Browsing by Author "Lopes, Manuel Pereira"
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- A container loading algorithm with static mechanical equilibrium stability constraintsPublication . Ramos, A. Galrão; Oliveira, José F.; Gonçalves, José F.; Lopes, Manuel PereiraThe Container Loading Problem (CLP) literature has traditionally guaranteed cargo static stability by imposing the full support constraint for the base of the box. Used as a proxy for real-world static stability, this constraint excessively restricts the container space uti- lization and has conditioned the algorithms developed for this problem. In this paper we propose a container loading algorithm with static stability constraints based on the static mechanical equilibrium conditions applied to rigid bodies, which derive from Newton’s laws of motion. The algorithm is a multi-population biased random-key genetic algorithm, with a new placement procedure that uses the maximal-spaces representation to manage empty spaces, and a layer building strategy to fill the maximal-spaces. The new static stabil- ity criterion is embedded in the placement procedure and in the evaluation function of the algorithm. The new algorithm is extensively tested on well-known literature benchmark instances using three variants: no stability constraint, the classical full base support con- straint and with the new static stability constraint—a comparison is then made with the state-of-the-art algorithms for the CLP. The computational experiments show that by using the new stability criterion it is always possible to achieve a higher percentage of space utilization than with the classical full base support constraint, for all classes of problems, while still guaranteeing static stability. Moreover, for highly heterogeneous cargo the new algorithm with full base support constraint outperforms the other literature approaches, improving the best solutions known for these classes of problems.
- Development of a platform for lean manufacturing simulation gamesPublication . Ramos, A. G.; Lopes, Manuel Pereira; Ávila, PauloMore than ever, the economic globalization is creating the need to increase business competitiveness. Lean manufacturing is a management philosophy oriented to the elimination of activities that do not create any type of value and are thus considered a waste. One of the main differences from other management philosophies is the shop-floor focus and the operators' involvement. Therefore, the training of all organization levels is crucial for the success of lean manufacturing. Universities should also participate actively in this process by developing students' lean management skills and promoting a better and faster integration of students into their future organizations. This paper proposes a single realistic manufacturing platform, involving production and assembly operations, to learn by playing many of the lean tools such as VSM, 5S, SMED, poke-yoke, line balance, TPM, Mizusumashi, plant layout, and JIT/kanban. This simulation game was built in tight cooperation with experienced lean companies under the international program “Lean Learning Academy,”http://www.leanlearningacademy.eu/ and its main aim is to make bachelor and master courses in applied sciences more attractive by integrating classic lectures with a simulated production environment that could result in more motivated students and higher study yields. The simulation game results show that our approach is efficient in providing a realistic platform for the effective learning of lean principles, tools, and mindset, which can be easily included in course classes of less than two hours.
- Digital serious games and simulation games - comparison of two approaches to lean trainingPublication . Vaz de Carvalho, Carlos; Lopes, Manuel Pereira; Ramos, A. G.In an increasingly competitive and globalized world, companies need effective training methodologies and tools for their employees. However, selecting the most suitable ones is not an easy task. It depends on the requirements of the target group (namely time restrictions), on the specificities of the contents, etc. This is typically the case for training in Lean, the waste elimination manufacturing philosophy. This paper presents and compares two different approaches to lean training methodologies and tools: a simulation game based on a single realistic manufacturing platform, involving production and assembly operations that allows learning by playing; and a digital game that helps understand lean tools. This paper shows that both tools have advantages in terms of trainee motivation and knowledge acquisition. Furthermore, they can be used in a complementary way, reinforcing the acquired knowledge.
- Lean learning academy: an innovative framework for lean manufacturing trainingPublication . Vaz de Carvalho, Carlos; Lopes, Manuel Pereira; Ramos, A. G.; Ávila, PauloWorldwide competitiveness poses enormous challenges on managers, demanding a continuous quest to increase rationality in the use of resources. As a management philosophy, Lean Manufacturing focuses on the elimination of activities that do not create any type of value and therefore are considered waste. For companies to successfully implement the Lean Manufacturing philosophy it is crucial that the human resources of the organization have the necessary training, for which proper tools are required. At the same time, higher education institutions need innovative tools to increase the attractiveness of engineering curricula and develop a higher level of knowledge among students, improving their employability. This paper describes how Lean Learning Academy, an international collaboration project between five EU universities and five companies, from SME to Multinational/Global companies, developed and applied an innovative training programme for Engineers on Lean Manufacturing, a successful alternative to the traditional teaching methods in engineering courses.
- A physical packing sequence algorithm for the container loading problem with static mechanical equilibrium conditionsPublication . Ramos, António; Oliveira, José; Lopes, Manuel PereiraThe container loading problem (CLP) is a combinatorial optimization problem for the spatial arrangement of cargo inside containers so as to maximize the usage of space. The algorithms for this problem are of limited practical applicability if real-world constraints are not considered, one of the most important of which is deemed to be stability. This paper addresses static stability, as opposed to dynamic stability, looking at the stability of the cargo during container loading. This paper proposes two algorithms. The first is a static stability algorithm based on static mechanical equilibrium conditions that can be used as a stability evaluation function embedded in CLP algorithms (e.g. constructive heuristics, metaheuristics). The second proposed algorithm is a physical packing sequence algorithm that, given a container loading arrangement, generates the actual sequence by which each box is placed inside the container, considering static stability and loading operation efficiency constraints.
- Re-dimensioning of a warehouse layout: a practical casePublication . Madureira, Marlene; Sá, José Carlos; Lopes, Manuel Pereira; Ferreira, Luís Pinto; Pereira, Maria TeresaThis study aims to design a new warehouse layout as a solution to the warehouse’s main problem: lack of space to store all the materials in stock. Besides the existing warehouse building, which currently presents an unsuitable layout for the storage of large volumes, there is a second area right next to the first to increase the storage area. The two buildings were re-dimensioned to accommodate a great quantity of stock, enabling one to transform the warehouse building into an industrial warehouse with appropriate storage methods. The final layout increased the storage area by 64%, from a total of 1.471,41 m2 to 2.414,22 m2 overall.