A Petri net-based methodology to increase flexibility in service-oriented holonic manufacturing systems

Distributed control systems such as the holonic manufacturing systems and service-oriented architectures have demonstrated to provide higher levels of flexibility, notably in the planning and scheduling functionalities, if well exploited. In scheduling, the use of fixed process plans generated by traditional planning approaches, usually leads to unrealistic schedules due to the lack of considerations of the workshop status. IPPS approaches try to break the gap between these two functionalities in favor of providing flexible plans adapting to the shop floor's state. A key element in the creation of flexible process plans is the definition of a process model capable of representing alternatives solutions to the sequencing problem and therefore increasing the potential solution space. This paper presents a methodology to increase planning flexibility in service-oriented manufacturing systems (SOHMS). The methodology introduces a Petri net service-oriented process model (SOP model) capable of computing a product's deadlock free sequential space and adapts to the fractal character of holonic architectures. A set of modeling rules, with illustrations, is presented for the automatic generation of the Petri net, based on a set of precedence conditions. To explore the solution space represented by the SOP model a holonic interaction protocol is presented. Moreover, a set of behavioral strategies is proposed in order to cope with the effects of a possible combinatorial explosion. A study case applied workshop example is presented to illustrate the modeling process of SOP models, compute the sequential solution space and demonstrate how this notably increases the number of potentially goods feasible solutions.     

A dynamic scheduling holon for manufacturing orders

This paper deals with a new architecture and negotiation protocol for the dynamic scheduling of manufacturing systems. The architecture is based on two paradigms: multi-agent systems and holonic systems. The main contribution in the architecture is the existence of holons representing tasks together with holons representing resources. The well-known contract net protocol has been adapted to handle temporal constraints and to deal with conflicts. It also deals with conflict situations, namely with the case of the indecision problem. This approach assumes that deadlines are the most important constraints to consider.     

Designing Holonic manufacturing systems

This paper discusses the design of Holonic manufacturing systems (HMS), with emphasis on manufacturing control. First, it discusses the concept of a Holonic system. Second, it presents the HMS reference architecture for manufacturing control. Third, it addresses the overall design problem, i.e. designing both the holonic control system and the underlying manufacturing system. Finally, the paper addresses the design and development of the control software itself.     

Agent-based distributed manufacturing control: A state-of-the-art survey

Manufacturing has faced significant changes during the last years, namely the move from a local economy towards a global and competitive economy, with markets demanding for highly customized products of high quality at lower costs, and with short life cycles. In this environment, manufacturing enterprises, to remain competitive, must respond closely to customer demands by improving their flexibility and agility, while maintaining their productivity and quality. Dynamic response to emergence is becoming a key issue in manufacturing field because traditional manufacturing control systems are built upon rigid control architectures, which cannot respond efficiently and effectively to dynamic change. In these circumstances, the current challenge is to develop manufacturing control systems that exhibit intelligence, robustness and adaptation to the environment changes and disturbances. The introduction of multi-agent systems and holonic manufacturing systems paradigms addresses these requirements, bringing the advantages of modularity, decentralization, autonomy, scalability and re-usability. This paper surveys the literature in manufacturing control systems using distributed artificial intelligence techniques, namely multi-agent systems and holonic manufacturing systems principles. The paper also discusses the reasons for the weak adoption of these approaches by industry and points out the challenges and research opportunities for the future.     

A system architecture for holonic manufacturing planning and control (EtoPlan)

In this paper, we present the system architecture of a flexible manufacturing planning and control system, named EtoPlan. The concept is based on the holonic control approach of building multiple and temporary hierarchies (holarchies). This paper describes the system architecture for flexible planning and control of activities and (groups of) Resources in a manufacture-to-order environment. The system architecture consists of generic control modules that can be applied on different hierarchical levels and for different kinds of manufacturing activities. The main function of the Resource Controller is the Determine Applicability function.     

Collaborative reconfiguration mechanism for holonic manufacturing systems

Although holonic manufacturing systems (HMS) are recognized as a paradigm to cope with the changes in manufacturing environment based on a flexible architecture, development of reconfiguration mechanism is required to realize the advantages of HMS. Finding a solution from scratch to deal with changes in HMS is not an appropriate approach as it may lead to chaos at the shop floor. The objective of this paper is to propose a viable design methodology to achieve effective reconfiguration in HMS based on the cooperation of holons. We formulate and study a holarchy reconfiguration problem and define an impact function to characterize the impact of resource failures on different holons in a holarchy. A collaborative reconfiguration algorithm based on the impact function is proposed to effectively reconfigure the systems to achieve minimal cost solutions.     

H2CM: A holonic architecture for flexible hybrid control systems

Several studies typically arise from the interaction of discrete planning algorithms or control and continuous processes, normally called hybrid control systems. It consists in three distinct levels, the controller, the plant and the interface. Hybrid control systems are conventionally modeled by switching patterns using the whole system instead of atomic resource. Therefore, the reconfiguration process is complex because it must take into account the system as a whole, making the hybrid control systems inflexible and more susceptible to uncertainties. The need for flexibility thus leads several teams to investigate the application of holonic paradigm to hybrid control systems. The objective of this paper is to demonstrate the possibility to apply almost directly a holonic discrete-event based reference architecture to hybrid control systems. A case study of industrial electricity generation process was taken, specifically a combined cycle plant (CCP) for verifying the proper operation of the proposed architecture.     

Virtual approach to holonic control of the tyre-manufacturing system

Tyre manufacturers aiming to remain competitive in complex modern markets must promptly adjust to the changes within the production environment. With traditional tyre-manufacturing systems, a slow response during optimization of the manufacturing process and low-level adaptability to system disturbances is evident. The presented approach to virtual holonic control of the tyre-manufacturing system enables dynamic response in the event of new optimization demands, decrease of the impact of disturbances on system productivity and smaller future investments in the manufacturing equipment.     

A holonic approach to flexible flow shop scheduling under stochastic processing times

Flexible flow shop scheduling problems are NP-hard and tend to become more complex when stochastic uncertainties are taken into consideration. This paper presents a novel decomposition-based holonic approach (DBHA) for minimising the makespan of a flexible flow shop (FFS) with stochastic processing times. The proposed DBHA employs autonomous and cooperative holons to construct solutions. When jobs are released to an FFS, the machines of the FFS are firstly grouped by a neighbouring K-means clustering algorithm into an appropriate number of cluster holons, based on their stochastic nature. A scheduling policy, determined by the back propagation networks (BPNs), is then assigned to each cluster holon for schedule generation. For cluster holons of a low stochastic nature, the Genetic Algorithm Control (GAC) is adopted to generate local schedules in a centralised manner; on the other hand, for cluster holons of a high stochastic nature, the Shortest Processing Time Based Contract Net Protocol (SPT-CNP) is applied to conduct negotiations for scheduling in a decentralised manner. The combination of these two scheduling policies enables the DBHA to achieve globally good solutions, with considerable adaptability in dynamic environments. Computation results indicate that the DBHA outperforms either GAC or SPT-CNP alone for FFS scheduling with stochastic processing times.     

Holarchy formation and optimization in holonic manufacturing systems with contract net

Holonic manufacturing systems (HMS) is based on the notion of holon, an autonomous, cooperative and intelligent entity to provide a econfigurable, flexible and decentralized manufacturing environment to respond to changing needs and opportunities. A set of holons that cooperate to achieve a goal forms a holarchy. How to design a mechanism to form a holarchy to achieve a goal while minimizing the overall cost is a challenge. The objectives of this paper are to propose models and develop collaborative algorithms to guide the holons to form a holarchy to coherently move toward the desired goal state ultimately. We adopt contract net protocol (CNP) to model mutual selection of holons in forming a holarchy. We formulate a holarchy optimization problem to minimize the cost subject to the feasibility constraints. To analyze the feasibility of a holarchy, a Petri net (PN) model is proposed. As classical PN models do not take into account the cost involved in firing transitions, we augment the PN model with cost functions in the problem formulation. Due to the distributed architecture of HMS, the internal structure of each potential holarchy that acts as bidder in CNP is not available to the manager. A key issue is to determine the feasibility of a holarchy without constructing the whole PN model of the given hierarchy. We study the feasible conditions for a holarchy and propose a collaborative algorithm to analyze the feasibility and award contracts to holons without constructing the whole model of a holarchy.     

Development of holonic manufacturing execution systems

Rapid changes of market demands and pressures of competition require manufacturers to maintain highly flexible manufacturing systems to cope with a complex manufacturing environment. To meet these requirements, this work adopts the concepts of holon and holarchy to design manufacturing systems. Holon and holarchy are derived from the studies of social organizations and living organisms and possess the properties of intelligence, autonomy, cooperation, reconfigurability, and extensibility. Moreover, advanced manufacturing systems also require the properties of security certification and failure recovery. Based on the requirements of these properties, a systematic approach is proposed to develop a holonic manufacturing execution system (HMES) for the semiconductor industry. This systematic approach starts with a system analysis by collecting domain requirements and analyzing domain knowledge. The HMES Holarchy is designed by the procedure of constructing an abstract object model based on domain knowledge, partitioning application domain into functional holons, identifying generic parts among functional holons, developing the Generic Holon, defining holarchy messages and the holarchy framework of HMES, and finally designing functional holons based on the Generic Holon. It is believed that this proposed systematic approach provides a novel and efficient way to design HMES.     

A survey of dynamic scheduling in manufacturing systems

In most real-world environments, scheduling is an ongoing reactive process where the presence of a variety of unexpected disruptions is usually inevitable, and continually forces reconsideration and revision of pre-established schedules. Many of the approaches developed to solve the problem of static scheduling are often impractical in real-world environments, and the near-optimal schedules with respect to the estimated data may become obsolete when they are released to the shop floor. This paper outlines the limitations of the static approaches to scheduling in the presence of real-time information and presents a number of issues that have come up in recent years on dynamic scheduling. The paper defines the problem of dynamic scheduling and provides a review of the state-of-the-art of currently developing research on dynamic scheduling. The principles of several dynamic scheduling techniques, namely, heuristics, meta-heuristics, multi-agent systems, and other artificial intelligence techniques are described in detail, followed by a discussion and comparison of their potential.     

ORCA-FMS: a dynamic architecture for the optimized and reactive control of flexible manufacturing scheduling

Reactive and effective hybrid manufacturing control architectures, combining hierarchy and heterarchy adapted to the current constraints of the industrial market and its environment were created. In this article, a new generic hybrid control architecture called ORCA (dynamic Architecture for an Optimized and Reactive Control) is first proposed. This hybrid architecture is able to dynamically and partially switch between a hierarchical predictive architecture and a heterarchical reactive architecture, if an event forbidding the planned behavior to be followed occurs. In this article, this architecture was applied to a Flexible Manufacturing System (FMS) problem and denoted ORCA-FMS. ORCA-FMS was tested on an existing manufacturing cell with simulations and real experiments to prove the applicability and the effectiveness of this kind of hybrid architecture in an industrial environment.     

知识化制造系统中动态调度的自适应策略研究

针对知识化制造系统中的动态调度问题,结合知识化制造单元的高智能特征,提出了B-Q学习算法．并基于该算法构建了一种自适应调度控制策略．针对知识化制造系统运行过程中系统状态空间较大的特点,通过提取系统状态特征,对系统状态进行合理聚类,有效地降低了系统状态空间的复杂性．根据系统当前所处的瞬时状态．选取不同的调度规则对缓冲区中工件进行有效调度．仿真结果验证了所提出调度控制策略的有效性．     

The model-based product agent: A control oriented architecture for intelligent products in multi-agent manufacturing systems

The multi-agent control strategy has been previously shown to improve the flexibility of complex, dynamic manufacturing systems. One key component of this strategy is the product agent. The product agent is responsible for autonomously guiding a physical part in the manufacturing system based on its production goals. Though the product agent has been described in previous works, a fully developed software architecture for the product agent that uses a model-based optimization approach has not been proposed. In this work, a product agent architecture with the capabilities to explore the local environment, plan and schedule events based on its knowledge, and request desired actions from the resources in the system is presented and tested.     

Customer order management in service oriented holonic manufacturing

One of the most important problems when considering the design of manufacturing systems based on SOA paradigms is the integration of shop floor devices in the business processes at the enterprise level. This paper presents the design and implementation of the Customer Order Management (COM) module based on SOA architecture in the context of holonic manufacturing systems. The COM module is integrating with SOA enabled shop floor devices using industry standards. The implementation leverages a multi agent system suited for industrial applications integrated in a SOA environment capable of dynamic BPEL workflow generation and execution. The prototype consists in a SCA application for core COM module functionality and an extension for NetLogo MAS platform for SOA integration. The COM module interacts with the MES layer using real time events handled by the BPEL process implementation in the execution stage. A web based portal frontend for the COM module has been developed to allow real time tracking of customer orders, providing data about product batch execution and individual progress of each product on the production line.     

Collaborative composition of processes in holonic manufacturing systems

Although it provides a flexible architecture to deal with changes and uncertainties, holonic manufacturing systems (HMS) also pose challenges in design and implementation. A challenge is to design a problem solving environment to guide the holons in HMS such that the decisions made by the individual holons as a whole collaboratively compose the production processes for the tasks. The objective of this paper is to propose a problem solving environment for the composition of minimal cost processes in HMS. Given a specific product type and due date, the problem is to dynamically compose a complete process in HMS to process the product by the due date. To achieve the objective, we combine multi-agent systems technology with Petri nets in this paper. We first propose architecture and a two-layer contract net protocol to describe the negotiation between order holons, product holons and resource holons in HMS. To determine whether it is feasible for a set product holons and resource holons to compose a process for an order holon, we propose Petri net models to capture the workflows and activities in product holons and resource holons, respectively. To optimize the cost in the composed manufacturing process, the concept of activity-based costing is adopted to assign the cost of the activities to Petri nets. The advantages of our design methodology include specification of workflows and resource activities with PNML to minimize the cost. To realize the two-layer contract net protocol relies on a mechanism for a holon to discover the services provided by other holons. We proposed a scheme for publication and discovery of holon services based on FIPA compliant multi-agent system platform. Based on the service publication and discovery scheme, interactions between holons with the two-layer contract net protocol can be realized. We develop a HMS system to solve the process composition problem.     

Virtual factory approach for implementation of holonic control in industrial applications: A case study in die-casting industry

Design and implementation of holonic manufacturing control systems for the real industrial applications require risky, careful decisions to ensure that the manufacturing system will successfully satisfy the demands of an ever-changing market. This paper suggests a virtual reality (VR)-based methodology for enhancing the design and implementation process of holonic control systems in manufacturing practice. The major focus has been given to the implementation of holonic control into the small to medium size manufacturing enterprises (SMEs).     

基于Petri网的柔性制造系统无死锁遗传调度算法

对以最小化加工时间为目标的柔性制造系统无死锁调度问题, 提出了一种遗传调度算法. 算法考虑到同类工件具有预先确定的相同加工路径, 而各工序的处理时间与工件有关. 用Petri网对工序和资源分配进行逻辑建模,利用遗传算法, 采用工序自然编码方式, 基于系统的最佳避免死锁Petri网控制器, 检测染色体的可行性, 修复不可行染色体使其对应的调度满足资源约束和无死锁控制约束, 从而保证算法所利用的所有染色体都对应系统的可行调度. 仿真结果表明了算法的可行性和有效性.