Data mining in manufacturing: a review based on the kind of knowledge

In modern manufacturing environments, vast amounts of data are collected in database management systems and data warehouses from all involved areas, including product and process design, assembly, materials planning, quality control, scheduling, maintenance, fault detection etc. Data mining has emerged as an important tool for knowledge acquisition from the manufacturing databases. This paper reviews the literature dealing with knowledge discovery and data mining applications in the broad domain of manufacturing with a special emphasis on the type of functions to be performed on the data. The major data mining functions to be performed include characterization and description, association, classification, prediction, clustering and evolution analysis. The papers reviewed have therefore been categorized in these five categories. It has been shown that there is a rapid growth in the application of data mining in the context of manufacturing processes and enterprises in the last 3 years. This review reveals the progressive applications and existing gaps identified in the context of data mining in manufacturing. A novel text mining approach has also been used on the abstracts and keywords of 150 papers to identify the research gaps and find the linkages between knowledge area, knowledge type and the applied data mining tools and techniques

Deep Reinforcement Learning Techniques For Solving Hybrid Flow Shop Scheduling Problems: Proximal Policy Optimization (PPO) and Asynchronous Advantage Actor-Critic (A3C)

Well-studied scheduling practices are fundamental for the successful support of core business processes in any manufacturing environment. Particularly, the Hybrid Flow Shop (HFS) scheduling problems are present in many manufacturing environments. The current advances in the field of Deep Reinforcement Learning (DRL) attracted the attention of both practitioners and academics to investigate their adoption beyond synthetic game-like applications. Therefore, we present an approach that is based on DRL techniques in conjunction with a discrete event simulation model to solve a real-world four-stage HFS scheduling problem. The main narrative behind the presented concepts is to expose a DRL agent to a game-like environment using an indirect encoding. Two types of DRL techniques namely, Proximal Policy Optimization (PPO) and Asynchronous Advantage Actor-Critic (A3C), are evaluated for solving problems of different complexity. The computational results suggest that the DRL agents successfully learn appropriate policies for solving the investigated problem. In addition, the investigation shows that the agent can adjust their policies when we expose them to a different problem. We further evaluate the approach to solving problem instances published in the literature to establish a comparison

Scheduling and discrete event control of flexible manufacturing systems based on Petri nets

A flexible manufacturing system (FMS) is a computerized production system that can simultaneously manufacture multiple types of products using various resources such as robots and multi-purpose machines. The central problems associated with design of flexible manufacturing systems are related to process planning, scheduling, coordination control, and monitoring. Many methods exist for scheduling and control of flexible manufacturing systems, although very few methods have addressed the complexity of whole FMS operations. This thesis presents a Petri net based method for deadlock-free scheduling and discrete event control of flexible manufacturing systems. A significant advantage of Petri net based methods is their powerful modeling capability. Petri nets can explicitly and concisely model the concurrent and asynchronous activities, multi-layer resource sharing, routing flexibility, limited buffers and precedence constraints in FMSs. Petri nets can also provide an explicit way for considering deadlock situations in FMSs, and thus facilitate significantly the design of a deadlock-free scheduling and control system. The contributions of this work are multifold. First, it develops a methodology for discrete event controller synthesis for flexible manufacturing systems in a timed Petri net framework. The resulting Petri nets have the desired qualitative properties of liveness, boundedness (safeness), and reversibility, which imply freedom from deadlock, no capacity overflow, and cyclic behavior, respectively. This precludes the costly mathematical analysis for these properties and reduces on-line computation overhead to avoid deadlocks. The performance and sensitivity of resulting Petri nets, thus corresponding control systems, are evaluated. Second, it introduces a hybrid heuristic search algorithm based on Petri nets for deadlock-free scheduling of flexible manufacturing systems. The issues such as deadlock, routing flexibility, multiple lot size, limited buffer size and material handling (loading/unloading) are explored. Third, it proposes a way to employ fuzzy dispatching rules in a Petri net framework for multi-criterion scheduling. Finally, it shows the effectiveness of the developed methods through several manufacturing system examples compared with benchmark dispatching rules, integer programming and Lagrangian relaxation approaches

A Scheduling Framework for Robotic Flexible Assembly Cells

Today’s companies develop flexible systems that are adaptable to assemble a mix of products with minimal reconfiguration. A Robotic Flexible Assembly Cell (RFAC) is an adaptable system which can assemble a variety of products using the same resources. A major limitation of Scheduling RFACs is that no prior research has documented the scheduling problem for assembly of multi-products. Hence, the objective of the present study is to layout a scheduling framework to overcome this limitation. The framework intends to propose an effective way to solve the scheduling problem through modelling, simulation and analysis of the RFACs

Allocation of component types to machines in the automated assembly of printed circuit boards

Duman, Ekrem (Dogus Author) -- An earlier version of this paper which has been presented at ISCIS'06: The 21st International Symposium on Computer and Information Sciences, November 1-3, 2006 Istanbul, Turkey, has been published in Lecture Notes in Computer Science [18].Although the use of electronic component placement machines has brought reliability and speed to the printed circuit board (PCB) assembly process, to get higher utilization, one needs to solve the resulting complex operations research problems efficiently. In this study, the problem of distributing the assembly workload to two machines deployed on an assembly line with two identical component placement machines to minimize the line idle time is considered. This problem is NP-Complete even in its simplest form. A mathematical model and several heuristics have been proposed to solve this problem efficiently

Design requirements for SRB production control system. Volume 5: Appendices

A questionnaire to be used to screen potential candidate production control software packages is presented

Minimizing The Number of Tardy Jobs in Hybrid Flow Shops with Non-Identical Multiple Processors

Two-stage hybrid flow shops (a.k.a., flow shops with multiple processors (FSMPs)) are studied wherein the multiple processors at a stage are non-identical, but related (a.k.a., uniform) in their processing speeds.   The impact of ten different dispatching procedures on a due-date based criterion (specifically, the number of tardy jobs) is analyzed over a set of 1,800 problems of varying configurations wherein the number of jobs per problem is between 20 and 100 and their due dates are randomly assigned.  Results indicate that the modified due date (MDD), earliest due date (EDD), slack (SLK), shortest processing time (SPT), and least work remaining (LWR) rules are statistically inseparable but yield superior performance to the other rules included in this study.  The longest processing time (LPT) and most work remaining (MWR) rules provide the poorest performance

An integrated approach for remanufacturing job shop scheduling with routing alternatives.

Remanufacturing is a practice of growing importance due to increasing environmental awareness and regulations. However, the stochastic natures inherent in the remanufacturing processes complicate its scheduling. This paper undertakes the challenge and presents a remanufacturing job shop scheduling approach by integrating alternative routing assignment and machine resource dispatching. A colored timed Petri net is introduced to model the dynamics of remanufacturing process, such as various process routings, uncertain operation times for cores, and machine resource conflicts. With the color attributes in Petri nets, two types of decision points, recovery routing selection and resource dispatching, are introduced and linked with places in CTPN model. With time attributes in Petri nets, the temporal aspect of recovery operations for cores as well as the evolution dynamics in cores\u27 operational stages is mathematically analyzed. A hybrid meta-heuristic algorithm embedded scheduling strategy over CTPN is proposed to search for the optimal recovery routings for worn cores and their recovery operation sequences on workstations, in minimizing the total production cost. The approach is demonstrated through the remanufacturing of used machine tool and its effectiveness is compared against another two cases: baseline case with fixed recovery process routings and case 2 using standard SA/MST

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