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RESEARCH PAPERS

# Design For Existing Lines: Part and Process Plan Optimization to Best Utilize Existing Production Lines

[+] Author and Article Information
Arlene G. Smithson

NVFE Laboratory, Environmental Protection Agency, 2565 Plymouth Road, Ann Arbor, MI 48105smithson.arlene@epa.gov

Karim Hamza

Dept. of Mechanical Engineering,  University of Michigan, Ann Arbor, MI 48109-2125khamza@umich.edu

Kazuhiro Saitou1

Dept. of Mechanical Engineering,  University of Michigan, Ann Arbor, MI 48109-2125kazu@umich.edu

$2R3$ is a power set (set of subsets) of $R3$.

1

Corresponding author.

J. Comput. Inf. Sci. Eng 7(2), 126-131 (Oct 23, 2006) (6 pages) doi:10.1115/1.2720886 History: Received August 07, 2005; Revised October 23, 2006

## Abstract

This paper presents a method for modifying the design of the new part for the maximum utilization of existing production lines dedicated to other products. The method takes as inputs a nominal part design and the process information of the (potentially multiple) existing line(s), and produces a modified part design and a process sequence of the new part that maximizes the utilization of available manufacturing processes in the existing lines or equivalently minimizes the addition of new processes dedicated to the new product. The problem is formulated as mixed discrete-continuous multiobjective optimization. A multiobjective genetic algorithm is used to generate Pareto optimal designs for the optimization analysis. A case study on the production of a new machine bracket considering two available production lines is presented.

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## Figures

Figure 1

(a) Part manufactured by an existing line and (b) new part. The critical dimensions, for which both of the end faces are milled, are indicated by circles.

Figure 2

Process sequence of the existing line: (a) stock, (b) bottom face milling (p1), (c) left face milling (p2), (d) top face milling (p3), (e) slot milling (p4), and (f) finished part

Figure 7

Products with existing production lines: (a) product A and (b) product B. All specified dimensions are in inches.

Figure 3

A possible process sequence of the new product without utilizing processes in the existing line: (a) stock, (b) left face milling, (c) slot milling, and (d) finished part

Figure 4

Alternative process sequence for new part utilizing two processes in the existing line: (a) stock, (b) left face milling (p2), (c) slot milling (p4), (d) face milling (new process), and (e) finished part. Part width is not reduced to 2 since it is not indicated as critical.

Figure 5

Representation of the jth operation pj in a production line: (a) incoming part sj−1, (b) relocation rj, (c) machining operation oj, and (d) outgoing part sj=oj[rj(sj−1)]

Figure 6

Encoding of the design variables in a chromosome. Slacks for e and s are to accommodate their variations in length as specified by the value of m0.

Figure 8

Shape and main dimensions of the new product. All specified dimensions are in inches.

Figure 9

Pareto solutions obtained by ten GA runs (circles) and their improvements via the subsequent local search (squares). All objectives are normalized to the interval of [0,1].

## Errata

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