Simulation Assisted Simulation Assisted Optimization and Real-Time Optimization and Real-Time Control Aspects of Flexible Control Aspects of Flexible

Production Systems Production Systems Subject to DisturbancesSubject to Disturbances

Authors: Wilhelm DangelmaierKiran R MahajanThomas SeegerBenjamin KlöpperMark Aufenanger

Presenter:Greg Broderick

Date:November 17, 2008

Function of Paper/Function of Paper/Things ConsideredThings Considered

Describes how to Design and Describes how to Design and Develop a Predictive and Reactive Develop a Predictive and Reactive system for Scheduling and system for Scheduling and ReschedulingRescheduling

Rescheduling Methods for real-time Rescheduling Methods for real-time ControlsControls

Do this while considering Flexible Do this while considering Flexible and Fixed Flows with Parallel and Fixed Flows with Parallel MachinesMachines

Why it is Important to UsWhy it is Important to Us

This System Benefits ProductionThis System Benefits Production• Increases PerformanceIncreases Performance• Reduce Material Buffer Reduce Material Buffer • Reduce Material HandlingReduce Material Handling• StabilityStability• Real-Time ControlReal-Time Control

Show Accuracy and Importance of Show Accuracy and Importance of SimulationsSimulations

References 1References 1 Brah, S. A. and J. L. Hunsucker. 1991. Branch and BoundBrah, S. A. and J. L. Hunsucker. 1991. Branch and Boundalgorithm for the algorithm for the flow shop with multiple processorsflow shop with multiple processors,,European Journal of Operational ResearchEuropean Journal of Operational Research, Vol. 51,, Vol. 51,pp- 88-99.pp- 88-99. Cheng, J., Y. Karuno, and H. Kise. 2001. A shifting Cheng, J., Y. Karuno, and H. Kise. 2001. A shifting bottleneckbottleneckprocedure for a parallel machineprocedure for a parallel machine flow shop flow shopscheduling problem. scheduling problem. Journal of Operations Research,Journal of Operations Research,Society of JapanSociety of Japan, 29, No. 2, pp. 140-156., 29, No. 2, pp. 140-156. Chong, C. S., A. I. Sivakumar, and R. Gay. 2003. Chong, C. S., A. I. Sivakumar, and R. Gay. 2003. Simulation-Simulation-based schedulingbased scheduling for dynamic discrete production. for dynamic discrete production.In Proceedings of the 2003 Winter Simulation ConferenceIn Proceedings of the 2003 Winter Simulation Conference,,ed. S. Chick, P. J. Sanchez, D. Ferrin, and D. J.ed. S. Chick, P. J. Sanchez, D. Ferrin, and D. J.Morrice, 1465 - 1473. Piscataway, New Jersey: InstituteMorrice, 1465 - 1473. Piscataway, New Jersey: Instituteof Electrical and Electronics Engineers.of Electrical and Electronics Engineers. Church, L. K., and R. Uzsoy. 1992. Church, L. K., and R. Uzsoy. 1992. Analysis of periodicAnalysis of periodicand event driven reschedulingand event driven rescheduling policies in dynamic policies in dynamic

References 2References 2shops. International shops. International Journal of Computer IntegratedJournal of Computer IntegratedManufacturing 5Manufacturing 5, 153-163., 153-163. Gupta, J. N. D., and A. J. Ruiz-Torres. 2000. Gupta, J. N. D., and A. J. Ruiz-Torres. 2000. MinimizingMinimizingmakespanmakespan subject to minimum total flow time on identical subject to minimum total flow time on identicalparallel machines, parallel machines, European Journal of OperationalEuropean Journal of OperationalResearchResearch, Vol. 125, No.5, pp.616-625., Vol. 125, No.5, pp.616-625. Haldun, A., M. Lawley, K. McKay, S. Mohan and R.Haldun, A., M. Lawley, K. McKay, S. Mohan and R.Uzsoy. 2005. Executing production schedules in theUzsoy. 2005. Executing production schedules in theface of disturbances: A review. face of disturbances: A review. European Journal ofEuropean Journal ofOperational Research 161Operational Research 161, 86-110., 86-110. Harmonosky, C. M., R. H. Farr, and M. C. Ni. 1997. SelectiveHarmonosky, C. M., R. H. Farr, and M. C. Ni. 1997. Selectivererouting using simulated steady state systemrerouting using simulated steady state systemdata. data. In Proceedings of the 1997 Winter SimulationIn Proceedings of the 1997 Winter SimulationConferenceConference, ed. S. Andradottir, K. J. Healy, D. H., ed. S. Andradottir, K. J. Healy, D. H.Withers, and B. L. Nelson, 1293 - 1298. Piscataway,Withers, and B. L. Nelson, 1293 - 1298. Piscataway,New Jersey: Institute of Electrical and Electronics Engineers.New Jersey: Institute of Electrical and Electronics Engineers. Leon, V. J., S. D. Wu, and R. H. Storer. 1994. A Leon, V. J., S. D. Wu, and R. H. Storer. 1994. A

References 3References 3control approach for job shops in the presencecontrol approach for job shops in the presenceof disruptions. of disruptions. International International journal of productionjournal of productionresearch 32research 32: 1451-1476.: 1451-1476. Leon, V. J., S. D. Wu, and R. H. Storer. 1993. RobustnessLeon, V. J., S. D. Wu, and R. H. Storer. 1993. Robustnessmeasures and robust scheduling for job shops. measures and robust scheduling for job shops. IIEIIETransactions 26Transactions 26, 32-43., 32-43. Phadniis, S., and S. Irani. 2003. Development of a newPhadniis, S., and S. Irani. 2003. Development of a newheuristic for scheduling flow-shops with parallel machinesheuristic for scheduling flow-shops with parallel machinesby prioritizing bottleneck stages. by prioritizing bottleneck stages. TransactionsTransactionsof the SDPSof the SDPS, Vol. 7, No. 1, pp 87-97., Vol. 7, No. 1, pp 87-97. Wu, S. D., and R. A. Wysk. 1989. An application of discrete-Wu, S. D., and R. A. Wysk. 1989. An application of discrete-event simulation to on-line control and schedulingevent simulation to on-line control and schedulingof flexible manufacturing. of flexible manufacturing. International Journal ofInternational Journal ofProduction ResearchProduction Research, Vol. 27 (9)., Vol. 27 (9). Wu, S. D., E. Byeon, and R. H. Storer. 1999. A graphtheoreticWu, S. D., E. Byeon, and R. H. Storer. 1999. A graphtheoreticdecomposition of job shop schedulingdecomposition of job shop schedulingproblems to achieve scheduling robustness. problems to achieve scheduling robustness. OperationsOperationsResearchResearch, Vol. 47, pp. 113-124., Vol. 47, pp. 113-124.

How it Relates to Me En 482How it Relates to Me En 482

The PaperConsidersDifferent Types of Planning

How it Relates to Me En 482How it Relates to Me En 482

Parameters and Terms DefinedParameters and Terms Defined Scheduling?Scheduling?

• Initial Factory Plan Before ProductionInitial Factory Plan Before Production• Based on Make Span/Time (1) or Upper Bounds/Quantity (2) Based on Make Span/Time (1) or Upper Bounds/Quantity (2)

Disturbance?Disturbance?• Slows or Alters ProductionSlows or Alters Production• Due to Complexity and Business DynamicsDue to Complexity and Business Dynamics

Re-Scheduling or Realized Solution (3)?Re-Scheduling or Realized Solution (3)?• Change in Plan after Production StartsChange in Plan after Production Starts• Requires Real-Time Controls and DataRequires Real-Time Controls and Data

Parameters Required For OptimizationParameters Required For Optimization• Processing and Waiting TimesProcessing and Waiting Times• Jobs and Materials AvailableJobs and Materials Available• Machines and maintenance SchedulesMachines and maintenance Schedules• Stages and Traveling TimeStages and Traveling Time

Black Box – Optimization AlgorithmBlack Box – Optimization Algorithm KPI – Key Performance Indicator – How a Model is EvaluatedKPI – Key Performance Indicator – How a Model is Evaluated Stability - Job Starting Time and Job Sequence DeviationsStability - Job Starting Time and Job Sequence Deviations FAM – Flow Analyzer ModuleFAM – Flow Analyzer Module

Design Principles/ConsiderationsDesign Principles/Considerations

Optimization and Their Trade OffsOptimization and Their Trade Offs• Global Vs. Localized SchedulingGlobal Vs. Localized Scheduling• Reducing Disturbances Vs. Developing Reducing Disturbances Vs. Developing

Complicated Scheduling LogicComplicated Scheduling Logic When to initiate a Re-schedulingWhen to initiate a Re-scheduling

• Event Driven –New Job –Machine BreaksEvent Driven –New Job –Machine Breaks• Periodic –One day –One ShiftPeriodic –One day –One Shift

What should it beWhat should it be

Experimental EquipmentExperimental EquipmentWhat is the foundation for the ResultsWhat is the foundation for the Results

Aggregate production planningAggregate production planning Master production planningMaster production planning Material requirements planning (MRP)Material requirements planning (MRP) Capacity planningCapacity planning

Design Principles AppliedDesign Principles Applied

CombiningSimulation and Optimizationto Achieve Validityand Optimality of the Predictive Schedule

Design Principles AppliedDesign Principles Applied

Combinationof Simulationand Optimization for Rescheduling and real-time control

Design Principles AppliedDesign Principles Applied

SelectiveReschedulingStabilityAlgorithm

Results (data/tables/design)Results (data/tables/design)

Here they Here they show the show the Difference Difference between between the three the three Design Design PrinciplesPrinciples

Results Results Correlated Correlated with Modelwith Model

Sometimes Sometimes Re-Scheduling Re-Scheduling slows down slows down the Processthe Process

Practical Industrial UsePractical Industrial Use

Provides an ability to actively Provides an ability to actively regulate the production of a factory regulate the production of a factory to meet needs.to meet needs.

Could boost efficiencyCould boost efficiency Agile manufacturing Vs. Lean

production

Technical AdvancementsTechnical Advancements

Agile manufacturing

Industries most ImpactedIndustries most Impacted

Most FactoriesMost Factories Factories that are subject to Factories that are subject to

DisturbancesDisturbances Factories that make custom partsFactories that make custom parts Small Factories that produce quality Small Factories that produce quality

itemsitems

ThanksThanks

Questions?Questions?