Journal Of Industrial Engineering International
Volume:16 Issue: 1, Winter 2020

This paper presents a mathematical programming model for dynamic cell formation to minimize changeover-related costs (i.e., machine relocation costs and machine setup cost) and inter-cell material handling cost to cope with the volatile production environments in apparel manufacturing industry. The model is formulated through findings of a comprehensive literature review. Developed model is validated based on data collected from three different factories in apparel industry, manufacturing fast fashion products. A program code is developed using Lingo 16.0 software package to generate optimal cells for developed model and to determine the possible cost-saving percentage when the existing layouts used in three factories are replaced by generated optimal cells. The optimal cells generated by developed mathematical model result in significant cost saving when compared with existing product layouts used in production/assembly department of selected factories in apparel industry. The developed model can be considered as effective in minimizing the considered cost terms in dynamic production environment of fast fashion apparel manufacturing industry. Findings of this paper can be used for further researches on minimizing the changeover-related costs in fast fashion apparel production stage.

In this study, we propose a three-stage weighted sum method for identifying the group ranks of alternatives. In the first stage, a rank matrix, similar to the cross-efficiency matrix, is obtained by computing the individual rank position of each alternative based on importance weights. In the second stage, a secondary goal is defined to limit the vector of weights since the vector of weights obtained in the first stage is not unique. Finally, in the third stage, the group rank position of alternatives is obtained based on a distance of individual rank positions. The third stage determines a consensus solution for the group so that the ranks obtained have a minimum distance from the ranks acquired by each alternative in the previous stage. A numerical example is presented to demonstrate the applicability and exhibit the efficacy of the proposed method and algorithms.

Machines are a key element in the production system and their failure causes irreparable effects in terms of cost and time. In this paper, a new multi-objective mathematical model for dynamic cellular manufacturing system (DCMS) is provided with consideration of machine reliability and alternative process routes. In this dynamic model, we attempt to resolve the problem of integrated family (part/machine cell) formation as well as the operators’ assignment to the cells. The first objective minimizes the costs associated with the DCMS. The second objective optimizes the labor utilization and, finally, a minimum value of the variance of workload between different cells is obtained by the third objective function. Due to the NP-hard nature of the cellular manufacturing problem, the problem is initially validated by the GAMS software in small-sized problems, and then the model is solved by two well-known meta-heuristic methods including non-dominated sorting genetic algorithm and multi-objective particle swarm optimization in large-scaled problems. Finally, the results of the two algorithms are compared with respect to five different comparison metrics.

A debutanizer column is an integral part of any petroleum refinery. Online composition monitoring of debutanizer column outlet streams is highly desirable in order to maximize the production of liquefied petroleum gas. In this article, data-driven models for debutanizer column are developed for real-time composition monitoring. The dataset used has seven process variables as inputs and the output is the butane concentration in the debutanizer column bottom product. The input–output dataset is divided equally into a training (calibration) set and a validation (testing) set. The training set data were used to develop fuzzy inference, adaptive neuro fuzzy (ANFIS) and regression tree models for the debutanizer column. The accuracy of the developed models were evaluated by simulation of the models with the validation dataset. It is observed that the ANFIS model has better estimation accuracy than other models developed in this work and many data-driven models proposed so far in the literature for the debutanizer column.

Formation of effective teams of experts has played a crucial role in successful projects especially in social networks. In this paper, a new particle swarm optimization (PSO) algorithm is proposed for solving a team formation optimization problem by minimizing the communication cost among experts. The proposed algorithm is called by improved particle optimization with new swap operator (IPSONSO). In IPSONSO, a new swap operator is applied within particle swarm optimization to ensure the consistency of the capabilities and the skills to perform the required project. Also, the proposed algorithm is investigated by applying it on ten different experiments with different numbers of experts and skills; then, IPSONSO is applied on DBLP dataset, which is an example for benchmark real-life database. Moreover, the proposed algorithm is compared with the standard PSO to verify its efficiency and the effectiveness and practicality of the proposed algorithm are shown in our results.

This paper develops an economic production quantity model in a three-echelon supply chain composing of a supplier, a manufacturer and a wholesaler under two scenarios. As the first scenario, we consider a return contract between the outside supplier and the supplier and also between the manufacturer and the wholesaler, but in the second one, the return policy between the manufacturer and the wholesaler is not applied. Here, it is assumed that shortage is permitted and demand is price-sensitive. The principal goal of the research is to maximize the total profit of the chain by optimizing the order quantity of the supplier and the selling prices of the manufacturer and the wholesaler. Nash-equilibrium approach is considered between the chain members. In the end, a numerical example is presented to clarify the applicability of the introduced model and compare the profit of the chain under two scenarios.

In recent years, as the weight of IT equipment has been reduced, the demand for motor fans for cooling the interior of electronic equipment is on the rise. Sensory test technique by inspectors is the mainstream for quality inspection of motor fans in the field. This sensory test requires a lot of experience to accurately diagnose differences in subtle sounds (sound pressures) of the fans, and the judgment varies depending on the condition of the inspector and the environment. In order to solve these quality problems, development of an analysis method capable of quantitatively and automatically diagnosing the sound/vibration level of a fan is required. In this study, it was clarified that the analysis method applying the MT system based on the waveform information of noise and vibration is more effective than the conventional frequency analysis method for the discrimination diagnosis technology of normal and abnormal items. Furthermore, it was found that due to the automation of the vibration waveform analysis system, there was a factor influencing the discrimination accuracy in relation between the fan installation posture and the vibration waveform.

In practice, most projects result in cost overruns and schedule slippage due to poor resource management. This paper presents an approach that aims at reducing project duration and costs by empowering project managers to assess different scenarios. The proposed approach addresses combinatorial modes for tasks, multi-skilled resources, and multiple calendars for resources. A case study reported in the literature is presented to demonstrate the capabilities of this method. As for practical implications, this approach enhances the decision-making process which results in improved solutions in terms of total project duration and cost. From an academic viewpoint, this paper adds empirical evidence to enrich the existing literature, as it highlights relevant issues to model properly the complexity of real-life projects.

Flexible manufacturing system (FMS) readily addresses the dynamic needs of the customers in terms of variety and quality. At present, there is a need to produce a wide range of quality products in limited time span. On-time delivery of customers’ orders is critical in make-to-order (MTO) manufacturing systems. The completion time of the orders depends on several factors including arrival rate, variability, and batch size, to name a few. Among those, batch size is a significant construct for effective scheduling of an FMS, as it directly affects completion time. On the other hand, constant batch size makes MTO less responsive to customers’ demands. In this paper, an FMS scheduling problem with n jobs and m machines is studied to minimize lateness in meeting due dates, with focus on the impact of batch size. The effect of batch size on completion time of the orders is investigated under following strategies: (1) constant batch size, (2) minimum part set, and (3) optimal batch size. A mathematical model is developed to optimize batch size considering completion time, lateness penalties and setup times. Scheduling of an FMS is not only a combinatorial optimization problem but also NP-hard problem. Suitable solutions of such problems through exact methods are difficult. Hence, a meta-heuristic Genetic algorithm is used to optimize scheduling of the FMS.

Advertisement of the product is an important factor in inventory analysis. Also, price and stock have an important role to attract more customers in the competitive business situations. Trade credit policy is another important role in inventory analysis. We have combined these three factors together in a two-warehouse inventory model and represented it mathematically. In addition, we have added deteriorating factor of our proposed problem with price- and stock-dependent demand under partial backlogged shortage and solved. The frequency of advertisement is considered constant for a year in this paper. The proposed model is highly nonlinear in nature. Due to highly nonlinearity, we could not find the closed form solution. In this paper, trade credit facility is taken in the perspective of retailer, and all the possible cases and subcases of the model are discussed and solved using lingo 10.0 software. The results of sensitivity analysis prove the effectiveness of the proposed model.

The current paper develops three different ways to measure the multi-period global cost efficiency for homogeneous networks of processes when the prices of exogenous inputs are known at all time periods. A multi-period network data envelopment analysis model is presented to measure the minimum cost of the network system based on the global production possibility set. We show that there is a relationship between the multi-period global cost efficiency of network system and its subsystems, and also its processes. The proposed model is applied to compute the global cost Malmquist productivity index for measuring the productivity changes of network system and each of its process between two time periods. This index is circular. Furthermore, we show that the productivity changes of network system can be defined as a weighted average of the process productivity changes. Finally, a numerical example will be presented to illustrate the proposed approach.

In this paper, teaching–learning-based optimization (TLBO) is proposed to solve flexible job shop scheduling problem (FJSP) based on the integrated approach with an objective to minimize makespan. An FJSP is an extension of basic job-shop scheduling problem. There are two sub problems in FJSP. They are routing problem and sequencing problem. If both the sub problems are solved simultaneously, then the FJSP comes under integrated approach. Otherwise, it becomes a hierarchical approach. Very less research has been done in the past on FJSP problem as it is an NP-hard (non-deterministic polynomial time hard) problem and very difficult to solve till date. Further, very less focus has been given to solve the FJSP using an integrated approach. So an attempt has been made to solve FJSP based on integrated approach using TLBO. Teaching–learning-based optimization is a meta-heuristic algorithm which does not have any algorithm-specific parameters that are to be tuned in comparison to other meta-heuristics. Therefore, it can be considered as an efficient algorithm. As best student of the class is considered as teacher, after few iterations all the students learn and reach the same knowledge level, due to which there is a loss in diversity in the population. So, like many meta-heuristics, TLBO also has a tendency to get trapped at the local optimum. To avoid this limitation, a new local search technique followed by a mutation strategy (from genetic algorithm) is incorporated to TLBO to improve the quality of the solution and to maintain diversity, respectively, in the population. Tests have been carried out on all Kacem’s instances and Brandimarte's data instances to calculate makespan. Results show that TLBO outperformed many other algorithms and can be a competitive method for solving the FJSP.