Dynamic scheduling in a multi-product manufacturing system

To remain competitive in global marketplace, manufacturing companies need to improve their operational practices. One of the methods to increase competitiveness in manufacturing is by implementing proper scheduling system. This is important to enable job orders to be completed on time, minimize waiting time and maximize utilization of equipment and machineries. The dynamics of real manufacturing system are very complex in nature. Schedules developed based on deterministic algorithms are unable to effectively deal with uncertainties in demand and capacity. Significant differences can be found between planned schedules and actual schedule implementation. This study attempted to develop a scheduling system that is able to react quickly and reliably for accommodating changes in product demand and manufacturing capacity. A case study, 6 by 6 job shop scheduling problem was adapted with uncertainty elements added to the data sets. A simulation model was designed and implemented using ARENA simulation package to generate various job shop scheduling scenarios. Their performances were evaluated using scheduling rules, namely, first-in-first-out (FIFO), earliest due date (EDD), and shortest processing time (SPT). An artificial neural network (ANN) model was developed and trained using various scheduling scenarios generated by ARENA simulation. The experimental results suggest that the ANN scheduling model can provided moderately reliable prediction results for limited scenarios when predicting the number completed jobs, maximum flowtime, average machine utilization, and average length of queue. This study has provided better understanding on the effects of changes in demand and capacity on the job shop schedules. Areas for further study includes: (i) Fine tune the proposed ANN scheduling model (ii) Consider more variety of job shop environment (iii) Incorporate an expert system for interpretation of results. The theoretical framework proposed in this study can be used as a basis for further investigation

Big data analytics: a predictive analysis applied to cybersecurity in a financial organization

Project Work presented as partial requirement for obtaining the Master’s degree in Information Management, with a specialization in Knowledge Management and Business IntelligenceWith the generalization of the internet access, cyber attacks have registered an alarming growth in frequency and severity of damages, along with the awareness of organizations with heavy investments in cybersecurity, such as in the financial sector. This work is focused on an organization’s financial service that operates on the international markets in the payment systems industry. The objective was to develop a predictive framework solution responsible for threat detection to support the security team to open investigations on intrusive server requests, over the exponentially growing log events collected by the SIEM from the Apache Web Servers for the financial service. A Big Data framework, using Hadoop and Spark, was developed to perform classification tasks over the financial service requests, using Neural Networks, Logistic Regression, SVM, and Random Forests algorithms, while handling the training of the imbalance dataset through BEV. The main conclusions over the analysis conducted, registered the best scoring performances for the Random Forests classifier using all the preprocessed features available. Using the all the available worker nodes with a balanced configuration of the Spark executors, the most performant elapsed times for loading and preprocessing of the data were achieved using the column-oriented ORC with native format, while the row-oriented CSV format performed the best for the training of the classifiers.Com a generalização do acesso à internet, os ciberataques registaram um crescimento alarmante em frequência e severidade de danos causados, a par da consciencialização das organizações, com elevados investimentos em cibersegurança, como no setor financeiro. Este trabalho focou-se no serviço financeiro de uma organização que opera nos mercados internacionais da indústria de sistemas de pagamento. O objetivo consistiu no desenvolvimento uma solução preditiva responsável pela detecção de ameaças, por forma a dar suporte à equipa de segurança na abertura de investigações sobre pedidos intrusivos no servidor, relativamente aos exponencialmente crescentes eventos de log coletados pelo SIEM, referentes aos Apache Web Servers, para o serviço financeiro. Uma solução de Big Data, usando Hadoop e Spark, foi desenvolvida com o objectivo de executar tarefas de classificação sobre os pedidos do serviço financeiros, usando os algoritmos Neural Networks, Logistic Regression, SVM e Random Forests, solucionando os problemas associados ao treino de um dataset desequilibrado através de BEV. As principais conclusões sobre as análises realizadas registaram os melhores resultados de classificação usando o algoritmo Random Forests com todas as variáveis pré-processadas disponíveis. Usando todos os nós do cluster e uma configuração balanceada dos executores do Spark, os melhores tempos para carregar e pré-processar os dados foram obtidos usando o formato colunar ORC nativo, enquanto o formato CSV, orientado a linhas, apresentou os melhores tempos para o treino dos classificadores

Adaptive Order Dispatching based on Reinforcement Learning: Application in a Complex Job Shop in the Semiconductor Industry

Heutige Produktionssysteme tendieren durch die Marktanforderungen getrieben zu immer kleineren Losgrößen, höherer Produktvielfalt und größerer Komplexität der Materialflusssysteme. Diese Entwicklungen stellen bestehende Produktionssteuerungsmethoden in Frage. Im Zuge der Digitalisierung bieten datenbasierte Algorithmen des maschinellen Lernens einen alternativen Ansatz zur Optimierung von Produktionsabläufen. Aktuelle Forschungsergebnisse zeigen eine hohe Leistungsfähigkeit von Verfahren des Reinforcement Learning (RL) in einem breiten Anwendungsspektrum. Im Bereich der Produktionssteuerung haben sich jedoch bisher nur wenige Autoren damit befasst. Eine umfassende Untersuchung verschiedener RL-Ansätze sowie eine Anwendung in der Praxis wurden noch nicht durchgeführt. Unter den Aufgaben der Produktionsplanung und -steuerung gewährleistet die Auftragssteuerung (order dispatching) eine hohe Leistungsfähigkeit und Flexibilität der Produktionsabläufe, um eine hohe Kapazitätsauslastung und kurze Durchlaufzeiten zu erreichen. Motiviert durch komplexe Werkstattfertigungssysteme, wie sie in der Halbleiterindustrie zu finden sind, schließt diese Arbeit die Forschungslücke und befasst sich mit der Anwendung von RL für eine adaptive Auftragssteuerung. Die Einbeziehung realer Systemdaten ermöglicht eine genauere Erfassung des Systemverhaltens als statische Heuristiken oder mathematische Optimierungsverfahren. Zusätzlich wird der manuelle Aufwand reduziert, indem auf die Inferenzfähigkeiten des RL zurückgegriffen wird. Die vorgestellte Methodik fokussiert die Modellierung und Implementierung von RL-Agenten als Dispatching-Entscheidungseinheit. Bekannte Herausforderungen der RL-Modellierung in Bezug auf Zustand, Aktion und Belohnungsfunktion werden untersucht. Die Modellierungsalternativen werden auf der Grundlage von zwei realen Produktionsszenarien eines Halbleiterherstellers analysiert. Die Ergebnisse zeigen, dass RL-Agenten adaptive Steuerungsstrategien erlernen können und bestehende regelbasierte Benchmarkheuristiken übertreffen. Die Erweiterung der Zustandsrepräsentation verbessert die Leistung deutlich, wenn ein Zusammenhang mit den Belohnungszielen besteht. Die Belohnung kann so gestaltet werden, dass sie die Optimierung mehrerer Zielgrößen ermöglicht. Schließlich erreichen spezifische RL-Agenten-Konfigurationen nicht nur eine hohe Leistung in einem Szenario, sondern weisen eine Robustheit bei sich ändernden Systemeigenschaften auf. Damit stellt die Forschungsarbeit einen wesentlichen Beitrag in Richtung selbstoptimierender und autonomer Produktionssysteme dar. Produktionsingenieure müssen das Potenzial datenbasierter, lernender Verfahren bewerten, um in Bezug auf Flexibilität wettbewerbsfähig zu bleiben und gleichzeitig den Aufwand für den Entwurf, den Betrieb und die Überwachung von Produktionssteuerungssystemen in einem vernünftigen Gleichgewicht zu halten

Hybrid Advanced Optimization Methods with Evolutionary Computation Techniques in Energy Forecasting

More accurate and precise energy demand forecasts are required when energy decisions are made in a competitive environment. Particularly in the Big Data era, forecasting models are always based on a complex function combination, and energy data are always complicated. Examples include seasonality, cyclicity, fluctuation, dynamic nonlinearity, and so on. These forecasting models have resulted in an over-reliance on the use of informal judgment and higher expenses when lacking the ability to determine data characteristics and patterns. The hybridization of optimization methods and superior evolutionary algorithms can provide important improvements via good parameter determinations in the optimization process, which is of great assistance to actions taken by energy decision-makers. This book aimed to attract researchers with an interest in the research areas described above. Specifically, it sought contributions to the development of any hybrid optimization methods (e.g., quadratic programming techniques, chaotic mapping, fuzzy inference theory, quantum computing, etc.) with advanced algorithms (e.g., genetic algorithms, ant colony optimization, particle swarm optimization algorithm, etc.) that have superior capabilities over the traditional optimization approaches to overcome some embedded drawbacks, and the application of these advanced hybrid approaches to significantly improve forecasting accuracy

Enabling flexibility through strategic management of complex engineering systems

”Flexibility is a highly desired attribute of many systems operating in changing or uncertain conditions. It is a common theme in complex systems to identify where flexibility is generated within a system and how to model the processes needed to maintain and sustain flexibility. The key research question that is addressed is: how do we create a new definition of workforce flexibility within a human-technology-artificial intelligence environment? Workforce flexibility is the management of organizational labor capacities and capabilities in operational environments using a broad and diffuse set of tools and approaches to mitigate system imbalances caused by uncertainties or changes. We establish a baseline reference for managers to use in choosing flexibility methods for specific applications and we determine the scope and effectiveness of these traditional flexibility methods. The unique contributions of this research are: a) a new definition of workforce flexibility for a human-technology work environment versus traditional definitions; b) using a system of systems (SoS) approach to create and sustain that flexibility; and c) applying a coordinating strategy for optimal workforce flexibility within the human- technology framework. This dissertation research fills the gap of how we can model flexibility using SoS engineering to show where flexibility emerges and what strategies a manager can use to manage flexibility within this technology construct”--Abstract, page iii

Intelligent shop scheduling for semiconductor manufacturing

Semiconductor market sales have expanded massively to more than 200 billion dollars annually accompanied by increased pressure on the manufacturers to provide higher quality products at lower cost to remain competitive. Scheduling of semiconductor manufacturing is one of the keys to increasing productivity, however the complexity of manufacturing high capacity semiconductor devices and the cost considerations mean that it is impossible to experiment within the facility. There is an immense need for effective decision support models, characterizing and analyzing the manufacturing process, allowing the effect of changes in the production environment to be predicted in order to increase utilization and enhance system performance. Although many simulation models have been developed within semiconductor manufacturing very little research on the simulation of the photolithography process has been reported even though semiconductor manufacturers have recognized that the scheduling of photolithography is one of the most important and challenging tasks due to complex nature of the process. Traditional scheduling techniques and existing approaches show some benefits for solving small and medium sized, straightforward scheduling problems. However, they have had limited success in solving complex scheduling problems with stochastic elements in an economic timeframe. This thesis presents a new methodology combining advanced solution approaches such as simulation, artificial intelligence, system modeling and Taguchi methods, to schedule a photolithography toolset. A new structured approach was developed to effectively support building the simulation models. A single tool and complete toolset model were developed using this approach and shown to have less than 4% deviation from actual production values. The use of an intelligent scheduling agent for the toolset model shows an average of 15% improvement in simulated throughput time and is currently in use for scheduling the photolithography toolset in a manufacturing plant