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

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

Optimization of transport constraints and quality of service for joint resolution of uncertain scheduling and the job-shop problem with routing (JSSPR) as opposed to the job-shop problem with transport (JSSPT)

To better meet the qualitative and quantitative requirements of customers or relevant sector managers, workshop environments are implementing increasingly complex task management systems. The job shop scheduling problem (JSSP) involves assigning each task to a single machine while scheduling many tasks on different machines. Finding the best scheduling for machines is one of the challenging optimizations of difficult non-deterministic polynomial (NP) time problems. The fundamental goal of optimization is to shorten the makespan (total execution time of all tasks). This paper is interested in the joint resolution of scheduling and transport problems and more particularly the Job-shop problem with Routing (JSSPR) as opposed to the Job-shop problem with Transport (JSSPT). These two problems are modeled in the form of a disjunctive graph. For the JSSPT, the solution to the transport problem is not linked to any quality of service (QoS) criterion and the solution is therefore often semi-active. The Job-shop with Routing explicitly considers transport operations and uses algorithms from the transport community to solve the transport problem. It is shown that the routing part of the JSSPR is a problem of the vehicle routing family and of the Pickup and Delivery Problem family. QoS in the JSSPR is defined by the duration of tours, the duration of transport of parts and the waiting time for them. A new evaluation function – named Time-Lag Insertion Heuristic (TLH) – is proposed to evaluate a disjunctive graph by simultaneously minimizing the makespan and maximizing the quality of service. Thus, the solution obtained is not semi-active, but a compromise between the different criteria. This evaluation function is included in a metaheuristic. Our numerical evaluations demonstrate that, on the one hand, the TLH evaluation can find almost optimal solutions regarding the QoS criterion; and on the other hand, the TLH evaluation is not very sensitive to the order of insertion of the maximum time-lags during the different minimization steps

An economic lot and delivery scheduling problem with the fuzzy shelf life in a flexible job shop with unrelated parallel machines

This paper considers an economic lot and delivery scheduling problem (ELDSP) in a fuzzy environment with the fuzzy shelf life for each product. This problem is formulated in a flexible job shop with unrelated parallel machines, when the planning horizon is finite and it determines lot sizing, scheduling and sequencing, simultaneously. The proposed model of this paper is based on the basic period (BP) approach. In this paper, a mixed-integer nonlinear programming (MINLP) model is presented and then it is changed into two models in the fuzzy shelf life. The main model is dependent to the multiple basic periods and it is difficult to solve the resulted proposed model for large-scale problems in reasonable amount of time; thus, an efficient heuristic method is proposed to solve the problem. The performance of the proposed model is demonstrated using some numerical examples

An Effective Hybrid Genetic Algorithm for Hybrid Flow Shops with Sequence Dependent Setup Times and Processor Blocking

Hybrid flow-shop or flexible flow shop problems have remained subject of intensive research over several years. Hybrid flow-shop problems overcome one of the limitations of the classical flow-shop model by allowing parallel processors at each stage of task processing. In many papers the assumptions are generally made that there is unlimited storage available between stages and the setup times are neglected or considered independent from sequences of jobs. In this paper we study the hybrid flow shop problems with sequence dependent setup times and processor blocking. We present an effective hybrid genetic algorithm with some state-of-the-art procedures for these NP-hard problems to minimize total completion time or makespan. We established a benchmark to draw an analogy between the performance of our algorithm and RKGA. The obtaining results clearly show the superiority performance of our algorithm