New Directions for Operations Research in Manufacturing: Proceedings of a Joint US/German Conference, Gaithersburg, Maryland, USA, July 30–31, 1991

526 Pages·1992·16.535 MB·English

by  Richard H. F. Jackson (auth.), Prof. Dr. Günter Fandel, Prof. Dr. Thomas Gulledge, Dr. Albert Jones (eds.)

Gunter Fandel· Thomas Gulledge
Albert Jones (Eds.)
New Directions
for Operations Research
in Manufacturing
Proceedings of a Joint US/German Conference,
Gaithersburg, Maryland, USA, July 30-31,1991
Under the Auspices of
Operations Research Society of America (ORSA),
Deutsche Gesellschaft flir Operations Research (DGOR)
With 149 Figures
Springer-Verlag
Berlin Heidelberg New York
London Paris Tokyo
Hong Kong Barcelona
Budapest
Prof. Dr. Gunter Fandel
Institute of Production Management
Femuniversitat Hagen
D-5800 Hagen 1, FRG
Prof. Dr. Thomas Gulledge
The Institute of Public Policy
George Mason University
Fairfax, VA 22030-444, USA
Dr. Albert Jones
AMFR
NIST B 124 Metrology
Gaithersburg, MD 20899, USA
ISBN-13: 978-3-642-77539-0 e-ISBN-13: 978-3-642-77537-6
001: 10.1007/978-3-642-77537-6
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© Springer-Verlag Berlin· Heidelberg 1992
Softcover reprint of the hardcover 1s t edition 1992
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PREFACE
In 1989, the German operations Research Society (DGOR) approached
the Manufacturing Management special interest group of the Operations
Research Society of America (ORSA-SIGMA) with the idea of jointly
organizing two conferences on New Directions for operations Research in
Manufacturing. It was agreed that the first conference would be held in
the united States, and the second would be held in Germany.
In discussing possible conference locations, a decision was made to
approach the Manufacturing Engineering Laboratory at the National
Institute of Standards and Technology (NIST) in Gaithersburg, Maryland.
NIST was receptive, and the decision was made to host the conference on
the NIST campus, with three sponsoring organizations: DGOR, ORSA-SIGMA,
and NIST.
In the early planning stages, the principal organizers contacted the
Division of Design and Manufacturing Systems of the National Science
Foundation, and proposed that NSF provide financial support for the
conference. After formalizing the arrangements, the conference was held
on July 30-31, 1991 under the sponsorship of DGOR, ORSA-SIGMA, and NIST,
and with the financial support of the National Science Foundation.
We do not wish to summarize each paper in this volume, but we do
want to point out the special nature of this book. We requested papers
that address new and unique theoretical developments and applications
related to operations research in manufacturing. The challenge to address
these new problems in manufacturing was discussed by Richard H.F. Jackson
in the conference plenary address. The plenary presentation is printed as
the lead article in this volume.
After the refereeing process, forty papers were selected for
presentation at the conference. The subset of the papers that are printed
in this proceedings documents the quality of the submissions and the
adherence to the conference theme.
We wish to thank everyone who helped make this conference a success.
In particular, we thank Prof. Dr. Wolfgang BUhler of DGOR, Dr. Thomas
Baker of ORSA-SIGMA, and Dr. Richard Jackson of NIST. We owe special
thanks to Professors Donald Gross, Thomas Hodgson, and Louis Martin-vega,
who represented the National Science Foundation in supporting this
conference.
Gunter Fandel, Co-Program Chairperson, DGOR
Thomas Gulledge, Co-Program Chairperson, ORSA-SIGMA
Al Jones, General Chairperson, NIST
TABLE OF CONTENTS
I. Plenary Address
Whither Manufacturing and Operations Research? 3
Richard H.F. Jackson
II. Planning and Control
An Hierarchical Planning, Loading, Routing and 25
Control Scheme for Flexible Manufacturing Systems
Ronald G. Askin, Manbir S. Sodhi, Suvrajeet Sen,
and Alessandro Agnetis
Analysis of Production Planning and Control (PPC) 40
Systems as an Efficient Combination of Information
Activities
Gunter Fandel
Hierarchical Production Planning in Group 60
Technologies
Klaus-Peter Kistner, Stephan Schumacher, and
Marion Steven
Design of an Information-Based Distributed 75
Production Planning System
Joachim Reese
LP-Models in Production Planning and Control 91
D.B. Pressmar
A Realization for a Generic Controller in 101
Production Planning Hierarchies
W.J. Davis and S.D. Thompson
III. Genetic Algorithms
Sequence scheduling with Genetic Algorithms 129
T. starkweather, D. Whitley, K. Mathias, and
S. McDaniel
Local Search in Problem and Heuristic Space 149
for Job Shop Scheduling Genetic Algorithms
Robert H. Storer, S. David Wu, and Renzo Vaccari
The Application of a Parallel Genetic Algorithm 161
to the n/m/P/Cmax Flowshop Problem
S. Stoppler and C. Bierwirth
VUI
IV. scheduling
Scheduling Semiconductor Test operations: 179
Optimization and Approximation
Reha Uzsoy, chung-Yee Lee, Louis A. Martin-Vega,
and Jim Hinchman
Job and Tool Scheduling for Flexible Machining 200
Cells
S. Webster
Scheduling and Control of Flexible Manufacturing 216
Systems: Some Experiences and Observations
Richard A. Wysk, Sanjay Joshi, and Ning-shu
(Bob) Yang
Dispatching Issues in Job Shop Scheduling 234
Khosrow Hadavi, Yuan-Wang HOu, Wen-Ling HSu,
David Levy, and Michael Pinedo
V. Real-Time scheduling
Dynamic Task Assignment in Distributed 249
Manufacturing Systems
A. Aman, A. Balakrishnan, and V. Chandru
An Object-oriented Knowledge Representation 263
in Real-Time Scheduling
Pierre Lerranqois, Marie-Helene Jobin, and
Benoit Montreuil
An Expert System for Distributed Real-Time 280
Scheduling of Factory Communications Resources
M.D. Pardue
A Rescheduling Procedure for Manufacturing 292
Systems Under Random Disruptions
S. David Wu, Robert H. storer, and P.-C. chang
VI. Neural Networks
A Hybrid Approach to Flexible Manufacturing Systems 309
Scheduling Using Neural and Symbolic Processing
Luis Carlos Rabelo and Sema Alptekin
Applying Artificial Neural Networks to Process 331
Planning
Luis Carlos Rabelo and Derya Alasya
A Hybrid Intelligent Architecture for Automated 346
PCB Assembly
Mahesh Vellanki and Cihan H. Dagli
Neural Networks for Detection of Process Change 369
in Manufacturing systems
Tep Sastri
VII. Applications of Mathematical Programming
Tabu Search Techniques for the Quadratic 389
Semi-Assignment Problem
Wolfgang Domschke, Peter Forst, and Stephan VoB
The Impact of Correlated Demands on Integrated 406
Safety Stock optimization in Multi-Stage Manufacturing
Systems
Karl Inderfurth
VIII. Applications of Modelling
An Integrated system Shell Concept for 425
Computer Aided Design and Planning
Amy J.e. Trappey and C. Richard Liu
Service Level in Multistage MRP and Base Stock 445
Controlled Production Systems
John A. Buzacott, Suzanne M. Price, and
J. George Shanthikumar
Rapid Modeling: Methods and Tools for Strategic 464
and Operational Planning of Manufacturing Systems
Kenneth R. Anderson and Maryam Shahraray
Enterprise Models for the Design and Management 476
of Manufacturing systems
Bruce E. Koenig and R. Lal Tummala
Responsive Tool Management: Making Fixed 500
Manufacturing Systems More Flexible
P. Rogers, D. veeramani, and M.M. Barash
Multicriteria Design of Manufacturing Systems 520
Gerald W. Evans, sai Kolli, and Mansooreh
Mollaghasemi
List of Sponsors 531
I. Plenary Address
WHITIlER MANUFACTURING AND OPERATIONS RESEARCH?
Richard H. F. Jackson
Deputy Director
Manufacturing Engineering Laboratory
National Institute of Standards and Technology
Gaithersburg, MD 20899
I. INTRODUCTION
This paper is based on opening remarks made at the First Joint US/German
Conference on New Directions for OR in Manufacturing. It was an honor to be invited
to make those opening remarks, and an additional honor to have the opportunity to
include them in these proceedings. In this paper, we explore the current status of
manufacturing technology in the United States, describe a vision of next-generation
manufacturing systems, and discuss ongoing research at the National Institute of
Standards and Technology (NIST) in support of U.S. industry's efforts to achieve that
vision. In addition, we discuss some of the history of the operations research (OR)
profession, make some observations concerning its present state of health, and
comment on the important role OR professionals can play in this national effort to
help U.S. industry survive and thrive in the next century.
II. HISTORICAL CONTEXT
The United States is at a critical juncture in its manufacturing history. Since the
first industrial revolution, the U.S. manufacturing sector has maintained a position of
strength in competition for world market share. The strength of this industrial base has
provided incredible growth in the U.S. gross national product and contributed
immensely to the material well-being of the citizenry. Unfortunately, this position and
its beneficial effects on the standard of living can no longer be taken for granted. U.S.
industries are being threatened from all sides: market share has been slipping, capital
equipment is becoming outdated, and the basic structure of the once mighty U.S.
corporation is being questioned.
4
A growing national debate has focused on this decline of U.S. industry's
competitiveness and the resultant loss of market share in the global marketplace. This
rapid loss of competitiveness of American industry in international markets is an
extremely serious problem with wide-ranging consequences for the United States'
material well-being, political influence, and security. The national debate on this
subject has identified many possible culprits, ranging from trade deficits to short-term,
bottom-line thinking on the part of U.S. management to inappropriate and outdated
management and engineering curricula at U.S. universities. Nevertheless, among them
certainly are the slow rate at which new technology is incorporated in commercial
products and processes, and the lack of attention paid to manufacturing. There is a
clear need to compete in world markets with high-value-added products, incorporating
the latest innovations, manufactured in short runs with flexible manufacturing methods.
Research, management, and manufacturing methods that support change and
innovation are key ingredients needed to enhance our nation's competitive position.
As America's industry faces these greater and greater economic challenges,
increasing emphasis will be placed, not just on technological solutions to these
problems, but on our effectiveness in managing these new technologies. While
operations research and management science methods may be helpful to those
addressing these managerial and economic issues, these methods surely can help
improve productivity in the manufacturing sector. These techniques, if effectively
applied, can be helpful in the classical ways, e.g., scheduling, routing, layout, and
process modeling. In addition, they could be critical to attempts to implement the new
advanced manufacturing technologies and make them operate efficiently.
In fact, efforts in these areas seem to be paying off already. In his upbeat
message on technology opportunities for America [1], John Lyons, the NIST Director,
reports recent impressive gains in the cost of labor, productivity and the balance of
trade. As Lyons notes, one key area in which we must focus continued effort is in
commercializing new technologies. As a nation, we have been slow to capitalize on
new technology developed from America's own intellectual capability. Many ideas
originating in the American scientific and technical community are being commercially
exploited in other parts of the world. In the past, small and mid-sized companies have
led U.S. industry in innovation. The nation must now find ways to help such companies
meet the demands of global competition, when the speed with which firms are able to