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Li 2019
Li 2019
The State Key Laboratory of Digital Manufacturing Equipment and Technology, Huazhong University of Science and Technology, Wuhan, China
Keywords: Integrated process planning and scheduling (IPPS) is a hot research topic on providing a blueprint of efficient
Uncertain integrated process planning and manufacturing system. Most existing IPPS models and methods focus on the static machining shop status.
scheduling However, in the real-world production, the machining shop status changes dynamically because of external and
Interval processing time internal fluctuations. The uncertain IPPS can better model the practical machining shop environment but is
Interval number
rarely researched because of its complexity (including the difficulties of modelling and algorithm design). To
Particle swarm optimization
Hybrid algorithm
deal with the uncertain IPPS problem, this paper presents a new uncertain IPPS model with uncertain processing
time represented by the interval number. A new probability and preference-ratio based interval ranking method
is proposed for precise interval computation. Particle swarm optimization (PSO) algorithm hybridizing with
genetic algorithm (GA) is designed to achieve the good solution. To improve the search capability of the hybrid
algorithm, the special genetic operators are adopted corresponding to the characteristics of uncertain IPPS
problem. Some strategies are designed to prevent the particles from trapping into a local optimum. Six ex-
periments which are adopted from some famous IPPS benchmark problems have been used to evaluate the
performance of the proposed algorithm. The experimental results illustrate that the proposed algorithm has
achieved good improvement and is effective for uncertain IPPS problem.
1. Introduction end up with severely unbalanced resource load and create superfluous
bottlenecks; (3) Because of the time dealy, even though process plan-
Process planning and scheduling are two of the most important sub- ners consider the restriction of the current resources on the shop floor,
systems in a manufacturing system (Li, Xiao, Wang, & Yi, 2019; Lu, Li, the constraints in the process planning phase may have already
Gao, Liao, & Yi, 2017; Qin et al., 2019; Zhang & Wong, 2018). Process changed. Investigations show that the 20–30% of the total production
route selects the flexible process plan based on the design requirement plans in a given period have to be rescheduled to adapt to dynamic
and the machining shop resources (Li, Gao, & Wen, 2013; Li, Tang, Li, & changes in a production environment; (4) The process planning and
Li, 2013). The shop scheduling receives the process route information scheduling may have conflicting objectives. Process planning empha-
and determines the sequence for each operation (Li, Lu, Gao, Xiao, & sizes to meet the technological requirements of a job, while scheduling
Wen, 2018; Li, Gao, Pan, Wan, & Chao, 2019). The traditional ap- attaches importance to the timing aspects and resource sharing of all
proaches often carried out the process planning and scheduling in a jobs. If there is no appropriate coordination, it may create conflicting
sequential way. These have become the obstacles to improve the pro- problems.
ductivity and responsiveness of the manufacturing systems and to cause Based on the above analysis, it is obvious that process planning and
the following problems (Manupati, Putnik, Tiwari, Avila, & Cruz- scheduling are interrelated and should be solved simultaneously (Li,
Cunha, 2016; Sobeyko & Monch, 2017): (1) Because process planner Shao, Gao, & Qian, 2010; Manupati et al., 2016; Sobeyko & Monch,
often plans jobs individually in practical manufacturing, the shop floor 2017). The integration of both functions can contribute much to the
resources are usually assigned on each job without considering the activities of the whole production process. Both of the two functions
competition for the resources from other jobs. This may lead to the assign the factory machines in the production process; that is why they
resulting optimal process plans often become infeasible when they are should be solved collectively. The merit of IPPS is to increase the pro-
carried out in practice at the later stage; (2) Pre-defined process plans duction feasibility and optimality by combining both the process
reduce the flexibilities of scheduling and may drive scheduling plans to planning and scheduling problems (Li, Gao, Pan, Wan, & Chao, 2019).
⁎
Corresponding author.
E-mail address: gaoliang@mail.hust.edu.cn (L. Gao).
https://doi.org/10.1016/j.cie.2019.04.028
Thus, IPPS can dynamically react to the production environment and method.
provide an optimal or near-optimal solution. There is an increasing The remainder of this paper is organized as follows. Section 2 pre-
need for deep research and application of IPPS system (Petrovic, sents the related work. Section 3 describes the calculation of preference
Vukovic, Mitic, & Miljkovic, 2016). ratio and the ranking procedure of interval numbers. Section 4 shows
In the real manufacturing process, the machining data sometimes the definition of uncertain IPPS problem. Section 5 gives the hybridized
cannot be recorded or collected precisely under some unexpected si- GAPSO algorithm for uncertain IPPS problem. Section 6 reports the
tuations (Joo, Shim, Chua, & Cai, 2018), such as machine failure in experimental results. Section 7 provides the conclusions and future
production process, energy shortages, urgent order insertion, and tool works.
loading and unloading (Shahrabi, Adibi, & Mahootchi, 2017). However,
in previous studies, processing time, completion time and delivery time 2. Related work
were treated as fixed, which may be impossible to accurately describe
the actual production (Jamrus, Chien, Gen, & Sethanan, 2018). IPPS Since the concept of IPPS was first proposed by Chryssolouris, Chan,
considering uncertain situations needs to be addressed for better and Cobb (1984), IPPS has been extensively researched by many re-
modeling of the real production environment. Due to the complexity of searchers. Li, Gao, Zhang, and Shao (2010) conducted a detailed review
the integrated problem and the flexibility of the processing route of the development of IPPS before 2010. The integration model and
choices, IPPS in uncertain shop environment becomes much more approaches of IPPS were stated and summarized.
complicated. Few work have been done about uncertain IPPS. We have In recent years, the problems of IPPS have been researched ex-
reported some works about IPPS problem. But, we also did not do the tensively. More optimization approaches were proposed or hybridized
research on the uncertain IPPS problem. Comparing with our previous to achieve the better solutions. Li, Gao, and Li (2012) studied the multi-
works, the new model and algorithm have been proposed according to objective IPPS considering three objectives, including makespan, the
the features of uncertain IPPS problem in this paper. maximal machine workload and the total workload of machines. An
The uncertain processing time is almost represented as triangular active learning GA was developed by Li, Gao, and Shao (2012) to im-
fuzzy numbers based on probability theory concerning randomness prove the quality of the offspring after genetic manipulation. Zhang,
(Joo et al., 2018). However, it is difficult to determine the membership Gen, and Jo (2014) presented a hybrid sampling strategy-based multi-
function and an accurate probability distribution in reality (Lei, 2011). objective evolutionary algorithm to deal with the IPPS problem. Zhang
The use of interval numbers is more convenient. An interval number and Wong (2015) proposed an object-coding GA for IPPS. Manupati
can be thought of as an extension of the concept of a real number and et al. (2016) described a mobile-agent based negotiation approach for
also as a subset of a real line (Moore, 1979). An interval number gives IPPS in a networked manufacturing environment. Petrovic et al. (2016)
an upper and lower bounds of one parameter. In this study, the pro- used a chaotic PSO for IPPS. Zhang and Wong (2016) proposed an ant
cessing time is modeled as the interval number which is simple and easy colony optimization (ACO) for IPPS. Sobeyko and Monch (2017) de-
to understand. IPPS is a typical NP-hard problem. Moreover, uncertain signed a variable neighbourhood search based appaorch for the IPPS in
IPPS becomes even more complex. As a result, developing an effective large-scale flexible job shops. Luo, Wen, Li, Ming, and Xie (2017)
algorithm to deal with IPPS is a challenging work. proposed an multi-objective GA based on immune principle and ex-
Genetic algorithm (GA) which is a very effective evolutionary al- ternal archive for multi-objective IPPS problem. Zhang and Wong
gorithm has been applied to solve many optimization problems (Wang, (2018) developed an enhanced ACO to accomplish the IPPS problem in
Lai, Wu, Xing, Wang, et al., 2018; Xiang, Xing, Wang, & Zou, 2019; Yi the job-shop environment.
et al., 2018). It also has been successfully used in a wide range of However, the researches of under IPPS are limited. Seker, Erol, and
scheduling problems (Li & Gao, 2016; Shao, Li, Gao, & Zhang, 2009; Wu Botsali (2013) trained artificial neural network to adapt to change
& Wu, 2017). The framework of GA is very suitable for the scheduling conditions after the scheduling plan obtained by GA. The changing
problem and it can efficiently obtain the competitive results in large conditions included cancelation of orders, change in due dates, failure
and complex solution spaces. Meanwhile, particle swarm optimization of a machine and so on. Their work is of importance to obtain the best
(PSO) algorithm has the advantage of simplicity for implementation performing solution after the manufacturing condition has changed.
and can quickly converge to a reasonably good solution. It has very Haddadzade, Razfar, and Zarandi (2014) used stochastic programming
good global searching ability. However, the original PSO cannot be to allow IPPS system making decisions under uncertainty. Processing
used to solve the scheduling problem directly because of its update time was considered as stochastic parameters and one possible scenario.
fomulas. Therefore, this paper uses the genetic operators to re-define One new approach was proposed to adapt real-world uncertain shop
the update strategy of PSO. For better development and to combine the status. Xia, Li, and Gao (2016) proposed a hybrid algorithm for the
advantages of PSO and GA, a hybrid algorithm combining PSO with GA dynamic IPPS problem.
(GAPSO) is used to solve the uncertain IPPS problem in this paper. The From the above research, although the uncertain issues were con-
main contributions of this work include the following aspects. First, the sidered, a general IPPS model for dealing with uncertainty is still
mathematical model of uncertain IPPS problem is given. The interval missing. For real-world problems, uncertain situation is unavoidable
theory is used to represent the uncertain processing time. Interval and common. Developing an IPPS model under uncertain environment
number is one of the simplest form of representing uncertainty in the is essential because it matches the real production situation. Among all
decision matrix and requires a minimum amount of information about the uncertain issues, the processing time including set-up time and
the values of attributes. So, the the interval number is adopted to model traveling time between machines is usually uncertain (Ghrayeb, 2003).
the uncertain processing time. To improve the performance of interval It is reasonable to model the IPPS problem with uncertain processing
theory for uncertaint IPPS, a preference-ratio based ranking method is time.
used to calculate the probability of different comparing results between Many researches have been devoted to the scheduling problems
two interval numbers. Second, the GAPSO algorithm with corre- with uncertain processing time. Both of triangular fuzzy number and
sponding operations is designed to solve the proposed model. Based on trapezoidal fuzzy number were used to represent the uncertain pro-
the discreteness of uncertain IPPS problem, the learning ability of cessing time. Gao, Suganthan, Pan, Tasgetiren, and Sadollah (2016)
particles is redefined by genetic operators. The proposed algorithm can proposed an effective artificial bee colony (ABC) algorithm for the
improve the computational ability of the system. Finally, six experi- scheduling and rescheduling of fuzzy flexible job shop problem. They
ments of uncertain IPPS problem are utilized to evaluate the perfor- also proposed an improved ABC algorithm for the flexible job shop
mance of proposed hybrid algorithm. The comparison results between scheduling problem with fuzzy processing time respectively (Gao,
the proposed GAPSO and GA illustrate the effectiveness of the proposed Suganthan, Pan, Chua, Chong, et al., 2016). Lu, Gao, Li, and Xiao
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(2017) proposed a hybrid multi-objective grey wolf optimizer for dy- the upper bound of the interval number. If AL = AR , then A is
namic scheduling in a real-world welding industry. Shahrabi et al. a real number. Or, in alternative notation, A=
(2017) used a reinforcement learning based scheduling method for (m (A), (A)) = {t|(m (A) (A)) t (m (A) + (A))} where m (A) is
dynamic job shop scheduling problem. Mou, Gao, Li, Pan, and Mu the midpoint and (A) is the half-width of the interval number A.
(2017) investigated a multi-objective inverse scheduling problem in The interval arithmetic is defined as:
single-machine shop system with uncertain due-dates and processing
[AL , AR ] for 0
parameters. Jamrus et al. (2018) proposed a hybrid PSO algorithm for A= is scalar
the FJSP with uncertain processing time for semiconductor manu- [AR , AL ] for <0 (1)
facturing. Mou, Gao, Guo, Xu, and Li (2018) investigated a single-ma-
chine inverse scheduling problem with uncertain due-dates. A + B = [AL + BL, AR + BR] (2)
Summing up, uncertain processing time was almost modeled as the
A B = [AL BR , AR B L] (3)
triangular fuzzy number. Probability distribution and membership
function need to be known in advance, which requires much historical
data. Sometimes, in an uncertain shop status, it is difficult to define an 3.2. Ranking method
accurate membership function. The use of interval number overcomes
the disadvantages of fuzzy number. Interval number only needs the Among the studies and applications of interval theory, the com-
upper and lower bounds of one interval. Decision-makers prefer using parison of two interval numbers is important for choosing the right
easy models to represent uncertain conditions (Lei, 2011). It is therefore interval number (Lei, 2011). Some comparison methods of interval
of importance to establish the uncertain IPPS model based on interval number can be found in Jiang, Han, and Liu (2008). In this study, we
number. combine the possibility degree-based ranking method proposed by
As an observation, most researchers used single algorithm to derive Jiang et al. (2008) with the preference ratio concept introduced by
the model of IPPS. Because of the complexity of this integration pro- Modarres and Sadi-Nezhad (2011). The possibility is obtained from the
blem, PSO and GA are hybridized to explore optimal solution. Particles overall distribution of interval numbers while the preference ratio is
flying in the search space are coded as chromosomes carrying process relative rather than absolute. In preference ratio method, the uncertain
plans. The learning operator of PSO is defined as a genetic operator. numbers are evaluated point by point and ranked at each point. Then,
IPPS with uncertain processing time, represented as an interval the comparison between interval numbers can be calculated by the
number, is researched in this study. To ensure the accuracy of the overall preference ratio. The combination of these two methods of
calculation process of interval number, a new interval ranking method overall and local comparison enhances the accuracy and efficiency of
based on possibility and preference-ratio is used. The optimal interval the ranking method. The possibility method used to rank two interval
makespan obtained should also have a smaller uncertain span. Finally, numbers is given in the following equation.
0 AL BR
BR AL BR AL
0.5 × × BL AL < BR AR
AR AL BR BL
BL AL BR BL
+ 0.5 × AL < BL < BR AR
AR AL AR AL
P (A B) =
BL AL AR BL BR AR AR BL AR BL
+ × + 0.5 × × AL < BL AR < BR
AR AL AR AL BR BL AR AL BR BL
BR AR AR AL
+ 0.5 × BL AL < AR < BR
BR BL BR BL
1 AR BL (4)
the uncertainty of the interval makespan is taken into consideration as where P (A B ) is the possibility of A B , which is in the range of [0,
one part of the objective. 1], and P (A B ) + P (B A) = 1. If P (A B ) = P (B A) , then
A = B . Membership function of A B is as follows:
3. Related interval operations
µA B = Z=X Y (µA (X ) µB (Y )) (5)
3.1. Interval number Therefore,
Interval number is one of the simplest form of representing un- A B = [max(AL , BL), max(AR , BR )] (6)
certainty in the decision matrix and requires a minimum amount of
information about the values of attributes. That is why choosing the The preference ratio method is used to rank the triangular fuzzy
interval number to model the uncertain processing environment. Note number (TFN) in Nezhad and Assadi (2008). The basic theory is as
that the interval numbers do not contain the information about how follows. Suppose the objective is to rank i fuzzy numbers. The related
probable it is for the value to be in the interval and which of the many coefficients are listed in Table 1.
values in the interval is the most likely to occur. An interval number can
be defined as follows (Sayadi, Heydari, & Shahanaghi, 2009): Table 1
Relevant coefficients.
(1) An extension of the concept of a real number and also a subset of a Coefficient Significance
real line,
Ni The ith fuzzy number
(2) A degenerated flat fuzzy number or fuzzy interval with zero lower
Si The domain of the ith fuzzy number, and Si R .Si is the support
and upper spreads, of Ni
(3) An a-cut of a fuzzy number. µ Ni (x ), x Si The membership function and µ Ni [0, 1], Si = {x µ Ni (x ) > 0}
I The union of the support of all fuzzy numbers to be ranked
= Si
An interval number has the following form: i=1
A = [AL , AR ] = {t |AL t AR } , where AL is the lower bound and AR is
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X. Li, et al. Computers & Industrial Engineering 135 (2019) 1036–1046
which denotes at the point a that the ith fuzzy number is the most
preferred one because the preference function of the ith fuzzy number
at point a is the biggest one.
Let i be the set of points at which the ith number is ranked as
number one.
i ={a , p (a ) = i } (9)
The preference ratio is the percentage of that the ith fuzzy number
is the most preferred one.
| i|
R (i ) =
| | (10)
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Table 2 A
xµA (x ) d (x )
An illustration of the problem. Mu (A ) =
µ (x ) d (x )
A A (15)
Job Operation Optional Interval Processing Optional Process
Machines Time Plan
2 A
x 2µA (x ) d (x )
u (A ) = Mu2 (A )
1 O1 M1, M2, M4 [4.25,6.5],[4.25,6.5], O1-O2
µ (x ) d (x )
A A (16)
[5.1,7.8]
O2 M2 , M5 [4.25,6.5],[5.1,7.8]
For the interval number, the mean value and the variance can be
2 O3 M3 , M5 [5.1,7.8],[5.1,7.8] O3-O4 simplified as:
O4 M2, M4, M5 [4.25,6.5],[4.25,6.5],
a+b
[5.1,7.8] Mu (A ) =
3 O5 M1, M3, M4 [3.4,5.2],[2.55,3.9], O5-O6-O7 2 (17)
[4.25,6.5]
O6 M1, M3, M5 [6.8,10.4],[5.95,9.1], O6-O5-O7 2 a2 + b 2 2ab
u (A ) =
[6.8,10.4] 12 (18)
O7 M2 [4.25,6.5]
4 O8 M1 , M3 [3.4,5.2],[3.4,5.2] O8-O9-O10
where the bigger the u (A ) ,
the more uncertain the makespan.
2
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Step 4–1. Based on the process routing of each part, initialize the
scheduling population;
Step 4–2. Calculate the fitness of each particle and update pbest,
gbest;
Step 4–3. If the stop criteria is satisfied, output the best routing
and scheduling solution. If not, go to step 4–4;
Step 4–4. For each particle in the population, do mutation op-
eration, crossover operation with pbest and crossover operation
with gbest. The best one out of the three is choosen as the final
offspring. Go to Step 4–2;
Step 5. When the scheduling part is finished, update the best solu-
tion;
Step 6. If the stop criteria of the process planning system is satisfied,
output the best solution.
If not, go to the next step;
Step 7. For each particle in the process planning system, perform
mutation operation, crossover operation with pbest and crossover
operation with gbest. Randomly choose one out of three as the off-
spring. Go to step 3.
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Table 6
Computational results of experiment 3. 6.4. Experiment 4
Fitness Fitness Fitness Lower bound of
( =0) ( =0.5) ( =1) determined IPPS This experiment contains 8 jobs and 5 machines and is adopted in
Chan, Kumar, and Tiwari (2006). The detailed manufacturing in-
GAPSO 18.27 19.38 20.48 17
formation can be found in Chan et al. (2006). The computational results
GA 19.35 20.519 21.688
obtained by GAPSO and GA are illustrated in Table 7. It can be seen that
The bold numbers are represent the best ones. GAPSO outperforms GA.
Table 9
Computational results of experiment 6.
Problem Number of jobs Jobs GA ( =0) GAPSO ( =0) Lower bound of determined IPPS
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6.7. Discussion Grant 2018CFA078 and the Program for HUST Academic Frontier
Youth Team under Grant 2017QYTD04.
From the above six experiments with different scales, we can see
that the hybridized algorithm GAPSO outperforms the GA except ex- References
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https://doi.org/10.1007/s12293-019-00283-4.
reseach work. The above research directions could make the future Lu, C., Gao, L., Li, X., & Xiao, S. (2017). A hybrid multi-objective grey wolf optimizer for
uncertain IPPS problems more realistic. dynamic scheduling in a real-world welding industry. Engineering Applications of
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Lu, C., Li, X., Gao, L., Liao, W., & Yi, J. (2017). An effective multi-objective discrete virus
Acknowledgments optimization algorithm for flexible job-shop scheduling problem with controllable
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This research work was supported by the National Natural Science Luo, G., Wen, X., Li, H., Ming, W., & Xie, G. (2017). An effective multi-objective genetic
algorithm based on immune principle and external archive for multi-objective in-
Foundation of China (NSFC) under Grant nos. 51775216 and
tegrated process planning and scheduling. International Journal of Advanced
51825502, the Natural Science Foundation of Hubei Province under
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