An agile and adaptive holonic architecture for manufacturing control

Tese de doutoramento. Engenharia Electrotécnica e de Computadores. 2004. Faculdade de Engenharia. Universidade do Port

Proposition d’une architecture holonique auto-organisée et évolutive pour le pilotage des systèmes de production

The manufacturing world is being deeply challenged with a set of ever demanding constraints where from one side, the costumers are requiring products to be more customizable, with higher quality at lower prices, and on other side, companies have to deal on a daily basis with internal disturbances that range from machine breakdown to worker absence and from demand fluctuation to frequent production changes. This dissertation proposes a manufacturing control architecture, following the holonic principles developed in the ADAptive holonic COntrol aRchitecture (ADACOR) and extending it taking inspiration in evolutionary theories and making use of self- organization mechanisms. The use of evolutionary theories enrich the proposed control architecture by allowing evolution in two distinct ways, responding accordingly to the type and degree of the disturbance that appears. The first component, named behavioural self- organization, allows each system’s entity to dynamically adapt its internal behaviour, addressing small disturbances. The second component, named structural self-organization, addresses bigger disturbances by allowing the system entities to re-arrange their rela- tionships, and consequently changing the system in a structural manner. The proposed self-organized holonic manufacturing control architecture was validated at a AIP-PRIMECA flexible manufacturing cell. The achieved experimental results have also shown an improvement of the key performance indicators over the hierarchical and heterarchical control architecture.Le monde des entreprises est profondément soumis à un ensemble de contraintes toujours plus exigeantes provenant d’une part des clients, exigeant des produits plus personnalisables, de qualité supérieure et à faible coût, et d’autre part des aléas internes auxentreprises, comprenant les pannes machines, les défaillances humaines, la fluctuation de la demande, les fréquentes variations de production. Cette thèse propose une architecture de contrôle de systèmes de production, basée sur les principes holoniques développées dans l’architecture ADACOR (ADAptive holonic COntrol aRchitecture), et l’étendant en s’inspirant des théories de l’évolution et en utilisant des mécanismes d’auto-organisation. L’utilisation des théories de l’évolution enrichit l’architecture de contrôle en permettant l’évolution de deux manières distinctes, en réponse au type et au degré de la perturbation apparue. Le premier mode d’adaptation, appelé auto-organisation comportementale, permet à chaque entité qui compose le système d’adapter dynamiquement leur comportement interne, gérant de cette façon de petites perturbations. Le second mode, nommé auto-organisation structurelle, traite de plus grandes perturbations, en permettant aux entités du système de ré-organiser leurs relations, et par conséquent modifier structurellement le système. L’architecture holonique auto-organisée de contrôle de systèmes de production proposée dans cette thèse a été validée sur une cellule de production flexible AIP-PRIMECA. Les résultats ont montré une amélioration des indicateurs clés de performance par rapport aux architectures de contrôle hiérarchiques et hétérarchiques

An agile and adaptive holonic architecture for manufacturing control

In the last decades significant changes in the manufacturing environment have been noticed: moving from a local economy towards a global economy, with markets asking for products with high quality at lower costs, highly customised and with short life cycle. In this environment, the manufacturing enterprises, to avoid the risk to lose competitiveness, search to answer more closely to the customer demands, by improving their flexibility and agility, while maintaining their productivity and quality. Actually, the dynamic response to emergence is becoming a key issue, due to the weak response of the traditional manufacturing control systems to unexpected disturbances, mainly because of the rigidity of their control architectures. In these circumstances, the challenge is to develop manufacturing control systems with autonomy and intelligence capabilities, fast adaptation to the environment changes, more robustness against the occurrence of disturbances, and easier integration of manufacturing resources and legacy systems. Several architectures using emergent concepts and technologies have been proposed, in particular those based in the holonic manufacturing paradigm. Holonic manufacturing is a paradigm based in the ideas of the philosopher Arthur Koestler, who proposed the word holon to describe a basic unit of organisation in biological and social systems. A holon, as Koestler devised the term, is an identifiable part of a (manufacturing) system that has a unique identity, yet is made up of sub-ordinate parts and in turn is part of a larger whole. The introduction of the holonic manufacturing paradigm allows a new approach to the manufacturing problem, bringing the advantages of modularity, decentralisation, autonomy, scalability, and re-use of software components. This dissertation intends to develop an agile and adaptive manufacturing control architecture to face the current requirements imposed to the manufacturing enterprises. The architecture proposed in this dissertation addresses the need for the fast reaction to disturbances at the shop floor level, increasing the agility and flexibility of the enterprise, when it works in volatile environments, characterised by the frequent occurrence of unexpected disturbances. The proposed architecture, designated by ADACOR (ADAptive holonic COntrol aRchitecture for distributed manufacturing systems), is based in the holonic manufacturing paradigm, build upon autonomous and cooperative holons, allowing the development of manufacturing control applications that present all the features of decentralised and holonic systems. ADACOR holonic architecture introduces an adaptive control that balances dynamically between a more centralised structure and a more decentralised one, allowing to combine the global production optimisation with agile reaction to unexpected disturbances. Nas últimas décadas têm-se assistido a mudanças significativas no ambiente de fabrico: evoluindo de uma economia local para um economia global, com os mercados a procurar produtos com elevada qualidade a baixos preços, altamente customizados e com um ciclo de vida curto. Neste ambiente, as empresas de manufactura, para evitar o risco de perda de competitividade, procuram responder às solicitações dos clientes, melhorando a sua flexibilidade e agilidade, mantendo os mesmos índices de produtividade e qualidade. Na verdade, a resposta dinâmica à emergência está a tornar-se num assunto chave, devido `a fraca resposta a perturbações que os sistemas de controlo de fabrico tradicionais apresentam, principalmente devido à rigidez das suas arquitecturas de controlo. Nestas circunstâncias, é fundamental o desenvolvimento de sistemas de controlo de fabrico com capacidades de autonomia e inteligência, rápida adaptação às mudanças, maior robustez à ocorrência de perturbações e fácil integração de recursos físicos e sistemas legados. Diversas arquitecturas usando conceitos e tecnologias emergentes têm sido propostas, em particular algumas baseadas no paradigma da produção holónica. O paradigma da produção holónica é inspirado nas ideias de Arthur Koestler, que propôs a palavra holon para descrever uma unidade básica de organização de sistemas biológicos e sociais. Um holon, de acordo com a definição de Koestler, é uma parte identificável do sistema com identidade única, composta por sub-partes e fazendo simultaneamente parte do todo. A introdução do paradigma da produção holónica permite uma nova abordagem aos sistemas de controlo de fabrico, trazendo vantagens de modularidade, descentralização, autonomia, escalabilidade e reutilização de componentes. Esta dissertação pretende desenvolver uma arquitectura de controlo ágil e adaptativa que suporte os requisitos actuais impostos `as empresas de manufactura. A arquitectura proposta visa a necessidade de uma reacção rápida a perturbações, ao nível da planta fabril, melhorando a flexibilidade e agilidade da empresa quando esta opera em ambientes voláteis, caracterizados pela ocorrência frequente de perturbações inesperadas. A arquitectura proposta, designada por ADACOR (ADAptive holonic COntrol aRchitecture for distributed manufacturing systems), é baseada no paradigma da produção holónica e construída sobre holons autónomos e cooperativos, permitindo o desenvolvimento de aplicações de controlo de fabrico que apresentem todas as características dos sistemas descentralizados e holónicos. A arquitectura holónica ADACOR introduz um controlo adaptativo que balança dinamicamente entre uma estrutura de controlo mais centralizada e uma mais descentralizada, permitindo combinar a optimização da produção com a ágil reacção a perturbações

An Architecture for the Integration of Human Workers into an Industry 4.0 Manufacturing Environment.

Thesis (PhD)--Stellenbosch University, 2021.ENGLISH SUMMARY: With the rise of Industry 4.0 and the development in technologies that contribute to this revolution in manufacturing, research has focused mainly on the machines and automated digital systems contributing to the manufacturing environment. Humans are still critical to manufacturing; offering unmatched ingenuity, robustness, and flexibility despite their apparent disadvantages in strength or precision. Many successful manufacturing firms still include humans in their manufacturing processes for these reasons, and it is critical that the integration of humans in an I4.0 manufacturing environment is given research attention. This dissertation first explores the requirements for the integration of human workers into an I4.0 environment. It was determined that the largest problem with human integration exists with data related to the human being digitised, managed, and communicated with other entities in processes that are identified as Administrative Logistics. It is identified that an administration shell similar to the RAMI4.0 administration shell concept is required to manage these Administrative Logistics on behalf of the human, and that a holonic systems approach is beneficial. The dissertation then proposes the concept of a Human Resource Holon Administration shell (HRH-AS). An architecture to implement such an administration shell is then developed, here named the BASE architecture. This administration shell facilitates the interfacing, data processing, and connectivity to other I4.0 components on behalf of the human, to aid in their integration to the digital factory environment around them. The BASE architecture addresses three identified responsibilities of such an administration shell, namely interfacing, digital data management, and delegation to other I4.0 components. BASE stands for Biography, Attributes, Schedule, and Execution, and is a time-based separation of concerns for key augmentations provided to the human worker. The BASE architecture separates value-adding and decision-making plugin components, which are specific to an application, from the core components, which are generic to any application. The BASE architecture led to the development of the 3SAL activity structure to facilitate the communication and management of industrial activities in a digital environment. With the help of an industry partner, two case studies were developed to evaluate an implementation of the BASE architecture. The company is an aerospace composites manufacturer and was chosen for the labour-intensive requirements of the composites industry. The case studies aimed to evaluate the architecture against the three identified administration shell responsibilities and determine if the human workers are elevated to resource holon status. The first case study aimed to show how BASE facilitates interfacing with humans in an I4.0 environment and also acted as a technology demonstrator for the second case study. The second case study evaluated the effect BASE had on the Administrative Logistics involved in the business processes workers were involved in. Together these case studies fully evaluate BASE’s ability to facilitate the integration of humans into an I4.0 manufacturing environment through identified responsibilities of the administration shell. The evaluation found that the BASE HRH-AS improves the effectiveness of Administrative Logistics of business processes the human workers were involved with, as well as opened new opportunities for decision making on the shop floor previously not possible. Value-adding, by means of the plug-in components of a BASE administration shell, has also been proven by the ability to do automated schedule management, automatic calculation of standard work and improved traceability using the 3SAL activity structure.AFRIKAANS OPSOMMING: Met die opkoms van Industrie 4.0 (I4.0) en die ontwikkeling in tegnologieë wat bydra tot hierdie revolusie in vervaardiging, het navorsing grotendeels gefokus op die masjiene en digitale stelsels wat tot die vervaardigingsomgewing bydra. Menslike werkers is steeds van kritieke belang vir vervaardiging, en bied ongeëwenaarde vindingrykheid, robuustheid en buigsaamheid, ondanks hul oënskynlike nadele in sterkte of noukeurigheid. Baie suksesvolle vervaardigingsondernemings sluit nogsteeds mense in hul vervaardigingsprosesse in om hierdie redes. Dit is dus noodsaaklik dat die integrasie van mense met 'n I4.0 vervaardigingsomgewing navorsingsaandag geniet. Hierdie verhandeling ondersoek eerstens die vereistes vir die integrasie van menslike werkers in 'n I4.0 omgewing. Daar word eerstens geïdentifiseer dat die grootste probleem met die integrasie van mense bestaan uit oneffektiewe prosesse wat data en informasie tussen mense en ander komponente in die vervaardigingsprosesse komminikeer, stoor en bestuur. Hierdie prosesse word na verwys as Administratiewe Logistieke. Daar word ook geïdentifiseer dat 'n administrasie-dop soortgelyk aan die RAMI4.0 administrasie-dop konsep benodig word om Administratiewe Logistieke te bestuur namens die mens, en dat 'n holoniese stelselbenadering voordelig is. Die verhandeling stel dan die konsep van 'n Human Resource Holon Administration Shell (HRH-AS) voor. Daarna word 'n argitektuur ontwikkel om so 'n administrasie-dop te implementeer, hier genoem die BASE argitektuur. Hierdie administrasie-dop vergemaklik die inskakeling, dataverwerking en konnektiwiteit met ander I4.0 komponente namens die mens. Die integrasie van die mens in die digitale fabrieksomgewing is dus bevoordeel. Die BASE argitektuur spreek drie geïdentifiseerde verantwoordelikhede van so 'n administrasie-dop aan, naamlik: koppelling met die mens, digitale databestuur, en delegering na ander I4.0 komponente namens die mens. BASE staan vir Biography, Attributes, Schedule en Execution, en is 'n tydgebaseerde skeiding van belange vir aanvullings wat aan die menslike werker verskaf word. Die BASE argitektuur skei waardetoevoeging- en besluitneming-inpropkomponente, wat spesifiek vir 'n toepassing is, van die kernkomponente, wat generies is vir enige toepassing. Die BASE argitektuur het gelei tot die ontwikkeling van die 3SAL aktiwiteitstruktuur om die kommunikasie en bestuur van industriële aktiwiteite in 'n digitale omgewing te vergemaklik. Met die hulp van 'n bedryfsvennoot is twee gevallestudies ontwikkel om 'n implementering van die BASE argitektuur te evalueer. Die maatskappy is 'n lugvaart saamgestelde-mater komponent vervaardiger en is gekies vir die arbeidsintensiewe vereistes van die saamgestelde-mater bedryf. Die gevallestudies was daarop gemik om die argitektuur teen die drie geïdentifiseerde verantwoordelikhede van die administrasiedop te evalueer en te bepaal of die menslike werkers verhoog word tot holon status. Die eerste gevallestudie se doel was om te wys hoe BASE n koppelvlak tussen mense en digitale stelsels toelaat. Die eerste gevallestudie was ook 'n demonstrasie dat 'n toepassing in die bedryfsvenoot se fabriek toegepas kon word vir die tweede gevallestudie. Die tweede gevallestudie het die effek geëvalueer wat BASE het op die Administratiewe Logistiek betrokke by die besigheidsprosesse waarby werkers betrokke was. Saam evalueer hierdie gevallestudies BASE se vermoë om die integrasie van mense in 'n I4.0 vervaardigingsomgewing te fasiliteer deur geïdentifiseerde verantwoordelikhede van die administrasiedop. Die evaluering het bevind dat die BASE HRH-AS die doeltreffendheid van Administratiewe Logistiek van besigheidsprosesse wat menslike werkers benut, asook nuwe geleenthede vir besluitneming op die winkelvloer, verbeter tot n mate wat voorheen nie moontlik was nie. Waarde-toevoeging, deur middel van die inpropkomponente van 'n BASE administrasie dop, is ook bewys deur die vermoë om outomatiese skedule-bestuur, outomatiese berekening van standaardwerk en verbeterde naspeurbaarheid met behulp van die 3SAL-aktiwiteitsstruktuur te doen.Doctora

A Capacity Planning Simulation Model for Reconfigurable Manufacturing Systems

Important objectives and challenges in today’s manufacturing environment include the introduction of new products and the designing and developing of reconfigurable manufacturing systems. The objective of this research is to investigate and support the reconfigurability of a manufacturing system in terms of scalability by applying a discrete-event simulation modelling technique integrated with flexible capacity control functions and communication rules for re-scaling process. Moreover, the possible extension of integrating the discrete-event simulation with an agent-based model is presented as a framework. The benefits of this framework are collaborative decision making using agents for flexible reaction to system changes and system performance improvement. AnyLogic multi-method simulation modelling platform is utilized to design and create different simulation modelling scenarios. The developed capacity planning simulation model results are demonstrated in terms of a case study using the configurable assembly Learning Factory (iFactory) in the Intelligent Manufacturing Systems (IMS) Center at the University of Windsor. The main benefit of developed capacity planning simulation in comparison to traditional discrete-event simulation is, with a single simulation run, the recommended capacity for manufacturing system will be determined instead of running several discrete-event simulation models to find the needed capacity

Metodología dirigida por modelos para las pruebas de un sistema distribuido multiagente de fabricación

Las presiones del mercado han empujado a las empresas de fabricación a reducir costes a la vez que mejoran sus productos, especializándose en las actividades sobre las que pueden añadir valor y colaborando con especialistas de las otras áreas para el resto. Estos sistemas distribuidos de fabricación conllevan nuevos retos, dado que es difícil integrar los distintos sistemas de información y organizarlos de forma coherente. Esto ha llevado a los investigadores a proponer una variedad de abstracciones, arquitecturas y especificaciones que tratan de atacar esta complejidad. Entre ellas, los sistemas de fabricación holónicos han recibido una atención especial: ven las empresas como redes de holones, entidades que a la vez están formados y forman parte de varios otros holones. Hasta ahora, los holones se han implementado para control de fabricación como agentes inteligentes autoconscientes, pero su curva de aprendizaje y las dificultades a la hora de integrarlos con sistemas tradicionales han dificultado su adopción en la industria. Por otro lado, su comportamiento emergente puede que no sea deseable si se necesita que las tareas cumplan ciertas garantías, como ocurren en las relaciones de negocio a negocio o de negocio a cliente y en las operaciones de alto nivel de gestión de planta. Esta tesis propone una visión más flexible del concepto de holón, permitiendo que se sitúe en un espectro más amplio de niveles de inteligencia, y defiende que sea mejor implementar los holones de negocio como servicios, componentes software que pueden ser reutilizados a través de tecnologías estándar desde cualquier parte de la organización. Estos servicios suelen organizarse como catálogos coherentes, conocidos como Arquitecturas Orientadas a Servicios (‘Service Oriented Architectures’ o SOA). Una iniciativa SOA exitosa puede reportar importantes beneficios, pero no es una tarea trivial. Por este motivo, se han propuesto muchas metodologías SOA en la literatura, pero ninguna de ellas cubre explícitamente la necesidad de probar los servicios. Considerando que la meta de las SOA es incrementar la reutilización del software en la organización, es una carencia importante: tener servicios de alta calidad es crucial para una SOA exitosa. Por este motivo, el objetivo principal de la presente Tesis es definir una metodología extendida que ayude a los usuarios a probar los servicios que implementan a sus holones de negocio. Tras considerar las opciones disponibles, se tomó la metodología dirigida por modelos SODM como punto de partida y se reescribió en su mayor parte con el framework Epsilon de código abierto, permitiendo a los usuarios que modelen su conocimiento parcial sobre el rendimiento esperado de los servicios. Este conocimiento parcial es aprovechado por varios nuevos algoritmos de inferencia de requisitos de rendimiento, que extraen los requisitos específicos de cada servicio. Aunque el algoritmo de inferencia de peticiones por segundo es sencillo, el algoritmo de inferencia de tiempos límite pasó por numerosas revisiones hasta obtener el nivel deseado de funcionalidad y rendimiento. Tras una primera formulación basada en programación lineal, se reemplazó con un algoritmo sencillo ad-hoc que recorría el grafo y después con un algoritmo incremental mucho más rápido y avanzado. El algoritmo incremental produce resultados equivalentes y tarda mucho menos, incluso con modelos grandes. Para sacar más partidos de los modelos, esta Tesis también propone un enfoque general para generar artefactos de prueba para múltiples tecnologías a partir de los modelos anotados por los algoritmos. Para evaluar la viabilidad de este enfoque, se implementó para dos posibles usos: reutilizar pruebas unitarias escritas en Java como pruebas de rendimiento, y generar proyectos completos de prueba de rendimiento usando el framework The Grinder para cualquier Servicio Web que esté descrito usando el estándar Web Services Description Language. La metodología completa es finalmente aplicada con éxito a un caso de estudio basado en un área de fabricación de losas cerámicas rectificadas de un grupo de empresas español. En este caso de estudio se parte de una descripción de alto nivel del negocio y se termina con la implementación de parte de uno de los holones y la generación de pruebas de rendimiento para uno de sus Servicios Web. Con su soporte para tanto diseñar como implementar pruebas de rendimiento de los servicios, se puede concluir que SODM+T ayuda a que los usuarios tengan una mayor confianza en sus implementaciones de los holones de negocio observados en sus empresas

Control architectures for industrial additive manufacturing systems

As the emergent technologies of Industrial Additive Manufacturing become increasingly employed in commercial manufacturing environments, challenges arise in terms of how resources of the manufacturing system should be marshalled and controlled for sustainable manufacturing. While control architectures are well established for conventional manufacturing, to-date there has been little explicit consideration for Industrial Additive Manufacturing. This article provides redress for this research gap by exploring four feasible control architectures employed in current manufacturing practice. Drawing upon 12 case studies and the operations of three companies, the relative merits, demerits, and challenges for each architecture are explored in terms of changeability criteria for sustainable manufacturing