Celeritas: a coloured Petri net approach to simulation and control of flexible manufacturing systems

In many areas of computerization today, the capabilities of hardware systems far exceed the sophistication of software systems needed for optimum control. This research is an attempt to advance software control capabilities of flexible manufacturing systems (FMSs). To this end, an FMS controller architecture, called Celeritas, has been designed and a software system conforming to this architecture has been designed and implemented. Celeritas is a generic, data-configurable FMS controller designed using the coloured Petri nets (CP-nets) modelling paradigm augmented with decision support software to provide both FMS simulation and control. Formalisms of the CP-net paradigm provide straightforward representation of both the inherent concurrency and resource conflicts present in such a complex system. Augmentations provide user-defined routines for real-time interfaces to this information which is utilized to provide resource arbitration services among jobs competing for scarce resources and overall job scheduling.     

A synthesis approach to distributed supervisory control design for manufacturing systems with Grafcet implementation

In supervisory control, computational complexity and implementation flexibility represent major challenges when a large number of local components compose a target system. To overcome these difficulties, we propose a formal approach to distributed control synthesis and implementation for automated manufacturing systems (AMS). We assume that the system is modelled with automata in a local modular fashion. Local control specifications are defined for each local subsystem by means of logical equations to construct local controllers (LCs). Then, global control specifications, stated as logical implications, are applied to the LCs, which allows synchronisation and cooperative interaction among the subsystems. This paper makes two contributions. First, it outlines a formal method for constructing minimally restrictive and deadlock-free distributed controllers (DCs). Second, it proposes a method for the interpretation of these DCs into Grafcet, which is a graphical modelling formalism widely used to design the controller’s dynamic behaviour for AMS. An experimental manufacturing system illustrates the approach.     

An approach to the dynamic modelling of manufacturing systems

Because of their complexity manufacturing systems are difficult to model. However, modelling is very often required in order to study the behaviour of the system. In this paper an approach is described, where an analogy is drawn between the behaviour of a manufacturing and a mechanical system. Manufacturing systems have to respond to a dynamic demand, namely, a demand that changes over time. Flexibility of a manufacturing system can be thought of as the ability and the rapidness with which the system responds to the dynamic demand. This resembles the behaviour of a mechanical system under the excitation of a force that changes over time. The paper attempts to establish a modelling method based on this analogy and uses this method in the study of a real industrial system.     

An expert system based approach to manufacturing cell design

The design of cellular systems is a complex, multi-criteria and multi-step process which can have significant implications for the entire organization. Most research in this area focuses on the formation of pan families and associated machine groups, one step in the cell design process. Numerous quantitative techniques have been developed to address this part-family/machine group formation problem. Existing approaches include math programming, algorithms for matrix diagonalization, the application of network modelling and the use of similarity coefficients. These mathematically-oriented techniques can handle a relatively limited set of quantitative objectives and. in addition, require many simplifying assumptions. For this reason, the solutions generated by these techniques are of limited usefulness in actual cell design. This paper proposes an expert system approach to cell system design. The starting point for the expert system is the initial solution generated by traditional mathematical techniques. Based on a flexible set of user-driven quantitative and qualitative factors, the expert system evaluates these preliminary solutions for feasibility and quality. If the solutions are not satisfactory (infeasible or of low quality), the system suggests modifications.     

An integrated fuzzy multi-criteria group decision-making approach for green supplier evaluation

Purchasing is one of the most vital functions within a company and supplier performance evaluation is one of the most important business processes of the purchasing function. Traditionally, companies have considered factors such as price, quality, flexibility, etc. while evaluating suppliers. However, environmental pressures urge them to consider green issues. This study proposes a decision model for supplier performance evaluation by considering various environmental performance criteria. An integrated, fuzzy group decision-making approach is adopted to evaluate green supplier alternatives. More precisely, a fuzzy analytic hierarchy process (AHP) is applied to determine the relative weights of the evaluation criteria and an axiomatic design (AD)-based fuzzy group decision-making approach is applied to rank the green suppliers. Finally, a case study is given to demonstrate the potential of the methodology.     

Making IT fit: the design of integrated manufacturing systems

One of the important implications of information technology (IT) is that it has made possible widespread automation in manufacturing industry. However, the bulk of this has involved discrete automation of single plant items or process elements rather than the total production system. Although the capital cost of such total system automation is a significant factor in slowing the rate of change in this direction, there are also a number of problem issues related to the integration of machines, computers and human systems within manufacture and design. Arguably the types of issue involved are not fully understood and in many cases the technological change is demanding totally new approaches and responses to the design of production systems and the traditional manufacture/design connections.The paper explores some of the issues raised in advanced manufacturing systems, drawing on case study research into the adoption of flexible manufacturing systems as an example of computer-integrated manufacture. It comments on the experience of case study firms and presents some comments on the design problems facing those responsible for integrated manufacturing systems.     

A genetic algorithms-based approach for design of manufacturing systems: An industrial application

This paper presents a design methodology and a genetic algorithm-based approach for redesign of a manufacturing system for a small steel pre-fabricated building manufacturer. Through the application of celular manufacturing principles, we discuss the application of the design methodology that takes a topdown approach to determine system needs and a bottom-up integrated design approach to develop the configurations of the manufacturing system. The integrated design approach uses a genetic algorithm and an AutoCAD interface to minimize the inter and intra cell material movements during cell formation. A selected set of solutions obtained are further analysed using discrete event modelling and simulation. The final results presented indicate a substantial improvement in overall performance compared to the original layout. The company has implemented a modified version of the final solution and has achieved the significant improvements in material handling and overall productivity.     

Launching and dispatching strategies for multi-criteria control of closed manufacturing systems with flexible routeing capability

In this paper, we study the problems of launching and dispatching of parts in closed manufacturing systems with flexible routeing. For the manufacturing systems being operated against multiple performance criteria, we postulate that controlling different aspects of the operational control strategy to meet one single performance criterion would improve overall system performance. It is suggested that to achieve production rates, launching rules be utilized and to affect flowtime, dispatching rules be manipulated. Also, for measurement of routeing flexibility, an entropic measure of flexibility is refined. The entropy-based rule is then compared with the dispatching rules commonly used in the industry. Control strategies are developed for a test system and it is shown that a hierarchical control strategy works best when multiple performance criteria are of interest.     

Improving manufacturing lead time using holistic approach to planning and execution with integrated data structures: numerical simulation and comparison

Manufacturing planning and control (MPC) plays a significant role in effective planning of requirements and execution of those plans. It also influences various performance measures, in particular on-time delivery, which is dependent on many factors including manufacturing lead time. This paper aims to address key issues of infinite loading of resources, lack of forward planning, and limited simultaneous planning capabilities of MRP through a holistic approach to planning of various components and execution of those plans, based on integrated data structures. It is shown that integrated data structures, combining hierarchical single-level BOMs and sequential operations routings using a holistic approach to planning and execution enable reducing lead time by eliminating slack times associated with traditional methods. Furthermore, manufacturing lead time, based on integrated data structures is a true representation of operation times and is shorter compared with traditional lead time. Sensitivity analysis on lead-time with bills-of-materials (BOM) levels and floats shows that the holistic approach to planning and execution with integrated data structures is an effective way of improving lead-time, in particular when product structures involve many levels of BOMs and floats (slack times). The proposed holistic approach provides forward planning, simultaneous planning of components, and finite loading of resources. It is expected that the concept of integrated data structures be extended to model transaction data with process functions (e.g. production order cycle), which would improve overall cycle times by eliminating manual functions associated with current methods.     

Framework for the control of automated material-handling systems using the holonic manufacturing approach

In today's global economy, manufacturing companies must be able to change both the product variety and production quantity without incurring major disturbances in the production process. A manufacturing system capable of performing these changes efficiently needs a control system flexible enough to go from one state to another without significant delays in production. To compensate for the deficiencies of both hierarchical and heterarchical control systems, a control architecture based on the holonic concept is proposed. After presenting the general holonic control architecture, the paper focuses on the integration of the holonic-based control concept in the design of an automated material-handling control system. When performing transport activities in a manufacturing system, due to its architecture, the holonic system can operate both as a hierarchical system, following a predefined schedule during normal operation conditions, and as a heterarchical system in the presence of disturbances.     

A new approach to modelling,control and simulation of knowledgeable manufacturing cell

The running of the knowledgeable manufacturing cell (KMC) is a typical discrete event dynamic process. Methods used to model and analyse discrete event dynamic systems (DEDS) include Petri net and automata theory. In this paper, a new matrix-automaton is proposed to model the KMC and solve the task control problems existing in the KMC. The automaton is of structured property and can be used to analyse the dynamic performance of the KMC. Stochastic dynamic programming is used to derive the optimal task control strategy of the automaton, and a simulation method and program are proposed to simulate the running of the KMC. The matrix-automaton model of an experimental KMC including m manufacturing agents and n classes of workpieces is built and solved by the methods in this paper. Compared with the random control principle, the objective function value of the control strategy in this paper is obviously lower, which testifies the validity and feasibility of the control strategy.     

A multi-objective genetic algorithm approach to the design of cellular manufacturing systems

In this paper, a multi-objective integer programming model is constructed for the design of cellular manufacturing systems with independent cells. A genetic algorithm with multiple fitness functions is proposed to solve the formulated problem. The proposed algorithm finds multiple solutions along the Pareto optimal frontier. There are some features that make the proposed algorithm different from other algorithms used in the design of cellular manufacturing systems. These include: (1) a systematic uniform design-based technique, used to determine the search directions, and (2) searching the solution space in multiple directions instead of single direction. Four problems are selected from the literature to evaluate the performance of the proposed approach. The results validate the effectiveness of the proposed method in designing the manufacturing cells.     

Dealing with design options in the optimization of manufacturing systems: An evolutionary approach

When designing a manufacturing system, several features have often to be determined to optimize a performance criterion. We propose an optimization simulation method that can be applied to optimize problems taking into account design options and any type of parameters. This method is based on the association of an evolutionary algorithm using a specific data structure and a simulation model. New mutation and recombination operators are proposed, which are adapted to this specific data structure. This approach is implemented on a network of Sun workstations, each station being responsible for running its own simulation model and its own evolutionary algorithm. This method is illustrated through the problem of designing a manufacturing system.     

An integrated approach to the facilities and material handling system design

The facility layout problem involves the optimal location of manufacturing facilities into a workshop. The classical approach to the layout design is carried out in two separate steps: the first step is the construction of the block layout, i.e. the location of the departments into the workshop, and the second step is the design of the material handling system. The separate optimization of these two aspects of the problem leads to solutions that can be far from the total optimum. In this paper, an integrated approach to the facilities and material handling system design is proposed. Referring to a physical model, named the bay structure , and to a unidirectional AGV system, a genetic approach is proposed to individuate the locations of the departments, the positions of the pickup/delivery stations and the direction of the flow-path. The minimization of material handling cost is adopted as optimality criterion.     

An integrated IDEF0-3/CTPN/SFC approach for design and analysis of discrete event control systems

Due to its low cost and increased reliability, the programmable logical controller (PLC) plays an important role in industry automation. However, as systems become larger and more complex, efficient and systematic analysis and design of PLCs become a more important issue. In this research, an integrated IDEF0-3/CTPN/SFC (IPS) for developing discrete event control systems (DECSs) is presented. The proposed integrated methodology provides a complete and systematic development process for the DECSs. The development process is divided into four stages: functional analysis, system behaviour analysis, system design, and system implementation. The IDEF0-3, coloured timed Petri net (CTPN) and sequential function chart (SFC) are integrated into the corresponding stages based on their characteristics. In addition, the transformation rules between the IDEF0-3 and CTPN and between CTPN and SFC are also conducted for developing DECSs. The transformation rules provide a straightforward mapping from the IDEF0-3 to CTPN and from the CTPN to SFC. The result of the integrated IPS systematically leads to SFC for PLC implementation. Finally, a ball assorting system is given to illustrate how the integrated IPS approach is implemented for developing the DECSs.     

Cellular manufacturing system design using a holonistic approach

We propose an integrated algorithm that will solve the part-family and machinecell formation problem by simultaneously considering the within-cell layout problem. To the best of our knowledge, this is the first study that considers the efficiency of both individual cells and the overall system in monetary terms. Each cell should make at least a certain amount of profit to attain self-sufficiency, while we maximize the total profit of the system using a holonistic approach. The proposed algorithm provides two alternative solutions; one with independent cells and the other one with inter-cell movement. Our computational experiments indicate that the results are very encouraging for a set of randomly generated problems.     

多类型冰箱的集成式仿真设计平台

为了实现在同一平台下对常用的不同类型冰箱进行仿真设计,本文开发了多类型冰箱的集成式仿真设计平台。本文首先提出冰箱部件的通用计算模型,包括压缩机通用计算模型、换热器通用计算模型和箱体通用计算模型。然后,开发了多类型冰箱仿真平台的数据交互方法和系统控制策略的集成方法,从而建立了多类型冰箱的集成式仿真设计平台。实验验证结果表明,多类型冰箱的集成式仿真设计平台能够对常用类型的冰箱进行仿真计算,计算得出的冰箱耗电量和开机率的计算误差都在10%以内。     

An integrated framework for multi-scale materials simulation and design

In this paper, we describe initial results of an ongoing research activity involving materials scientists, computer scientists, mathematicians, and physicists from academia, industry and a national laboratory. The present work aims to develop a set of integrated computational tools to predict the relationships among chemistry, microstructure and mechanical properties of multicomponent materials systems. It contains a prototype grid-enabled package for multicomponent materials design with efficient information exchange between structure scales and effective algorithms and parallel computing schemes within individual simulation/modeling stages. As part of our multicomponent materials design framework, this paper reports the materials simulation segment in developing materials design knowledgebase, which involves four major computational steps: (1) Atomic-scale first-principles calculations to predict thermodynamic properties, lattice parameters, and kinetic data of unary, binary and ternary compounds and solutions phases; (2) CALPHAD data optimization approach to compute thermodynamic properties, lattice parameters, and kinetic data of multicomponent systems; (3) Multicomponent phase-field approach to predict the evolution of microstructures in one to three dimensions (1–3D); and (4) Finite element analysis to generate the mechanical response from the simulated microstructure. These four stages are to be integrated with advanced discretization and parallel algorithms and a software architecture for distributed computing systems.     

An application of discrete-event simulation to on-line control and scheduling in flexible manufacturing

The on-line control and scheduling of flexible manufacturing systems has been a major interest in the production research area since these systems first appeared. In this paper, a scheduling algorithm is described which employs discrete simulation in combination with straightforward part dispatching rules in a dynamic fashion. The result is that, instead of scheduling being planned ahead of time and then being applied to a rapidly changing system, a dispatching rule is determined for each short period just before the implementation time occurs. In the long run, the algorithm combines various dispatching rules in response to the dynamic status of the system. The algorithm is described in detail. The efficacy of the algorithm is discussed and demonstrated on a prototype system.