Process modeling and analysis of manufacturing supply chain networks using object-oriented Petri nets

This paper presents a systematic methodology for modeling and analysis of manufacturing supply chain business processes. The proposed approach first employs Computer Integrated Manufacturing Open System Architecture (CIMOSA) behavior rules to model the business process routing structures of manufacturing supply chain networks. Object-oriented predicate/transition nets (OPTNs) are then developed for the modular modeling and analysis of process models. Based on the structure of OPTNs, a procedure to obtain the system's P-invariants through objects’ P-invariants is suggested. From the P-invariants obtained, system structural properties such as deadlock and overflow can be analyzed. By using Petri net unfolding techniques and by extracting the process model of each object from the entire process model, the sequencing analysis for operations in supply chain processes becomes possible. Several manufacturing supply chain examples are used to illustrate the effectiveness of the proposed method.     

Supervisory control based on minimal cuts and Petri net sub-controllers coordination

This paper addresses the synthesis of Petri net (PN) controller for the forbidden state transition problem with a new utilisation of the theory of regions. Moreover, as any method of control synthesis based on a reachability graph, the theory of regions suffers from the combinatorial explosion problem. The proposed work minimises the number of equations in the linear system of theory of regions and therefore one can reduce the computation time. In this paper, two different approaches are proposed to select minimal cuts in the reachability graph in order to synthesise a PN controller. Thanks to a switch from one cut to another, one can activate and deactivate the corresponding?PNcontroller. An application is implemented in a flexible manufacturing system to illustrate the present method. Finally, comparison with previous works with experimental results in obtaining a maximally permissive controller is presented.     

Risk assessment and management for supply chain networks: A case study

The aim of this study is to show how a timed Petri nets framework can be used to model and analyze a supply chain (SC) network which is subject to various risks. The method is illustrated by an industrial case study. We first investigate the disruption factors of the SC network by a failure mode, effects and criticality analysis (FMECA) technique. We then integrate the risk management procedures into design, planning, and performance evaluation process of supply chain networks through Petri net (PN) based simulation. The developed PN model provides an efficient environment for defining uncertainties in the system and evaluating the added value of the risk mitigation actions. The findings of the case study shows that the system performance can be improved using risk management actions and the overall system costs can be reduced by mitigation scenarios.     

SCOlog: A logic-based approach to analysing supply chain operation dynamics

In a complex business world, characterised by globalisation and rapid rhythms of change, understanding supply chain (SC) operation dynamics is crucial. This paper describes a logic-based approach to analysing SC operation dynamics, named SCOlog. SC operation is modelled in a declarative fashion and it is simulated following rule-based execution semantics. This approach facilitates the automated explanation of simulated SC operational behaviours and performance. The automated explanation support provided by SCOlog is found to improve the understanding of the domain for non-SCM experts. Furthermore, SCOlog allows for maintainability and reusability.     

Developing a supply chain disruption analysis model: Application of colored Petri-nets

As a result of globalization in the past two decades, supply chains are encountering more unknown conditions and risks. One important category of risks is disruptions that block material flowing through a supply chain and that may even result in end-product manufacturing failure. This paper uses a Petri nets-based model as a tool to understand the dissemination of disruptions and to trace the operational performance of a supply chain. The presented approach models how changes propagate through a supply chain and calculates the impact of disruptions on supply chain attributes by concluding the states that are obtainable from a given initial status in the supply chain.     

Suboptimal supervisory control of Petri nets in presence of uncontrollable transitions via monitor places

This paper deals with the problem of enforcing generalized mutual exclusion constraints (GMEC) on place/transition nets with uncontrollable transitions. An efficient control synthesis technique, which has been proposed in the literature, enforces GMEC constraints by introducing monitor places to create suitable place invariants. The method has been shown to be maximally permissive and to give a unique control structure in the case that the set of legal markings is controllable. This paper investigates on and formally shows that the class of controllers obtained by this technique may not have a supremal element for uncontrollable specifications. Moreover, it is shown that the family of monitor places enforcing an uncontrollable specification can be parameterized with respect to the solution of a linear system of equation. An algorithm to obtain such parameterization is presented here.     

A two phase optimization method for Petri net models of manufacturing systems

Optimization is a key issue in the design of large manufacturing systems. An adequate modeling formalism to express the intricate interleaving of competition and cooperation relationships is needed first. Moreover, robust and efficient optimization techniques are necessary. This paper presents an integrated tool for the automated optimization of DEDS, with application to manufacturing systems. After a very quick overview of optimization problems in manufacturing systems, it presents the integration of two existing tools for the modeling and evaluation with Petri nets and a general-purpose optimization package based on simulated annealing. The consideration of a cache and a two phase technique for optimization allows to speed-up the optimization by a factor of about 35. During the first preoptimization phase, a rough approximation of the optimal parameter set is computed based on performance bounds. Two application examples show the benefits of the proposed technique.     

Measuring supply chain resilience using a deterministic modeling approach

To achieve a competitive edge in an uncertain business environment where change is imperative, one of the significant challenges for an organization is to mitigate risk by creating resilient supply chains. This research proposes a model using graph theory which holistically considers all the major enablers of resilience and their interrelationships for analysis using an Interpretive Structural Modeling approach. The uniqueness of this model lies in its ability to quantify resilience by a single numerical index. The quantification of resilience will help organizations assess the effectiveness of various risk mitigation strategies. This will provide tools for managers to compare different supply chains while offering a deeper knowledge of how supply chain characteristics increase or decrease resilience and consequently affect supply chain risk exposure. Thus, the research supports organizations in measuring and analyzing supply chain resilience and facilitates supply chain decision-making. The proposed method could simplify the dynamic nature of environment for managing disruptions in a supply chain. This novel approach for determining the supply chain resilience index (SCRI) advocates the consideration of resilience aspects in supply chain design, thus giving a competitive advantage to achieve market share even during a disruption.     

Synthesis a Petri net based control model for a FMS cell

Petri nets have been recognised as a high level formal and graphical specification language for modelling, analysis, and control of concurrent asynchronous distributed systems. This paper presents a PN model, synthesised by an extended version of the knitting synthesis technique. This method, as an incremental design approach, establishes the conditions under which the fundamental behavioural properties of the synthesised systems are fulfilled and preserved. That is, the synthesised models are live, bounded, and reversible (cyclic). A Petri net with the aforementioned properties is called a well-behaved Petri net system which is guaranteed to operate in a deadlock-free, stable, and cyclic fashion. Well-behaved Petri net models, synthesised using the proposed method can be compiled into control codes and implemented as real-time controllers for flexible manufacturing systems. The significance of this paper is due to the application of an extended version of knitting synthesis technique to a real life example of a flexible manufacturing system.     

A Petri net model for integrated process and job shop production planning

In this paper a new Petri net class (Chameleon systems) for modeling and analyzing joined process planning and job shop production planning is proposed based on the multi-level Petri net model introduced by Valk (1995). Chameleon system is a High-level Petri net extended with time that consists of a High-level Petri net modeling the workshop which is called system net and ordinary Petri net modeling the jobs and setups which act as tokens of the system net and therefore are called token nets. Process plans of the jobs are partial orders of operation groups and alternatives. The uncertainty of operation duration is captured by a new time model. The advantages of this new modeling approach are the following: (i) a modular construction of the joined process and job shop planning is allowed, (ii) classical known Petri net analysis methods can be applied and (iii) the analysis can be done at different levels of abstraction.     

Dynamic modeling and control of supply chain systems: A review

Supply chains are complicated dynamical systems triggered by customer demands. Proper selection of equipment, machinery, buildings and transportation fleets is a key component for the success of such systems. However, efficiency of supply chains mostly depends on management decisions, which are often based on intuition and experience. Due to the increasing complexity of supply chain systems (which is the result of changes in customer preferences, the globalization of the economy and the stringy competition among companies), these decisions are often far from optimum. Another factor that causes difficulties in decision making is that different stages in supply chains are often supervised by different groups of people with different managing philosophies. From the early 1950s it became evident that a rigorous framework for analyzing the dynamics of supply chains and taking proper decisions could improve substantially the performance of the systems. Due to the resemblance of supply chains to engineering dynamical systems, control theory has provided a solid background for building such a framework. During the last half century many mathematical tools emerging from the control literature have been applied to the supply chain management problem. These tools vary from classical transfer function analysis to highly sophisticated control methodologies, such as model predictive control (MPC) and neuro-dynamic programming. The aim of this paper is to provide a review of this effort. The reader will find representative references of many alternative control philosophies and identify the advantages, weaknesses and complexities of each one. The bottom line of this review is that a joint co-operation between control experts and supply chain managers has the potential to introduce more realism to the dynamical models and develop improved supply chain management policies.     

Integrated design of optimal supervisors for the enforcement of static and behavioral specifications in Petri net models

Petri net (PN) supervisory control is often performed through a sequential procedure that introduces additional constraint layers over an initial unconstrained PN model, using generalized mutual exclusion constraints (GMECs) implemented as monitor places. This is typical, e.g., in the context of flexible manufacturing systems, where the initial model represents the production sequences and the constraints are used to express static specifications, such as job limitations or the usage of resources, and behavioral ones, as liveness, controllability, etc. This sequential procedure may yield a redundant model, that is not easily reduced a posteriori. Also, it is difficult to ensure maximal permissivity with respect to multiple behavioral specifications. This paper, building on recent results regarding optimal supervisor design with branch & bound methods, proposes an integrated modeling approach that can be used to derive a minimal supervisor guaranteeing the attainment of an arbitrary set of static and behavioral specifications in a maximally permissive way. Among behavioral specifications, deadlock-freeness, liveness, reversibility and behavioral controllability are considered in the paper. The supervisor comes in the form of a simple set of GMECs or of a disjunction of sets of GMECs. Some examples emphasize the potential model size reductions that can be achieved.     

Robust control reconfiguration of resource allocation systems with Petri nets and integer programming

Supervisory control reconfiguration can handle the uncertainties including resource failures and task changes in discrete event systems. It was not addressed to exploit the robustness of closed-loop systems to accommodate some uncertainties in the prior studies. Such exploitation can cost-efficiently achieve reconfigurability and flexibility for real systems. This paper presents a robust reconfiguration method based on Petri nets (PNs) and integer programming for supervisory control of resource allocation systems (RASs) subject to varying resource allocation relationships. An allocation relationship is seen as a control specification while the execution processes requiring resources as an uncontrolled plant. First, a robust reconfiguration mechanism is proposed. It includes updating the P$P$-invariant-based supervisor and evolving the state of the closed-loop system. The latter adapts to the control specification changes by the self-regulation of the closed-loop system’s state. Next, two novel integer programming models for control reconfiguration are proposed, called a reconfiguration model with acceptability and reconfiguration one with specification correction. Since both models integrate the firability condition of transitions, no additional efforts are required for the state reachability analysis. Finally, a hospital emergency service system is used as an example to illustrate them.     

Petri net based process scheduling: A model of the control system of flexible manufacturing systems

In this paper, we propose a class of algorithms for the sub-optimal solution of a particular class of problems of process scheduling, particularly focusing on a case study in the area of flexible manufacturing systems (FMSs). The general class of problems we face in our approach is characterized as follows: there is a set of concurrent processes, each formed by a number of temporally related tasks (segments). Tasks are executable by alternate resource sets, different both in performance and costs. Processes and tasks are characterized by release times, due dates, and deadlines. Time constraints are also present in the availability of each resource in resource sets. It has been proven that such a problem does not admit an algorithm for an optimal solution in polynomial time. Our proposed algorithm finds a sub-optimal schedule according to a set of optimization criteria, based on task and process times (earliness, tardiness), and/or time independent costs of resources. Our approach to process scheduling is based on Timed Coloured Petri Nets. We describe the structure of the coordination and scheduling algorithms, concentrating on (i) the general-purpose component, and (ii) the application-dependent component. In particular, the paper focuses on the following issues: (i) theautomatic synthesis of Petri net models of the coordination subsystem, starting from the problem knowledge base; (ii) the dynamic behavior of the coordination subsystem, whose kernel is a High Level Petri net executor, a coordination process based on an original, general purpose algorithm; (iii) the structure of the real-time scheduling subsystem, based on particular heuristic sub-optimal multi-criteria algorithms. Furthermore, the paper defines the interaction mechanisms between the coordination and scheduling subsystems. Our approach clearly distinguishes the mechanism of the net execution from the decision support system. Two conceptually distinct levels, which correspond to two different, interacting implementation modules in the prototype CASE tool, have been defined: theexecutor and thescheduler levels. One of the outstanding differences between these levels is that the executor is conceived as a fast, efficient coordination process, without special-purpose problem-solving capabilities in case of conflicts. The scheduler, on the other hand, is the adaptive, distributed component, whose behavior may heavily depend on the problem class. If the scheduler fails, the executor is, in any case, able to proceed with a general-purpose conflict resolution strategy. Experimental results on the real-time performance of the kernel of the implemented system are finally shown in the paper. The approach described in this paper is at the basis of a joint project with industrial partners for the development of a CASE tool for the simulation of blast furnaces.     

Supervision Based on Place Invariants: A Survey

The supervision based on place invariants (SBPI) is an efficient technique for the supervisory control of Petri nets. This paper reveals the significance of the SBPI based on a literature survey, applications, and an analysis of problems and supervisory settings that can be addressed using SBPI. Special attention is given to the various settings within which the problem can be formulated. Such settings can be distinguished based on the concurrency type, the type of controllability and observability, and the centralized or decentralized type of supervision. As we show, it is possible to approach the most general settings in a purely structural way, without resorting to reachability analysis. We begin by describing the SBPI problem and the literature methods that address this problem or are related to it. Then, we proceed to show classes of problems that can be reduced to the SBPI problem. In the SBPI, the specification is described as a system of inequalities that the Petri net marking must satisfy at any time. However, as we show, problems involving more general specifications can be approached in the SBPI setting, sometimes under additional assumptions, by performing net and/or specification transformations. Four of the specifications we will consider are logic constraints, language specifications, disjunctions of linear constraints, and liveness. We conclude with a presentation of possible applications of the SBPI approach to programming with semaphores, fault tolerance, and synchronic-distance based designs.     

A game-based approach towards facilitating decision making for perishable products: An example of blood supply chain

Supply chains for perishable items consist of products with a fixed shelf life and limited production/collection; managing them requires competent decision-making. With the objective of placing the learners in the position of decision-makers, we propose the Blood Supply Chain Game which simulates the supply chain of blood units from donors to patients based on a real case study modeling the UK blood supply chain. The Excel-based game is an abstraction of the technical complex simulation model providing a more appropriate learning environment. This paper presents the game’s background, its mathematical formulations, example teaching scenarios and the learners’ evaluation. The game aims to translate qualitative aspects of a sensitive supply chain into quantitative economic consequences by presenting a process analysis and suggesting solutions for the patient’s benefit in a cost effective manner, trying to synchronize blood demand and supply and maximize the value of the whole supply chain. This innovative approach will be instructive for students and healthcare service professionals.     

A generalized Petri net modeling approach for the control of re-entrant flow semiconductor wafer fabrication

Re-entrant flow manufacturing lines, such as occur in semiconductor wafer fabrication, are characterized by a product routing that consists of multiple visits to a workstation or group of workstations during the manufacturing process. In this paper, a modeling approach is based on the use of generalized Petri nets for a re-entrant flow manufacturing line is presented. Specifically, three Petri net models representing a re-entrant flow line with three work centers and six machines are modeled. How these models may be used to represent a variety of queuing disciplines and work release policies is discussed.     

A systematic approach for supply chain improvement using design structure matrix

Supply chain is a complex system that involves many system elements from various functional areas. Performance of a supply chain heavily depends on the effectiveness of communication and coordination among these system elements and functional areas. However, a large and complex supply chain usually makes it difficult to coordinate and thus degrades its performance. This paper focuses on the development of a systematic approach with the following objectives: (1) to identify and quantify the interactions among the system elements in a supply chain; (2) to decompose the large interdependent group of system elements into smaller and manageable sub-groups; and thus (3) to improve the structure of the supply chain system. A supply chain system is first decomposed into subsystems and system elements from which the interactions (i.e., independent, dependent and interdependent relationships) are studied and documented by design structure matrix (DSM). Next, the interaction strengths among the related system elements are quantified. Cluster analysis is used to decompose the large interdependent group into smaller ones in order to provide a better supply chain system structure. The effectiveness of this systematic approach is demonstrated by an illustrative example. The result shows that it is able to improve the system structure of a supply chain that will be useful for the supply chain reengineering.     

Enterprise modelling methodology for forward and reverse supply chain flows integration

The paper proposes a new enterprise modelling methodology called ERE-GIO applicable to supply chain reengineering and integration. It is based on two major phases: reverse engineering of the supply chain and then forward engineering. It takes advantages of previous enterprise modelling methodologies, especially CIMOSA. The application of the defined methodology on the logistics flow of an industrial company has allowed the integration of the reverse logistics flows in the traditional supply chain, thanks to the modelling of business processes and the flows related to it.