Improving just-in-time delivery performance of IoT-enabled flexible manufacturing systems with AGV based material transportation

Autonomous guided vehicles (AGVs) are driverless material handling systems used for transportation of pallets and line side supply of materials to provide flexibility and agility in shop-floor logistics. Scheduling of shop-floor logistics in such systems is a challenging task due to their complex nature associated with the multiple part types and alternate material transfer routings. This paper presents a decision support system capable of supporting shop-floor decision-making activities during the event of manufacturing disruptions by automatically adjusting both AGV and machine schedules in Flexible Manufacturing Systems (FMSs). The proposed system uses discrete event simulation (DES) models enhanced by the Internet-of-Things (IoT) enabled digital integration and employs a nonlinear mixed integer programming Genetic Algorithm (GA) to find near-optimal production schedules prioritising the just-in-time (JIT) material delivery performance and energy efficiency of the material transportation. The performance of the proposed system is tested on the Integrated Manufacturing and Logistics (IML) demonstrator at WMG, University of Warwick. The results showed that the developed system can find the near-optimal solutions for production schedules subjected to production anomalies in a negligible time, thereby supporting shop-floor decision-making activities effectively and rapidly

Improving just-in-time delivery performance of IoT-enabled flexible manufacturing systems with AGV based material transportation

© 2020 by the authors. Licensee MDPI, Basel, Switzerland. Autonomous guided vehicles (AGVs) are driverless material handling systems used for transportation of pallets and line side supply of materials to provide flexibility and agility in shop-floor logistics. Scheduling of shop-floor logistics in such systems is a challenging task due to their complex nature associated with the multiple part types and alternate material transfer routings. This paper presents a decision support system capable of supporting shop-floor decision-making activities during the event of manufacturing disruptions by automatically adjusting both AGV and machine schedules in Flexible Manufacturing Systems (FMSs). The proposed system uses discrete event simulation (DES) models enhanced by the Internet-of-Things (IoT) enabled digital integration and employs a nonlinear mixed integer programming Genetic Algorithm (GA) to find near-optimal production schedules prioritising the just-in-time (JIT) material delivery performance and energy efficiency of the material transportation. The performance of the proposed system is tested on the Integrated Manufacturing and Logistics (IML) demonstrator at WMG, University of Warwick. The results showed that the developed system can find the near-optimal solutions for production schedules subjected to production anomalies in a negligible time, thereby supporting shop-floor decision-making activities effectively and rapidly

Intelligent Simulation Modeling of a Flexible Manufacturing System with Automated Guided Vehicles

Although simulation is a very flexible and cost effective problem solving technique, it has been traditionally limited to building models which are merely descriptive of the system under study. Relatively new approaches combine improvement heuristics and artificial intelligence with simulation to provide prescriptive power in simulation modeling. This study demonstrates the synergy obtained by bringing together the "learning automata theory" and simulation analysis. Intelligent objects are embedded in the simulation model of a Flexible Manufacturing System (FMS), in which Automated Guided Vehicles (AGVs) serve as the material handling system between four unique workcenters. The objective of the study is to find satisfactory AGV routing patterns along available paths to minimize the mean time spent by different kinds of parts in the system. System parameters such as different part routing and processing time requirements, arrivals distribution, number of palettes, available paths between workcenters, number and speed of AGVs can be defined by the user. The network of learning automata acts as the decision maker driving the simulation, and the FMS model acts as the training environment for the automata network; providing realistic, yet cost-effective and risk-free feedback. Object oriented design and implementation of the simulation model with a process oriented world view, graphical animation and visually interactive simulation (using GUI objects such as windows, menus, dialog boxes; mouse sensitive dynamic automaton trace charts and dynamic graphical statistical monitoring) are other issues dealt with in the study

An autonomous system for maintenance scheduling data-rich complex infrastructure:Fusing the railways’ condition, planning and cost

National railways are typically large and complex systems. Their network infrastructure usually includes extended track sections, bridges, stations and other supporting assets. In recent years, railways have also become a data-rich environment. Railway infrastructure assets have a very long life, but inherently degrade. Interventions are necessary but they can cause lateness, damage and hazards. Every day, thousands of discrete maintenance jobs are scheduled according to time and urgency. Service disruption has a direct economic impact. Planning for maintenance can be complex, expensive and uncertain. Autonomous scheduling of maintenance jobs is essential. The design strategy of a novel integrated system for automatic job scheduling is presented; from concept formulation to the examination of the data to information transitional level interface, and at the decision making level. The underlying architecture configures high-level fusion of technical and business drivers; scheduling optimized intervention plans that factor-in cost impact and added value. A proof of concept demonstrator was developed to validate the system principle and to test algorithm functionality. It employs a dashboard for visualization of the system response and to present key information. Real track incident and inspection datasets were analyzed to raise degradation alarms that initiate the automatic scheduling of maintenance tasks. Optimum scheduling was realized through data analytics and job sequencing heuristic and genetic algorithms, taking into account specific cost & value inputs from comprehensive task cost modelling. Formal face validation was conducted with railway infrastructure specialists and stakeholders. The demonstrator structure was found fit for purpose with logical component relationships, offering further scope for research and commercial exploitation

A graph based process model measurement framework using scheduling theory

Software development processes, as a means of ensuring software quality and productivity, have been widely accepted within the software development community; software process modeling, on the other hand, continues to be a subject of interest in the research community. Even with organizations that have achieved higher SEI maturity levels, processes are by and large described in documents and reinforced as guidelines or laws governing software development activities. The lack of industry-wide adaptation of software process modeling as part of development activities can be attributed to two major reasons: lack of forecast power in the (software) process modeling and lack of integration mechanism for the described process to seamlessly interact with daily development activities. This dissertation describes a research through which a framework has been established where processes can be manipulated, measured, and dynamically modified by interacting with project management techniques and activities in an integrated process modeling environment, thus closing the gap between process modeling and software development. In this research, processes are described using directed graphs, similar to the techniques with CPM. This way, the graphs can be manipulated visually while the properties of the graphs-can be used to check their validity. The partial ordering and the precedence relationship of the tasks in the graphs are similar to the one studied in other researches [Delcambre94] [Mills96]. Measurements of the effectiveness of the processes are added in this research. These measurements provide bases for the judgment when manipulating the graphs to produce or modify a process. Software development can be considered as activities related to three sets: a set of tasks (τ), a set of resources (ρ), and a set of constraints (y). The process, P, is then a function of all the sets interacting with each other: P = {τ, ρ, y). The interactions of these sets can be described in terms of different machine models using scheduling theory. While trying to produce an optimal solution satisfying a set of prescribed conditions using the analytical method would lead to a practically non-feasible formulation, many heuristic algorithms in scheduling theory combined with manual manipulation of the tasks can help to produce a reasonable good process, the effectiveness of which is reflected through a set of measurement criteria, in particular, the make-span, the float, and the bottlenecks. Through an integrated process modeling environment, these measurements can be obtained in real time, thus providing a feedback loop during the process execution. This feedback loop is essential for risk management and control

Enhancing the performance of automated guided vehicles through reliability, operation and maintenance assessment

Automated guided vehicles (AGVs), a type of unmanned moving robots that move along fixed routes or are directed by laser navigation systems, are increasingly used in modern society to improve efficiency and lower the cost of production. A fleet of AGVs operate together to form a fully automatic transport system, which is known as an AGV system. To date, their added value in efficiency improvement and cost reduction has been sufficiently explored via conducting in-depth research on route optimisation, system layout configuration, and traffic control. However, their safe application has not received sufficient attention although the failure of AGVs may significantly impact the operation and efficiency of the entire system. This issue becomes more markable today particularly in the light of the fact that the size of AGV systems is becoming much larger and their operating environment is becoming more complex than ever before. This motivates the research into AGV reliability, availability and maintenance issues in this thesis, which aims to answer the following four fundamental questions: (1) How could AGVs fail? (2) How is the reliability of individual AGVs in the system assessed? (3) How does a failed AGV affect the operation of the other AGVs and the performance of the whole system? (4) How can an optimal maintenance strategy for AGV systems be achieved? In order to answer these questions, the method for identifying the critical subsystems and actions of AGVs is studied first in this thesis. Then based on the research results, mathematical models are developed in Python to simulate AGV systems and assess their performance in different scenarios. In the research of this thesis, Failure Mode, Effects and Criticality Analysis (FMECA) was adopted first to analyse the failure modes and effects of individual AGV subsystems. The interactions of these subsystems were studied via performing Fault Tree Analysis (FTA). Then, a mathematical model was developed to simulate the operation of a single AGV with the aid of Petri Nets (PNs). Since most existing AGV systems in modern industries and warehouses consist of multiple AGVs that operate synchronously to perform specific tasks, it is necessary to investigate the interactions between different AGVs in the same system. To facilitate the research of multi-AGV systems, the model of a three-AGV system with unidirectional paths was considered. In the model, an advanced concept PN, namely Coloured Petri Net (CPN), was creatively used to describe the movements of the AGVs. Attributing to the application of CPN, not only the movements of the AGVs but also the various operation and maintenance activities of the AGV systems (for example, item delivery, corrective maintenance, periodic maintenance, etc.) can be readily simulated. Such a unique technique provides us with an effective tool to investigate larger-scale AGV systems. To investigate the reliability, efficiency and maintenance of dynamic AGV systems which consist of multiple single-load and multi-load AGVs traveling along different bidirectional routes in different missions, an AGV system consisting of 9 stations was simulated using the CPN methods. Moreover, the automatic recycling of failed AGVs is studied as well in order to further reduce human participation in the operation of AGV systems. Finally, the simulation results were used to optimise the design, operation and maintenance of multi-AGV systems with the consideration of the throughputs and corresponding costs of them.The research reported in this thesis contributes to the design, reliability, operation, and maintenance of large-scale AGV systems in the modern and rapidly changing world.</div

Application of a mobile robot to spatial mapping of radioactive substances in indoor environment

Nuclear medicine requires the use of radioactive substances that can contaminate critical areas (dangerous or hazardous) where the presence of a human must be reduced or avoided. The present work uses a mobile robot in real environment and 3D simulation to develop a method to realize spatial mapping of radioactive substances. The robot should visit all the waypoints arranged in a grid of connectivity that represents the environment. The work presents the methodology to perform the path planning, control and estimation of the robot location. For path planning two methods are approached, one a heuristic method based on observation of problem and another one was carried out an adaptation in the operations of the genetic algorithm. The control of the actuators was based on two methodologies, being the first to follow points and the second to follow trajectories. To locate the real mobile robot, the extended Kalman filter was used to fuse an ultra-wide band sensor with odometry, thus estimating the position and orientation of the mobile agent. The validation of the obtained results occurred using a low cost system with a laser range finder.A medicina nuclear requer o uso de substâncias radioativas que pode vir a contaminar áreas críticas, onde a presença de um ser humano deve ser reduzida ou evitada. O presente trabalho utiliza um robô móvel em ambiente real e em simulação 3D para desenvolver um método para o mapeamento espacial de substâncias radioativas. O robô deve visitar todos os waypoinst dispostos em uma grelha de conectividade que representa o ambiente. O trabalho apresenta a metodologia para realizar o planejamento de rota, controle e estimação da localização do robô. Para o planejamento de rota são abordados dois métodos, um baseado na heurística ao observar o problema e ou outro foi realizado uma adaptação nas operações do algoritmo genético. O controle dos atuadores foi baseado em duas metodologias, sendo a primeira para seguir de pontos e a segunda seguir trajetórias. Para localizar o robô móvel real foi utilizado o filtro de Kalman extendido para a fusão entre um sensor ultra-wide band e odometria, estimando assim a posição e orientação do agente móvel. A validação dos resultados obtidos ocorreu utilizando um sistema de baixo custo com um laser range finder

Analysis and Optimization of Mobile Business Processes

Mobility of workers and business processes rapidly gains the attention of businesses and business analysts. A wide variety of definitions exists for mobile business processes. This work considers a type of business processes concerned with the maintenance of distributed technical equipment as, e.g., telecommunication networks, utility networks, or professional office gear. Executing the processes in question, workers travel to the location where the equipment is situated and perform tasks there. Depending on the type of activities to be performed, the workers need certain qualifications to fulfill their duty. Especially in network maintenance processes, activities are often not isolated but depend on the parallel or subsequent execution of other activities at other locations. Like every other economic activity, the out- lined mobile processes are under permanent pressure to be executed more efficiently. Since business process reengineering (BPR) projects are the common way to achieve process improvements, business analysts need methods to model and evaluate mobile business processes. Mobile processes challenge BPR projects in two ways: (i) the process at- tributes introduced by mobility (traveling, remote synchronization, etc.) complicate process modeling, and (ii) these attributes introduce process dynamics that prevent the straightforward prediction of BPR effects. This work solves these problems by developing a modeling method for mobile processes. The method allows for simulating mobile processes considering the mobility attributes while hiding the complexity of these attributes from the business analysts modeling the processes. Simulating business processes requires to assign activites to workers, which is called scheduling. The spatial distribution of activities relates scheduling to routing problems known from the logistics domain. To provide the simula- tor with scheduling capabilities the according Mobile Workforce Scheduling Problem with Multitask-Processes (MWSP-MP) is introduced and analyzed in-depth. A set of neighborhood operators was developed to allow for the application of heuristics and meta-heuristics to the problem. Furthermore, methods for generating start solutions of the MWSP-MP are introduced. The methods introduced throughout this work were validated with real-world data from a German utility. The contributions of this work are a reference model of mobile work, a business domain independent modeling method for mobile business processes, a simulation environment for such processes, and the introduction and analysis of the Mobile Workforce Scheduling Problem with Multitask-Processes