Matching Items (17)
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- All Subjects: Industrial Engineering
- Creators: Zhang, Muhong
Description
A good production schedule in a semiconductor back-end facility is critical for the on time delivery of customer orders. Compared to the front-end process that is dominated by re-entrant product flows, the back-end process is linear and therefore more suitable for scheduling. However, the production scheduling of the back-end process is still very difficult due to the wide product mix, large number of parallel machines, product family related setups, machine-product qualification, and weekly demand consisting of thousands of lots. In this research, a novel mixed-integer-linear-programming (MILP) model is proposed for the batch production scheduling of a semiconductor back-end facility. In the MILP formulation, the manufacturing process is modeled as a flexible flow line with bottleneck stages, unrelated parallel machines, product family related sequence-independent setups, and product-machine qualification considerations. However, this MILP formulation is difficult to solve for real size problem instances. In a semiconductor back-end facility, production scheduling usually needs to be done every day while considering updated demand forecast for a medium term planning horizon. Due to the limitation on the solvable size of the MILP model, a deterministic scheduling system (DSS), consisting of an optimizer and a scheduler, is proposed to provide sub-optimal solutions in a short time for real size problem instances. The optimizer generates a tentative production plan. Then the scheduler sequences each lot on each individual machine according to the tentative production plan and scheduling rules. Customized factory rules and additional resource constraints are included in the DSS, such as preventive maintenance schedule, setup crew availability, and carrier limitations. Small problem instances are randomly generated to compare the performances of the MILP model and the deterministic scheduling system. Then experimental design is applied to understand the behavior of the DSS and identify the best configuration of the DSS under different demand scenarios. Product-machine qualification decisions have long-term and significant impact on production scheduling. A robust product-machine qualification matrix is critical for meeting demand when demand quantity or mix varies. In the second part of this research, a stochastic mixed integer programming model is proposed to balance the tradeoff between current machine qualification costs and future backorder costs with uncertain demand. The L-shaped method and acceleration techniques are proposed to solve the stochastic model. Computational results are provided to compare the performance of different solution methods.
ContributorsFu, Mengying (Author) / Askin, Ronald G. (Thesis advisor) / Zhang, Muhong (Thesis advisor) / Fowler, John W (Committee member) / Pan, Rong (Committee member) / Sen, Arunabha (Committee member) / Arizona State University (Publisher)
Created2011
Description
This dissertation transforms a set of system complexity reduction problems to feature selection problems. Three systems are considered: classification based on association rules, network structure learning, and time series classification. Furthermore, two variable importance measures are proposed to reduce the feature selection bias in tree models. Associative classifiers can achieve high accuracy, but the combination of many rules is difficult to interpret. Rule condition subset selection (RCSS) methods for associative classification are considered. RCSS aims to prune the rule conditions into a subset via feature selection. The subset then can be summarized into rule-based classifiers. Experiments show that classifiers after RCSS can substantially improve the classification interpretability without loss of accuracy. An ensemble feature selection method is proposed to learn Markov blankets for either discrete or continuous networks (without linear, Gaussian assumptions). The method is compared to a Bayesian local structure learning algorithm and to alternative feature selection methods in the causal structure learning problem. Feature selection is also used to enhance the interpretability of time series classification. Existing time series classification algorithms (such as nearest-neighbor with dynamic time warping measures) are accurate but difficult to interpret. This research leverages the time-ordering of the data to extract features, and generates an effective and efficient classifier referred to as a time series forest (TSF). The computational complexity of TSF is only linear in the length of time series, and interpretable features can be extracted. These features can be further reduced, and summarized for even better interpretability. Lastly, two variable importance measures are proposed to reduce the feature selection bias in tree-based ensemble models. It is well known that bias can occur when predictor attributes have different numbers of values. Two methods are proposed to solve the bias problem. One uses an out-of-bag sampling method called OOBForest, and the other, based on the new concept of a partial permutation test, is called a pForest. Experimental results show the existing methods are not always reliable for multi-valued predictors, while the proposed methods have advantages.
ContributorsDeng, Houtao (Author) / Runger, George C. (Thesis advisor) / Lohr, Sharon L (Committee member) / Pan, Rong (Committee member) / Zhang, Muhong (Committee member) / Arizona State University (Publisher)
Created2011
Description
Ionizing radiation used in the patient diagnosis or therapy has negative effects on the patient body in short term and long term depending on the amount of exposure. More than 700,000 examinations are everyday performed on Interventional Radiology modalities [1], however; there is no patient-centric information available to the patient or the Quality Assurance for the amount of organ dose received. In this study, we are exploring the methodologies to systematically reduce the absorbed radiation dose in the Fluoroscopically Guided Interventional Radiology procedures. In the first part of this study, we developed a mathematical model which determines a set of geometry settings for the equipment and a level for the energy during a patient exam. The goal is to minimize the amount of absorbed dose in the critical organs while maintaining image quality required for the diagnosis. The model is a large-scale mixed integer program. We performed polyhedral analysis and derived several sets of strong inequalities to improve the computational speed and quality of the solution. Results present the amount of absorbed dose in the critical organ can be reduced up to 99% for a specific set of angles. In the second part, we apply an approximate gradient method to simultaneously optimize angle and table location while minimizing dose in the critical organs with respect to the image quality. In each iteration, we solve a sub-problem as a MIP to determine the radiation field size and corresponding X-ray tube energy. In the computational experiments, results show further reduction (up to 80%) of the absorbed dose in compare with previous method. Last, there are uncertainties in the medical procedures resulting imprecision of the absorbed dose. We propose a robust formulation to hedge from the worst case absorbed dose while ensuring feasibility. In this part, we investigate a robust approach for the organ motions within a radiology procedure. We minimize the absorbed dose for the critical organs across all input data scenarios which are corresponding to the positioning and size of the organs. The computational results indicate up to 26% increase in the absorbed dose calculated for the robust approach which ensures the feasibility across scenarios.
ContributorsKhodadadegan, Yasaman (Author) / Zhang, Muhong (Thesis advisor) / Pavlicek, William (Thesis advisor) / Fowler, John (Committee member) / Wu, Tong (Committee member) / Arizona State University (Publisher)
Created2013
Description
In this dissertation, an innovative framework for designing a multi-product integrated supply chain network is proposed. Multiple products are shipped from production facilities to retailers through a network of Distribution Centers (DCs). Each retailer has an independent, random demand for multiple products. The particular problem considered in this study also involves mixed-product transshipments between DCs with multiple truck size selection and routing delivery to retailers. Optimally solving such an integrated problem is in general not easy due to its combinatorial nature, especially when transshipments and routing are involved. In order to find out a good solution effectively, a two-phase solution methodology is derived: Phase I solves an integer programming model which includes all the constraints in the original model except that the routings are simplified to direct shipments by using estimated routing cost parameters. Then Phase II model solves the lower level inventory routing problem for each opened DC and its assigned retailers. The accuracy of the estimated routing cost and the effectiveness of the two-phase solution methodology are evaluated, the computational performance is found to be promising. The problem is able to be heuristically solved within a reasonable time frame for a broad range of problem sizes (one hour for the instance of 200 retailers). In addition, a model is generated for a similar network design problem considering direct shipment and consolidation within the same product set opportunities. A genetic algorithm and a specific problem heuristic are designed, tested and compared on several realistic scenarios.
ContributorsXia, Mingjun (Author) / Askin, Ronald (Thesis advisor) / Mirchandani, Pitu (Committee member) / Zhang, Muhong (Committee member) / Kierstead, Henry (Committee member) / Arizona State University (Publisher)
Created2013
Description
A P-value based method is proposed for statistical monitoring of various types of profiles in phase II. The performance of the proposed method is evaluated by the average run length criterion under various shifts in the intercept, slope and error standard deviation of the model. In our proposed approach, P-values are computed at each level within a sample. If at least one of the P-values is less than a pre-specified significance level, the chart signals out-of-control. The primary advantage of our approach is that only one control chart is required to monitor several parameters simultaneously: the intercept, slope(s), and the error standard deviation. A comprehensive comparison of the proposed method and the existing KMW-Shewhart method for monitoring linear profiles is conducted. In addition, the effect that the number of observations within a sample has on the performance of the proposed method is investigated. The proposed method was also compared to the T^2 method discussed in Kang and Albin (2000) for multivariate, polynomial, and nonlinear profiles. A simulation study shows that overall the proposed P-value method performs satisfactorily for different profile types.
ContributorsAdibi, Azadeh (Author) / Montgomery, Douglas C. (Thesis advisor) / Borror, Connie (Thesis advisor) / Li, Jing (Committee member) / Zhang, Muhong (Committee member) / Arizona State University (Publisher)
Created2013
Description
This dissertation is to address product design optimization including reliability-based design optimization (RBDO) and robust design with epistemic uncertainty. It is divided into four major components as outlined below. Firstly, a comprehensive study of uncertainties is performed, in which sources of uncertainty are listed, categorized and the impacts are discussed. Epistemic uncertainty is of interest, which is due to lack of knowledge and can be reduced by taking more observations. In particular, the strategies to address epistemic uncertainties due to implicit constraint function are discussed. Secondly, a sequential sampling strategy to improve RBDO under implicit constraint function is developed. In modern engineering design, an RBDO task is often performed by a computer simulation program, which can be treated as a black box, as its analytical function is implicit. An efficient sampling strategy on learning the probabilistic constraint function under the design optimization framework is presented. The method is a sequential experimentation around the approximate most probable point (MPP) at each step of optimization process. It is compared with the methods of MPP-based sampling, lifted surrogate function, and non-sequential random sampling. Thirdly, a particle splitting-based reliability analysis approach is developed in design optimization. In reliability analysis, traditional simulation methods such as Monte Carlo simulation may provide accurate results, but are often accompanied with high computational cost. To increase the efficiency, particle splitting is integrated into RBDO. It is an improvement of subset simulation with multiple particles to enhance the diversity and stability of simulation samples. This method is further extended to address problems with multiple probabilistic constraints and compared with the MPP-based methods. Finally, a reliability-based robust design optimization (RBRDO) framework is provided to integrate the consideration of design reliability and design robustness simultaneously. The quality loss objective in robust design, considered together with the production cost in RBDO, are used formulate a multi-objective optimization problem. With the epistemic uncertainty from implicit performance function, the sequential sampling strategy is extended to RBRDO, and a combined metamodel is proposed to tackle both controllable variables and uncontrollable variables. The solution is a Pareto frontier, compared with a single optimal solution in RBDO.
ContributorsZhuang, Xiaotian (Author) / Pan, Rong (Thesis advisor) / Montgomery, Douglas C. (Committee member) / Zhang, Muhong (Committee member) / Du, Xiaoping (Committee member) / Arizona State University (Publisher)
Created2012
Description
This research by studies the computational performance of four different mixed integer programming (MIP) formulations for single machine scheduling problems with varying complexity. These formulations are based on (1) start and completion time variables, (2) time index variables, (3) linear ordering variables and (4) assignment and positional date variables. The objective functions that are studied in this paper are total weighted completion time, maximum lateness, number of tardy jobs and total weighted tardiness. Based on the computational results, discussion and recommendations are made on which MIP formulation might work best for these problems. The performances of these formulations very much depend on the objective function, number of jobs and the sum of the processing times of all the jobs. Two sets of inequalities are presented that can be used to improve the performance of the formulation with assignment and positional date variables. Further, this research is extend to single machine bicriteria scheduling problems in which jobs belong to either of two different disjoint sets, each set having its own performance measure. These problems have been referred to as interfering job sets in the scheduling literature and also been called multi-agent scheduling where each agent's objective function is to be minimized. In the first single machine interfering problem (P1), the criteria of minimizing total completion time and number of tardy jobs for the two sets of jobs is studied. A Forward SPT-EDD heuristic is presented that attempts to generate set of non-dominated solutions. The complexity of this specific problem is NP-hard. The computational efficiency of the heuristic is compared against the pseudo-polynomial algorithm proposed by Ng et al. [2006]. In the second single machine interfering job sets problem (P2), the criteria of minimizing total weighted completion time and maximum lateness is studied. This is an established NP-hard problem for which a Forward WSPT-EDD heuristic is presented that attempts to generate set of supported points and the solution quality is compared with MIP formulations. For both of these problems, all jobs are available at time zero and the jobs are not allowed to be preempted.
ContributorsKhowala, Ketan (Author) / Fowler, John (Thesis advisor) / Keha, Ahmet (Thesis advisor) / Balasubramanian, Hari J (Committee member) / Wu, Teresa (Committee member) / Zhang, Muhong (Committee member) / Arizona State University (Publisher)
Created2012
Description
Optimization of surgical operations is a challenging managerial problem for surgical suite directors. This dissertation presents modeling and solution techniques for operating room (OR) planning and scheduling problems. First, several sequencing and patient appointment time setting heuristics are proposed for scheduling an Outpatient Procedure Center. A discrete event simulation model is used to evaluate how scheduling heuristics perform with respect to the competing criteria of expected patient waiting time and expected surgical suite overtime for a single day compared to current practice. Next, a bi-criteria Genetic Algorithm is used to determine if better solutions can be obtained for this single day scheduling problem. The efficacy of the bi-criteria Genetic Algorithm, when surgeries are allowed to be moved to other days, is investigated. Numerical experiments based on real data from a large health care provider are presented. The analysis provides insight into the best scheduling heuristics, and the tradeoff between patient and health care provider based criteria. Second, a multi-stage stochastic mixed integer programming formulation for the allocation of surgeries to ORs over a finite planning horizon is studied. The demand for surgery and surgical duration are random variables. The objective is to minimize two competing criteria: expected surgery cancellations and OR overtime. A decomposition method, Progressive Hedging, is implemented to find near optimal surgery plans. Finally, properties of the model are discussed and methods are proposed to improve the performance of the algorithm based on the special structure of the model. It is found simple rules can improve schedules used in practice. Sequencing surgeries from the longest to shortest mean duration causes high expected overtime, and should be avoided, while sequencing from the shortest to longest mean duration performed quite well in our experiments. Expending greater computational effort with more sophisticated optimization methods does not lead to substantial improvements. However, controlling daily procedure mix may achieve substantial improvements in performance. A novel stochastic programming model for a dynamic surgery planning problem is proposed in the dissertation. The efficacy of the progressive hedging algorithm is investigated. It is found there is a significant correlation between the performance of the algorithm and type and number of scenario bundles in a problem instance. The computational time spent to solve scenario subproblems is among the most significant factors that impact the performance of the algorithm. The quality of the solutions can be improved by detecting and preventing cyclical behaviors.
ContributorsGul, Serhat (Author) / Fowler, John W. (Thesis advisor) / Denton, Brian T. (Thesis advisor) / Wu, Teresa (Committee member) / Zhang, Muhong (Committee member) / Arizona State University (Publisher)
Created2010
Description
Ultimate Frisbee or "Ultimate," is a fast growing field sport that is being played competitively at universities across the country. Many mid-tier college teams have the goal of winning as many games as possible, however they also need to grow their program by training and retaining new players. The purpose of this project was to create a prototype statistical tool that maximizes a player line-up's probability of scoring the next point, while having as equal playing time across all experienced and novice players as possible. Game, player, and team data was collected for 25 different games played over the course of 4 tournaments during Fall 2017 and early Spring 2018 using the UltiAnalytics iPad application. "Amount of Top 1/3 Players" was the measure of equal playing time, and "Line Efficiency" and "Line Interaction" represented a line's probability of scoring. After running a logistic regression, Line Efficiency was found to be the more accurate predictor of scoring outcome than Line Interaction. An "Equal PT Measure vs. Line Efficiency" graph was then created and the plot showed what the optimal lines were depending on what the user's preferences were at that point in time. Possible next steps include testing the model and refining it as needed.
ContributorsSpence, Andrea Nicole (Author) / McCarville, Daniel R. (Thesis director) / Pavlic, Theodore (Committee member) / Industrial, Systems and Operations Engineering Program (Contributor) / Barrett, The Honors College (Contributor)
Created2018-05
Description
The first step in process improvement is to scope the problem, next is measure the current process, but if data is not readily available and cannot be manually collected, then a measurement system must be implemented. General Dynamics Mission Systems (GDMS) is a lean company that is always seeking to improve. One of their current bottlenecks is the incoming inspection department. This department is responsible for finding defects on parts purchased and is critical to the high reliability product produced by GDMS. To stay competitive and hold their market share, a decision was made to optimize incoming inspection. This proved difficult because no data is being collected. Early steps in many process improvement methodologies, such as Define, Measure, Analyze, Improve and Control (DMAIC), include data collection; however, no measurement system was in place, resulting in no available data for improvement. The solution to this problem was to design and implement a Management Information System (MIS) that will track a variety of data. This will provide the company with data that will be used for analysis and improvement. The first stage of the MIS was developed in Microsoft Excel with Visual Basic for Applications because of the low cost and overall effectiveness of the software. Excel allows update to be made quickly, and allows GDMS to collect data immediately. Stage two would be moving the MIS to a more practicable software, such as Access or MySQL. This thesis is only focuses on stage one of the MIS, and GDMS will proceed with stage two.
ContributorsDiaz, Angel (Author) / McCarville, Daniel R. (Thesis director) / Pavlic, Theodore (Committee member) / Industrial, Systems (Contributor) / Barrett, The Honors College (Contributor)
Created2017-05