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A Framework to Generate a Smart Manufacturing System Configurations Using Agents and Optimization

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A Framework to Generate a Smart Manufacturing System Configurations Using Agents and Optimization University of Central Florida STARS Electronic Theses and Dissertations, 2004-2019 2016 A framework to generate a smart manufacturing system configurations using agents and optimization Khalid Nagadi University of Central Florida Part of the Industrial Engineering Commons Find similar works at: https://stars.library.ucf.edu/etd University of Central Florida Libraries http://library.ucf.edu This Doctoral Dissertation (Open Access) is brought to you for free and open access by STARS. It has been accepted for inclusion in Electronic Theses and Dissertations, 2004-2019 by an authorized administrator of STARS. For more information, please contact [email protected]. STARS Citation Nagadi, Khalid, "A framework to generate a smart manufacturing system configurations using agents and optimization" (2016). Electronic Theses and Dissertations, 2004-2019. 5329. https://stars.library.ucf.edu/etd/5329 A FRAMEWORK TO GENERATE SMART MANUFACTURING SYSTEM CONFIGURATIONS USING AGENTS AND OPTIMIZATION by KHALID AHMED NAGADI B.S. Industrial Engineering, King Abdulaziz University, Saudi Arabia, 2005 M.S. Industrial Engineering, Ohio State University, 2008 M.S. Industrial Engineering University of Central Florida, 2012 A dissertation submitted in partial fulfillment of the requirements for the degree of Doctor of Philosophy in the Department of Industrial Engineering and Management Systems in the College of Engineering and Computer Science at the University of Central Florida Orlando, Florida Spring Term 2016 Major Professor: Luis C. Rabelo ©2016 Khalid A. Nagadi ii ABSTRACT Manufacturing is a crucial element in the global economy. During the last decade, the national manufacturing sector loses nearly 30% of its workforce and investments. Consequently, the quality of the domestic goods, global share, and manufacturing capabilities has been declined. Therefore, innovative ways to optimize the usage of the Smart Manufacturing Systems (SMS) are required to form a new manufacturing era. This research is presenting a framework to optimize the design of SMS. This includes the determination of the suitable machines that can perform the job efficiently, the quantity of those machines, and the potential messaging system required for sharing information. Multiple reviews are used to form the framework. Expert machine selection matrix identifies the required machines and machine parameter matrix defines the specifications of those machines. While business process modeling and notation (BPMN) captures the process plan in object-oriented fashion. In addition, to agent unified modeling language (AUML) that guides the application of message sequence diagram and statecharts. Finally, the configuration is obtained from a hybrid simulation model. Agent based-modeling is used to capture the behavior of the machines where discrete event simulation mimics the process flow. A case study of a manufacturing system is used to verify the study. As a result, the framework shows positive outcomes in supporting upper management in the planning phase of establishing a SMS or evaluating an existing one. iii ACKNOWLEDGMENTS First and foremost, I thank Allah for giving me the health and strength to overcome all difficulties during my PhD journey. I would like to express my appreciation and thanks to my advisor Dr.Luis Rabelo, you have been a great educator and mentor. Thank you for your endless encouragement, patience, and guidance throughout my research. I am extremely grateful to my committee members: Dr.Ahamd Elshennawy, Dr.Gene Lee, and Dr.Ali Ahmad for their valuable advices. Much appreciation to Mr. Omar Silk and Mr. Christopher Rose Petrilli, for their support and assistance to accomplish this work. I would also extend my thanks to all faculty and staff in the Department of Industrial Engineering and Management Systems at the University of Central Florida who directly and indirectly contributed to my doctoral study. Special thanks to my parents, family, friends, and colleagues. Words cannot express how grateful I am for all of the sacrifices that you’ve made on my behalf. Your prayer for me was what sustained me thus far. iv TABLE OF CONTENT LIST OF FIGURES ............................................................................................................................. ix LIST OF TABLES............................................................................................................................ xiii CHAPTER 1 INTRODUCTION ............................................................................................... 1 1.1 Background........................................................................................................................... 1 1.1.1 Computer Aided Design (CAD) ..................................................................................... 6 1.1.2 Industrial Robots .............................................................................................................. 7 1.1.3 Group Technology (GT) .................................................................................................. 7 1.1.4 Flexible Manufacturing Systems (FMS) ........................................................................ 7 1.1.5 Automated material handling systems ............................................................................ 8 1.1.6 Automated Storage and retrieval systems (AS/RS) ....................................................... 8 1.1.7 Computer Numerically Control (CNC) machine ........................................................... 8 1.2 Flexible Manufacturing Systems (FMS) ............................................................................ 8 1.2.1 Classification of FMS ...................................................................................................... 9 1.2.2 Flexibility in FMS .......................................................................................................... 10 1.2.3 Long-Term Planning ...................................................................................................... 11 1.2.4 Short-term Planning of FMS ......................................................................................... 11 1.3 Problem Statement ............................................................................................................. 13 1.4 Research Objectives ........................................................................................................... 13 1.5 Research Questions ............................................................................................................ 14 1.6 Contribution ........................................................................................................................ 14 v 1.7 Organization of the Reminder of this Document ............................................................. 14 CHAPTER 2 LITERATURE REVIEW ................................................................................. 15 2.1 Introduction ........................................................................................................................ 15 2.2 Smart Manufacturing Systems .......................................................................................... 16 2.3 Design of FMS and Machine Tool Selection ................................................................... 23 2.4 Queuing............................................................................................................................... 25 2.5 Analytic Hierarchy Process (AHP) ................................................................................... 26 2.6 Other Models ...................................................................................................................... 32 2.7 Machine-tool selection ....................................................................................................... 33 2.8 Agent based-modeling in manufacturing ......................................................................... 39 2.8.1 Background .................................................................................................................... 39 2.8.2 Agent Characteristics ..................................................................................................... 40 2.8.3 Agent Structure .............................................................................................................. 41 2.8.4 Agent Architectures ....................................................................................................... 41 2.8.5 Agent Modeling and Frameworks ................................................................................ 41 2.8.6 Agents in Scheduling and Job-Shop Control ............................................................... 43 2.8.7 Decision-Making and Controls ..................................................................................... 49 2.8.8 Reconfiguration.............................................................................................................. 50 2.9 Optimization in AMS......................................................................................................... 51 2.10 FMS configuration ............................................................................................................. 51 2.11 Introduction of Genetic Algorithms .................................................................................. 52 2.11.1 Machine Loading Problem ........................................................................................ 53 vi 2.11.2 Scheduling
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