JOURNAL OF INDUSTRIAL ENGINEERING INTERNATIONAL
Year:2014 | Volume:10 | Issue:2|Papers Count:8

The article presents the application of total productive maintenance (TPM) to analyze the working time indicators of casting machines with particular emphasis on failures and unplanned downtime to reduce the proportion of emergency operation for preventive maintenance and diagnostics. The article presents that the influence of individual factors of complex machinery maintenance (TPM) is different and depends on the machines’ modernity level. In an original way, by using correlation graphs, research findings on the impact of individual TPM factors on the castings quality were presented and interpreted. The examination results conducted for machines with varying modernity degrees allowed to determine changes within the impact of individual TPM factors depending on machine parameters. These results provide a rich source of information for the improvement processes on casting quality of the foundry industry that satisfies the automotive industry demand.

The demand forecasting is essential for all production and non-production systems. However, nowadays there are only few researches on this area. Most of researches somehow benefited from simulation in the conditions of demand uncertainty. But this paper presents an iterative method to find most probable stochastic demand point with normally distributed and independent variables of n-dimensional space and the demand space is a nonlinear function. So this point is compatible with both external conditions and historical data and it is the shortest distance from origin to the approximated demand-state surface. Another advantage of this paper is considering n-dimensional and nonlinear (nth degree) demand function. Numerical results proved this procedure is convergent and running time is reasonable.

Flow-shop scheduling problem (FSP) deals with the scheduling of a set ofn jobs that visit a set of mmachines in the same order. As the FSP is NP-hard, there is no efficient algorithm to reach the optimal solution of the problem. To minimize the holding, delay and setup costs of large permutation flow-shop scheduling problems with sequence-dependent setup times on each machine, this paper develops a novel hybrid genetic algorithm (HGA) with three genetic operators. Proposed HGA applies a modified approach to generate a pool of initial solutions, and also uses an improved heuristic called the iterated swap procedure to improve the initial solutions. We consider the make-to-order production approach that some sequences between jobs are assumed as tabu based on maximum allowable setup cost. In addition, the results are compared to some recently developed heuristics and computational experimental results show that the proposed HGA performs very competitively with respect to accuracy and efficiency of solution.

Automotive emission is becoming a critical threat to today’s human health. Many researchers are studying engine designs leading to less fuel consumption. Gearbox selection plays a key role in an engine design. In this study, Taguchi quality engineering method is employed, and optimum gear ratios in a five speed gear box is obtained. A table of various gear ratios is suggested by design of experiment techniques. Fuel consumption is calculated through simulating the corresponding combustion dynamics model. Using a 95% confidence level, optimal parameter combinations are determined using the Taguchi method. The level of importance of the parameters on the fuel efficiency is resolved using the analysis of signal-to-noise ratio as well as analysis of variance.

The define–measure–analyze–improve–control (DMAIC) approach is a five-strata approach, namely DMAIC. This approach is the scientific approach for reducing the deviations and improving the capability levels of the manufacturing processes. The present work elaborates on DMAIC approach applied in reducing the process variations of the stub-end-hole boring operation of the manufacture of crankshaft. This statistical process control study starts with selection of the critical-to-quality (CTQ) characteristic in the define stratum. The next stratum constitutes the collection of dimensional measurement data of the CTQ characteristic identified. This is followed by the analysis and improvement strata where the various quality control tools like Ishikawa diagram, physical mechanism analysis, failure modes effects analysis and analysis of variance are applied. Finally, the process monitoring charts are deployed at the workplace for regular monitoring and control of the concerned CTQ characteristic. By adopting DMAIC approach, standard deviation is reduced from 0.003 to 0.002. The process potential capability index (CP) values improved from 1.29 to 2.02 and the process performance capability index (CPK) values improved from 0.32 to 1.45, respectively.

Distribution network design as a strategic decision has long-term effect on tactical and operational supply chain management. In this research, the location–allocation problem is studied under demand uncertainty. The purposes of this study were to specify the optimal number and location of distribution centers and to determine the allocation of customer demands to distribution centers. The main feature of this research is solving the model with unknown demand function which is suitable with the real-world problems. To consider the uncertainty, a set of possible scenarios for customer demands is created based on the Monte Carlo simulation. The coefficient of variation of costs is mentioned as a measure of risk and the most stable structure for firm’s distribution network is defined based on the concept of robust optimization. The best structure is identified using genetic algorithms and 14% reduction in total supply chain costs is the outcome. Moreover, it imposes the least cost variation created by fluctuation in customer demands (such as epidemic diseases outbreak in some areas of the country) to the logistical system. It is noteworthy that this research is done in one of the largest pharmaceutical distribution firms in Iran.

This paper presents a new approach to solve Fractional Programming Problems (FPPs) based on two different Swarm Intelligence (SI) algorithms. The two algorithms are: Particle Swarm Optimization, and Firefly Algorithm. The two algorithms are tested using several FPP benchmark examples and two selected industrial applications. The test aims to prove the capability of the SI algorithms to solve any type of FPPs. The solution results employing the SI algorithms are compared with a number of exact and metaheuristic solution methods used for handling FPPs. Swarm Intelligence can be denoted as an effective technique for solving linear or nonlinear, non-differentiable fractional objective functions. Problems with an optimal solution at a finite point and an unbounded constraint set, can be solved using the proposed approach. Numerical examples are given to show the feasibility, effectiveness, and robustness of the proposed algorithm. The results obtained using the two SI algorithms revealed the superiority of the proposed technique among others in computational time. A better accuracy was remarkably observed in the solution results of the industrial application problems.

To design a group layout of a cellular manufacturing system (CMS) in a dynamic environment, a multi-objective mixed-integer non-linear programming model is developed. The model integrates cell formation, group layout and production planning (PP) as three interrelated decisions involved in the design of a CMS. This paper provides an extensive coverage of important manufacturing features used in the design of CMSs and enhances the flexibility of an existing model in handling the fluctuations of part demands more economically by adding machine depot and PP decisions. Two conflicting objectives to be minimized are the total costs and the imbalance of workload among cells. As the considered objectives in this model are in conflict with each other, an archived multi-objective simulated annealing (AMOSA) algorithm is designed to find Pareto-optimal solutions. Matrix-based solution representation, a heuristic procedure generating an initial and feasible solution and efficient mutation operatorsare the advantages of the designed AMOSA. To demonstrate the efficiency of the proposed algorithm, the performance of AMOSA is compared with an exact algorithm (i.e., Î-constraint method) solved by the GAMS software and a well-known evolutionary algorithm, namely NSGAII for some randomly generated problems based on some comparison metrics. The obtained results show that the designed AMOSA can obtain satisfactory solutions for the multi-objective model.