A Digital Twin Framework for Production Planning Optimization: Applications for Make-To-Order Manufacturers

In this dissertation, we develop a Digital Twin framework for manufacturing systems and apply it to various production planning and scheduling problems faced by Make-To-Order (MTO) firms. While this framework can be used to digitally represent a particular manufacturing environment with high fidelity, our focus is in using it to generate realistic settings to test production planning and scheduling algorithms in practice. These algorithms have traditionally been tested by either translating a practical situation into the necessary modeling constructs, without discussion of the assumptions and inaccuracies underlying this translation, or by generating random instances of the modeling constructs, without assessing the limitations in accurately representing production environments. The consequence has been a serious gap between theory advancement and industry practice. The major goal of this dissertation is to develop a framework that allows for practical testing, evaluation, and implementation of new approaches for seamless industry adoption. We develop this framework as a modular software package and emphasize the practicality and configurability of the framework, such that minimal modelling effort is required to apply the framework to a multitude of optimization problems and manufacturing systems. Throughout this dissertation, we emphasize the importance of the underlying scheduling problems which provide the basis for additional operational decision making. We focus on the computational evaluation and comparisons of various modeling choices within the developed frameworks, with the objective of identifying models which are both effective and computationally efficient. In Part 1 of this dissertation, we consider a class of Production Planning and Execution problems faced by job shop manufacturing systems. In Part 2 of this dissertation, we consider a class of scheduling problems faced by manufacturers whose production system is dominated by a single operation

Survey on Ten Years of Multi-Depot Vehicle Routing Problems: Mathematical Models, Solution Methods and Real-Life Applications

A crucial practical issue encountered in logistics management is the circulation of final products from depots to end-user customers. When routing and scheduling systems are improved, they will not only improve customer satisfaction but also increase the capacity to serve a large number of customers minimizing time. On the assumption that there is only one depot, the key issue of distribution is generally identified and formulated as VRP standing for Vehicle Routing Problem. In case, a company having more than one depot, the suggested VRP is most unlikely to work out. In view of resolving this limitation and proposing alternatives, VRP with multiple depots and multi-depot MDVRP have been a focus of this paper. Carrying out a comprehensive analytical literature survey of past ten years on cost-effective Multi-Depot Vehicle Routing is the main aim of this research. Therefore, the current status of the MDVRP along with its future developments is reviewed at length in the paper

Planning and Scheduling Optimization

Although planning and scheduling optimization have been explored in the literature for many years now, it still remains a hot topic in the current scientific research. The changing market trends, globalization, technical and technological progress, and sustainability considerations make it necessary to deal with new optimization challenges in modern manufacturing, engineering, and healthcare systems. This book provides an overview of the recent advances in different areas connected with operations research models and other applications of intelligent computing techniques used for planning and scheduling optimization. The wide range of theoretical and practical research findings reported in this book confirms that the planning and scheduling problem is a complex issue that is present in different industrial sectors and organizations and opens promising and dynamic perspectives of research and development

Production Scheduling

Generally speaking, scheduling is the procedure of mapping a set of tasks or jobs (studied objects) to a set of target resources efficiently. More specifically, as a part of a larger planning and scheduling process, production scheduling is essential for the proper functioning of a manufacturing enterprise. This book presents ten chapters divided into five sections. Section 1 discusses rescheduling strategies, policies, and methods for production scheduling. Section 2 presents two chapters about flow shop scheduling. Section 3 describes heuristic and metaheuristic methods for treating the scheduling problem in an efficient manner. In addition, two test cases are presented in Section 4. The first uses simulation, while the second shows a real implementation of a production scheduling system. Finally, Section 5 presents some modeling strategies for building production scheduling systems. This book will be of interest to those working in the decision-making branches of production, in various operational research areas, as well as computational methods design. People from a diverse background ranging from academia and research to those working in industry, can take advantage of this volume

On-line planning and scheduling: an application to controlling modular printers

We present a case study of artificial intelligence techniques applied to the control of production printing equipment. Like many other real-world applications, this complex domain requires high-speed autonomous decision-making and robust continual operation. To our knowledge, this work represents the first successful industrial application of embedded domain-independent temporal planning. Our system handles execution failures and multi-objective preferences. At its heart is an on-line algorithm that combines techniques from state-space planning and partial-order scheduling. We suggest that this general architecture may prove useful in other applications as more intelligent systems operate in continual, on-line settings. Our system has been used to drive several commercial prototypes and has enabled a new product architecture for our industrial partner. When compared with state-of-the-art off-line planners, our system is hundreds of times faster and often finds better plans. Our experience demonstrates that domain-independent AI planning based on heuristic search can flexibly handle time, resources, replanning, and multiple objectives in a high-speed practical application without requiring hand-coded control knowledge

The investigation of the effect of scheduling rules on FMS performance

The application of Flexible Manufacturing Systems (FMSs) has an effect in competitiveness, not only of individual companies but of those countries whose manufactured exports play a significant part in their economy (Hartley, 1984). However, the increasing use of FM Ss to effectively provide customers with diversified products has created a significant set of operational challenges for managers (Mahmoodi et al., 1999). In more recent years therefore, there has been a concentration of effort on FMS scheduling without which the benefits of an FMS cannot be realized. The objective of the reported research is to investigate and extend the contribution which can be made to the FMS scheduling problem through the implementation of computer-based experiments that consider real-time situations. [Continues.

Considering skills evolutions in multi-skilled workforce allocation with flexible working hours

The growing need of responsiveness for manufacturing companies facing market volatility raises a strong demand for flexibility in their organisation. Since the company personnel are increasingly considered as the core of the organisational structures, a strong and forward-looking management of human resources and skills is crucial to performance in many industries. These organisations must develop strategies for the short, medium and long terms, in order to preserve and develop skills. Responding to this importance, this work presents an original model, looking at the line-up of multi-period project, considering the problem of staff allocation with two degrees of flexibility. The first results from the annualising of working time, and relies on policies of changing schedules, individually as well as collectively. The second degree of flexibility is the versatility of the operators, which induces a dynamic view of their skills and the need to predict changes in individual performance as a result of successive assignments. We are firmly in a context where the expected durations of activities are no longer predefined, but result from the performance of the operators selected for their execution. We present a mathematical model of this problem, which is solved by a genetic algorithm. An illustrative example is presented and analysed, and, the robustness of the solving approach is investigated using a sample of 400 projects with different characteristics