Abstract
Layout planning in a manufacturing company is an important economical consideration. In the past, research examining the facility layout problem (FLP) generally concerned static cases, where the material flows between facilities in the layout have been assumed to be invariant over time. However, in today’s real-world scenario, manufacturing system must operate in a dynamic and market-driven environment in which production rates and product mixes are continuously adapting. The dynamic facility layout problem (DFLP) addresses situations in which the flow among various facilities changes over time. Recently, there is an increasing trend towards implementation of industrial robot as a material handling device among the facilities. Reducing the robot energy usage for transporting materials among the facilities of an optimal layout for completing a product will result in an increased life for the robots and thus enhance the productivity of the manufacturing system. In this paper, we present a hybrid genetic algorithm incorporating jumping genes operations and a modified backward pass pair-wise exchange heuristic to determine its effectiveness in optimizing material handling cost while solving the DFLP. A computational study is performed with several existing heuristic algorithms. The experimental results show that the proposed algorithm is effective in dealing with the DFLP.
Similar content being viewed by others
References
S. S. Heragu, Facilities design, BWS, Boston, 1997
D. Li, P. L. P. Rau, Y. Li, A cross-cultural study: Effect of robot appearance and Task, INT J SOC ROBOT, 2, (2010), 175–186
K. Holck, C. Munoz, Robots in Manufacturing, Available from: http://mfg.eng.rpi.edu/gmp/SProjectsPwrpt/s11/ GMP Final Robotics Presentation.pdf
H. Zhang, Factory automation with industrial robots, ARB Robotics R&D Center, 2011
A. Tompkins, Facilities planning, 3rd ed., John Wiley & Sons, New York, 2003
A. R. McKendall Jr, J. Shang, Hybrid ant systems for the dynamic facility layout problem, COMPUT OPER RES, 33, (2006), 790–803
K. S. N. Ripon, K. Glette, M. Hovin, J. Torresen, Dynamic facility layout problem with hybrid genetic algorithm, In M. Oussalah, R. Mitchell, N. H. Siddique (Eds.), Proceedings of The IEEE 9th International Conference on Cybernetic Intelligent Systems (CIS), (2010, Reading, UK), IEEE Systems, Man, & Cybernetics Society, 2010, 33–38
M. A. El-Baz, A genetic algorithm for facility layout problems of different manufacturing environments, COMPUT IND ENG, 47, (2004), 233–246
Z. Jian, L. A. Ping, Genetic algorithm for robot workcell layout problem, (2009, Xiamen, China), Proceedings of The WRI World Congress on Software Engineering (WCSE 2009), 2009, 460–464
K. Mitsuhashi, K. Yamato, Layout planning and simulation for application of robots, ADV ROBOTICS, 2,1, (1987), 87–98
V. Nata, A. Tubaileh, The machine layout problem in robot cells, INT J PROD RES, 36,5, (1998), 1273–1292
A. Tubaileh, I. Hammad, L. A. Kafafi, Robot cell planning, ENG TECH, 26, (2007), World Academy of Science, 250–253, 2007
A. Drira, H. Pierreval, S. H. Gabouj, Facility layout problems: A survey, ANNU REV CONTROL, 31,2, (2007), 255–267
I. Castillo, T. Sim, A spring-embedding approach for the facility layout problem, J OPER RES SOC, 55,1, (2004), 73–81
J. Balakrishnan, C. H. Cheng, Dynamic layout algorithms: A state-of-the-art survey, OMEGA-INT J MGMT SCI, 26,4, (1998), 507–521
J. H. Holland, Adaptation in natural and artificial systems, The University of Michigan Press, Ann Arbor, MI, 1975
M. H. Hu, M. -J. Wang, Using genetic algorithms on facilities layout problems, INT J ADV MANUF TECH, 23, 3–4, (2004), 301–310
J. Balakrishnan, C. H. Cheng, D. G. Conway, An improved pair-wise exchange heuristic for the dynamic plant layout problem, INT J PROD RES, 38,13, (2000), 3067–3077
K. S. Tang, R. J. Yin, S. Kwong, K. T. Ng, K. F. Man, A theoretical development and analysis of jumping gene genetic algorithm, IEEE T IND INFORM, 7,3, (2011), 408–418
W. S. Tang, S. Kwong, K. F. Man, A jumping genes paradigm: Theory, verification and applications, IEEE CIRC SYST MANAG M, 8,4, (2008), 18–36
T. L. Urban, A heuristic for the dynamic facility layout problem, IIE TRANS, 25,4, (1993), 57–63
M. J. Rosenblatt, The dynamics of plant layout, MANAGE SCI, 32,1, (1986), 76–86
J. Balakrishnan, C. H. Cheng, The dynamic plant layout problem: Incorporating rolling horizons and forecast uncertainty, OMEGA-INT J MGMT SCI, 37,1, (2009), 165–177
S. P. Singh, R. R. K. Sharma, A review of different approaches to the facility layout problems, INT J ADV MANUF TECH, 30,5–6, (2006), 425–433
J. Balakrishnan, R. F. Jacobs, M. A. Venkataramanan, Solutions for the constrained dynamic facility layout problem, EUR J OPER RES, 57,2, (1992), 280–286
D. G. Conway, M. A. Venkataramanan, Genetic search and the dynamic facility layout problem, COMPUT OPER RES, 21,8, (1994), 955–960
J. Balakrishnan, C. H. Cheng, Genetic search and the dynamic layout problem, COMPUT OPER RES, 27,6, (2000), 587–593
J. Balakrishnan, C. H. Cheng, D. G. Conway, C. M. Lau, A hybrid genetic algorithm for the dynamic plant layout problem, INT J PROD ECON, 86, (2003), 107–120
S. P. Singh, R. R. K. Sharma, Genetic algorithm based heuristics for the dynamic facility layout problem, EUR J MGMT, 8,1, (2008), 128–134
B. K. Kaku, J. B. Mazzola, A tabu search heuristic for the dynamic plant layout problem, INFORMS J COMPUT, 9,4, (1997), 374–384
J. B. Erel, J. Ghosh, J. T. Simon, New heuristic for the dynamic layout problem, J OPER RES SOC, 54, (2003), 1275–1282
A. Baykasoglu, N. N. Z. Gindy, A simulated annealing algorithm for the dynamic layout problem, COMPUT OPER RES, 28, (2001), 1403–1426
A. R. McKendall Jr, J. Shang, S. Kuppusamy S, Simulated annealing heuristics for the dynamic facility layout problem, COMPUT OPER RES, 33,8, (2006), 2431–44
H. Rezazadeh, M. Ghazanfari, M. S. Mehrabad, An extended discrete particle swarm optimization algorithm for the dynamic facility layout problem, J ZHEJIANG UNIV-SC A, 10,4, (2009), 520–529
K. Deb, A. Pratap, S. Agarwal, T. Meyarivan, A fast and elitist multi-objective genetic algorithm: NSGA-II, IEEE T EVOLUT COMPUT, 6,2, (2002), 182–197
K. F. Man, T. M. Chan, K. S. Tang, S. Kwong, Jumping-genes in evolutionary computing, Proceedings of The 30th Annual Conference of the IEEE Industrial Electronics Society, (2004, Pusan, Korea), IEEE Industrial Electronics Society, 2004, 1268–1272
K. S. N. Ripon, K. Glette, M. Hovin, J. Torresen, Multi-objective evolutionary approach for solving facility layout problem using local search, In Proceedings of the 2010 ACM Symposium on Applied Computing, (2010, Sierre, Switzerland), ACM, New York, NY, USA, 2010, 1155–1156
S. Y. Zheng, S. H. Yeung, W. S. Chan, K. F. Man, K. S. Tang, Design of broadband hybrid coupler with tight coupling using jumping gene evolutionary algorithm, IEEE T IND ELECTRON, 56,8, (2009), 2987–2991.
K. S. N. Ripon, Hybrid evolutionary approach for multi-objective job-shop scheduling problem, MALAYAS J COMPUT SCI, 20,2, (2007), 183–198
T. M. Chan, K. F. Man, K. S. Tang, S. Kwong, A jumping-genes paradigm for optimizing factory WLAN network, IEEE T IND INFORM, 3,1, (2007), 33–43
K. S. N. Ripon, S. Kwong, K. F. Man, A real coding jumping gene genetic algorithm (RJGGA) for multiobjective optimization, INFORM SCIENCES, 177,2, (2007), 632–654
A. Kusiak, S. Heragu, The facility layout problem, EUR J OPER RES, 29, (1987), 229–251
L. Wang, S. Keshavarzmanesh, H. -Y. Feng, A hybrid approach for dynamic assembly shop floor layout, Proceedings of The 6th Annual IEEE Conference on Automation Science and Engineering (2010, Toronto, Ontario, Canada), 2010, 604–609
V. Kumar, G. Bekey, Y. Zheng, Industrial, personal and service robots, In: G. Bekey (Ed.), Robotics: State Of The Art And Future Challenges (World Technology Evaluation Center, Lancaster, 2008), 89–101
Author information
Authors and Affiliations
Corresponding author
Additional information
The paper has been partially published in IEEE 9th International Conference on Cybernetic Intelligent Systems (CIS), 2010, Reading, UK.
About this article
Cite this article
Ripon, K.S.N., Glette, K., Koch, D. et al. Genetic algorithm using a modified backward pass heuristic for the dynamic facility layout problem. Paladyn 2, 164–174 (2011). https://doi.org/10.2478/s13230-012-0008-1
Received:
Accepted:
Published:
Issue Date:
DOI: https://doi.org/10.2478/s13230-012-0008-1