Optimization of process planning with various flexibilities using an imperialist competitive algorithm

In this paper, we investigate the optimization of process planning in which various flexibilities are considered. The objective is to minimize total weighted sum of manufacturing costs. Various flexibilities, including process flexibility, sequence flexibility, machine flexibility, tool flexibility, and tool access direction (TAD) flexibility, generally exist in process planning and consideration of these flexibilities is essential for improving production efficiency and system flexibility. However, process planning is strongly NP-hard due to the existence of various flexibilities as well as complex machining precedence constraints. To tackle this problem, an imperialist competitive algorithm (ICA) is employed to find promising solutions with reasonable computational cost. ICA is a novel socio-politically motivated metaheuristic algorithm inspired by imperialist competition. It starts with an initial population and proceeds through assimilation, position exchange, imperialistic competition, and elimination. Computational experiments on three sets of process planning problem taken from literature are carried out, and comparisons with some existing algorithms developed for process planning are presented. The results show that the algorithm performs significantly better than existing algorithms like genetic algorithm (GA), simulated annealing (SA), tabu search (TS), and particle swarm optimization (PSO).