in-process holds under much more general conditions than are assumed in the analytical model. For those cases where the result does not hold, we have refined the model by developing a simple secondary measure which appears to work well in practice.
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    Minimization of Acquisition and Operational Costs in Horizontal Material Handling System Design
    (1995) Herrmann, Jeffrey W.; Ioannou, George; Minis, Ioannis; Proth, J.M.; ISR
    This paper considers the problem of minimizing the fixed cost of acquiring material handling transporters and the operational cost of material transfer in a manufacturing system. This decision problem arises during manufacturing facility design, and is modeled using an integer programming formulation. Two efficient heuristics are developed to solve it. Computational complexity, worst-case performance analysis, and extensive computational tests are provided for both heuristics. The results indicate that the proposed methods are well suited for large-scale manufacturing applications.
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    Design of Material Flow Networks in Manufacturing Facilities
    (1994) Herrmann, Jeffrey W.; Ioannou, George; Minis, Ioannis; Nagi, R.; Proth, J.M.; ISR
    In this paper we consider the design of material handling flow paths in a discrete parts manufacturing facility. A fixed-charge capacitated network design model is presented and two efficient heuristics are proposed to determine near-optimal solutions to the resulting NP- hard problem. The heuristics are tested against an implicit enumeration scheme used to obtain optimal solutions for small examples. For more realistic cases, the solutions of the heuristics are compared to lower bounds obtained by either the linear programming relaxation of the mixed integer program, or an iterative dual ascent algorithm. The results obtained indicate that the heuristics provide good solutions in reasonable time on the average. The proposed methodology is applied to design the flow paths of an existing manufacturing facility. The role of the flow path network problem in the integrated shop design is also discussed.
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    A Practical Method for Design of Hybrid-Type Production Facilities
    (1994) Harhalakis, George; Lu, Thomas C.; Minis, Ioannis; Nagi, R.; ISR
    A comprehensive methodology for the design of hybrid-type production shops that comprise both manufacturing cells and individual workcenters is presented. It targets the minimization of the material handling effort within the shop and comprises four basic steps: (1) identification of candidate manufacturing cells, (2) evaluation and selection of the cells to be implemented, (3) determination of the intra-cell layout, and (4) determination of the shop layout. For the cell formation step the ICTMM technique has been enhanced to cater for important practical issues. The layout of each significant cell is determined by a simulated annealing (SA)-based algorithm. Once the sizes and shapes of the selected cells are known, the shop layout is determined by a similar algorithm. The resulting hybrid shop consists of the selected cells and the remaining machines. The methodology has been implemented in an integrated software system and has been applied to redesign the shop of a large manufacturer of radar antennas.