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9780387709871

Throughput Optimization in Robotic Cells

by ; ; ;
  • ISBN13:

    9780387709871

  • ISBN10:

    0387709878

  • Format: Hardcover
  • Copyright: 2007-04-30
  • Publisher: Springer Verlag
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Summary

Modern manufacturing processes have thoroughly incorporated automation and repetitive processing. The use of computer-controlled material handling systems to convey raw materials through the multiple processing stages required to produce a finished product is widely employed in industry world-wide. Central to these systems are robot-served manufacturing cells, or robotic cells. These cells perform a variety of functions including arc welding, material handling, electroplating, textiles creation, and machining. In addition, they are used in many different industries, including injection molding of battery components, glass manufacturing and processing, building products, cosmetics, lawn tractors, fiber-optics, and semi-conductor manufacturing. In the medical field, robotic cells are used to produce components for magnetic resonance imaging systems, for automated pharmacy compounding, to process nucleic acids, and to generate compounds for tests in relevant biological screens. Cells for grinding, polishing, and buffing handle many products, including rotors, stainless steel elbows for the chemical and the food industries, sink levers and faucets, propane tanks, flatware, automotive products, and more. All of this has resulted with the rapid growth of robotic cell scheduling. As manufacturers have employed them in greater numbers and greater varieties, analysts have developed new models and techniques to maximize these cells productivity. Competitive pressures will result in the development of more advanced cells and, hence, more sophisticated studies. Therefore, robotic cell scheduling should continue to attract the attention of a growing number of practitioners and researchers. THROUGHPUT OPTIMIZATION IN ROBOTIC CELLS is a comprehensive introduction to the field of robotic scheduling. It discusses the basic properties of robotic cells and outlines in detail the tools most often used to analyze them. In doing so, the book will provide a thorough algorithmic analysis of optimal policies for a variety of implementations. The book provides a classification scheme for robot cell scheduling problems that is based on cell characteristics, and discusses the influence of these characteristics on the methods of analysis employed. Implementation issues are stressed. Specifically, these issues are explored in terms of implementing solutions and open problems.

Table of Contents

Prefacep. xv
Robotic Cells In Practicep. 1
Cellular Manufacturingp. 2
Robotic Cell Flowshopsp. 3
Throughput Optimizationp. 7
Historical Overviewp. 9
Applicationsp. 11
A Classification Scheme For Robotic Cells And Notationp. 15
Machine Environmentp. 15
Number of Machinesp. 15
Number of Robotsp. 16
Types of Robotsp. 17
Cell Layoutp. 17
Processing Characteristicsp. 17
Pickup Criterionp. 17
Travel-Time Metricp. 18
Number of Part-Typesp. 20
Objective Functionp. 20
An ¿ ß/¿ Classification for Robotic Cellsp. 20
Cell Datap. 24
Processing Timesp. 24
Loading and Unloading Timesp. 24
Notations for Cell States and Robot Actionsp. 25
Cyclic Productionp. 29
Operating Policies and Dominance of Cyclic Solutionsp. 29
Cycle Timesp. 34
Waiting Timesp. 34
Computation of Cycle Timesp. 35
Lower Bounds on Cycle Timesp. 39
Optimal 1-Unit Cyclesp. 40
Special Casesp. 40
General Cases: Constant Travel-Time Cellsp. 43
Optimization over Basic Cyclesp. 51
General Cases: Additive and Euclidean Travel-Time Cellsp. 61
Calculation of Makespan of a Lotp. 63
A Graphical Approachp. 63
Algebraic Approachesp. 64
Quality of 1-Unit Cycles and Approximation Resultsp. 65
Additive Travel-Time Cellsp. 66
Pyramidal Cyclesp. 68
A 1.5-Approximation Algorithmp. 68
A 10/7-Approximation for Additive Cellsp. 74
Constant Travel-Time Cellsp. 87
A 1.5-Approximation Algorithmp. 89
Euclidean Travel-Time Cellsp. 94
Dual-Gripper Robotsp. 101
Additional Notationp. 102
Cells with Two Machinesp. 104
A Cyclic Sequence for m-Machine Dual-Gripper Cellsp. 107
Dual-Gripper Cells with Small Gripper Switch Timesp. 114
Comparing Dual-Gripper and Single-Gripper Cellsp. 116
Comparison of Productivity: Computational Resultsp. 122
Efficiently Solvable Casesp. 128
Single-Gripper Cells with Output Buffers at Machinesp. 131
Dual-Gripper Robotic Cells: Constant Travel Timep. 141
Lower Bounds and Optimal Cycles: m-Machine Simple Robotic Cellsp. 143
One-Unit Cyclesp. 144
Multi-Unit Cyclesp. 146
Parallel Machines153
Single-Gripper Robotsp. 154
Definitionsp. 154
k-Unit Cycles and Blocked Cyclesp. 156
Structural Results for k-Unit Cyclesp. 156
Blocked Cyclesp. 157
LCM Cyclesp. 165
Practical Implicationsp. 169
Optimal Cycle for a Common Casep. 169
Fewest Machines Required to Meet Timelinesp. 171
Dual-Gripper Robotsp. 171
Lower Bound on Per Unit Cycle Timep. 172
An Optimal Cyclep. 175
Improvement from Using a Dual-Gripper Robot or Parallel Machinesp. 180
Installing a Dual-Gripper Robot in a Simple Robotic Cellp. 181
Installing Parallel Machines in a Single-Gripper Robot Cellp. 182
Installing a Dual-Gripper Robot in a Single-Gripper Robotic Cell with Parallel Machinesp. 183
An Illustration on Data from Implemented Cellsp. 187
Multiple-Part-Type Production: Single-Gripper Robotsp. 191
MPS Cycles and CRM Sequencesp. 192
Scheduling Multiple Part-Types in Two-Machine Cellsp. 194
Scheduling Multiple Part-Types in Three-Machine Cellsp. 206
Cycle Time Derivationsp. 207
Efficiently Solvable Special Casesp. 211
Steady-State Analysesp. 216
Reaching Steady State for the Sequence CRM(¿2)p. 217
Reaching Steady State for the Sequence CRM(¿6)p. 225
A Practical Guide to Initializing Robotic Cellsp. 229
Intractable Cycles for Three-Machine Cellsp. 231
MPS Cycles with the Sequence CRM(¿2)p. 231
MPS Cycles with the Sequence CRM(¿6)p. 238
Complexity of Three-Machine Robotic Cellsp. 244
Scheduling Multiple Part-Types in Large Cellsp. 247
Class U: Schedule Independent Problemsp. 250
Class V1: Special Cases of the TSPp. 251
Class V2: NP-Hard TSP Problemsp. 253
Class W: NP-Hard Non-TSP Problemsp. 264
Overviewp. 268
Heuristics for Three-Machine Problemsp. 270
A Heuristic Under the Sequence CRM(¿2)p. 270
A Heuristic Under the Sequence CRM(¿6)p. 273
Computational Testingp. 274
Heuristics for General Three-Machine Problemsp. 276
Heuristics for Large Cellsp. 281
The Cell Design Problemp. 284
Forming Cellsp. 285
Buffer Designp. 288
An Examplep. 292
Computational Testingp. 293
Multiple-Part-Type Production: Dual-Gripper Robotsp. 297
Two-Machine Cells: Undominated CRM Sequencesp. 300
Two-Machine Cells: Complexityp. 306
Cycle Time Calculationp. 306
Strong NP-Completeness Resultsp. 312
Polynomially Solvable Problemsp. 318
Analyzing Two-Machine Cells with Small Gripper Switch Timesp. 319
A Heuristic for Specific CRM Sequencesp. 324
A Performance Bound for Heuristic Hard-CRMp. 325
A Heuristic for Two-Machine Cellsp. 339
Comparison of Productivity: Single-Gripper Vs. Dual-Gripper Cellsp. 340
An Extension to m-Machine Robotic Cellsp. 342
Multiple-Robot Cellsp. 349
Physical Description of a Multiple-Robot Cellp. 350
Cycles in Multiple-Robot Cellsp. 352
Cycle Timesp. 354
Scheduling by a Heuristic Dispatching Rulep. 357
Computational Resultsp. 358
Applying an LCM Cycle to Implemented Cellsp. 361
No-Wait And Interval Robotic Cellsp. 363
No-Wait Robotic Cellsp. 363
Interval Pick-up Robotic Cellsp. 369
Open Problemsp. 371
Simple Robotic Cellsp. 371
Simple Robotic Cells with Multiple Part Typesp. 376
Robotic Cells with Parallel Machinesp. 376
Stochastic Datap. 377
Dual-Gripper Robotsp. 377
Flexible Robotic Cellsp. 378
Implementation Issuesp. 378
Using Local Material Handling Devicesp. 378
Revisiting Machinesp. 379
Appendices
p. 383
1-Unit Cyclesp. 383
1-Unit Cycles in Classical Notationp. 384
1-Unit Cycles in Activity Notationp. 385
p. 387
The Gilmore-Gomory Algorithm for the TSPp. 387
The Two-Machine No-Wait Flowshop Problemp. 387
Formulating a TSPp. 388
The Gilmore-Gomory Algorithmp. 389
The Three-Machine No-Wait Flowshop Problem as a TSPp. 394
Copyright Permissionsp. 409
Indexp. 413
Table of Contents provided by Publisher. All Rights Reserved.

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