Theory and methodology
Tool planning models for flexible manufacturing systems

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Abstract

Although the tool loading problem for Flexible Manufacturing Systems (FMSs) has been analyzed in the past, the tool planning problem, the basis of tool management, has largely been ignored. In this paper, the interface between tool planning and the FMS loading and routing decisions is analyzed. It is shown that tool policy has a pronounced effect on the flexibility and the planned makespan of an FMS. A tool planning model is developed and integrated into an overall FMS detailed tool loading and part routing procedure. This model while considerably reducing the number of tools required (by 55%) matches the performance of a policy that equips each machine with all tools in terms makespan, routing flexibility, and tool productivity.

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    • Cited by (18)

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      Gray, Seidmann, and Stecke (1993) suggested an integrated conceptual framework for resource planning in order to avoid underutilization of the system. On a related note, Mohamed and Bernardo (1997) claimed that an inadequate number of tools contributes to a decrease in FMS productivity. The problem of optimizing the insertions and removals of tools in flexible manufacturing machines was tackled predominantly by heuristic methods.

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      Veeramani et al. [2], Gray et al. [3], and Atan and Pandit [4] have pointed out that the lack of proper attention to tool planning and allocation problems can lead to underutilization of the system. In addition, Mohamed and Bernardo [5] emphasized that an inadequate number of tools results in low machine utilization and an unacceptable level of downtime, leading to decreased FMS productivity. Therefore, both problems, tool planning and allocation, are critical issues associated with the scheduling problem.

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      In addition, FMS-scheduling problems are strongly affected by the number of tool copies at hand. Veeramani et al. (1992) and Mohamed and Bernardo (1997) emphasized that the lack of proper attention to this number can prevent manufacturing systems from achieving their maximum flexibility and may result in an unacceptable level of downtime, leading to a reduced FMS productivity. Thus, the tool planning subproblem, which determines the required number of tool copies to achieve the production requirements, is another critical issue associated with the problem.

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    1

    Dr Bernardo passed away on July 12, 1995. His contributions to the field of operations management will be with us forever.

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