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

TOWARDS DIGITAL TWIN-DRIVEN PERFORMANCE EVALUATION METHODOLOGY OF FMS

The paper presents a method of automated modelling and performance evaluation of concurrent production flows carried out in Flexible Manufacturing Systems. The method allows for quick assessment of various variants of such systems, considering their structure and the organization of production flow of possible ways of their implementation. Its essence is the conditions imposed on the designed model, limiting the space of possible variants of the production flow only to deadlock-free variants. The practical usefulness of the model implemented in the proposed method illustrates the example, which describes the simultaneous assessment of alternative variants of the flexible machining module's structure and the planned multi-assortment production. The ability of the method to focus on feasible solutions offers attractive perspectives for guiding the Digital Twin-like scenario in situations caused by the need to change the production flow

Deadlock prevention and deadlock avoidance in flexible manufacturing systems using petri net models

Deadlocks constitute an important issue to be addressed in the design and operation of FMSs. It is shown that prevention and avoidance of FMS deadlocks can be implemented using Petri net models. For deadlock prevention, the reachability graph of a Petri net model of the given FMS is used, whereas for deadlock avoidance, a Petri-net-based online controller is proposed. The modeling of the General Electric FMS at Erie, PA, is discussed. For such real-world systems, deadlock prevention using the reachability graph is not feasible. A generic, Petri-net-based online controller for implementing deadlock avoidance in such real-world FMSs is developed

On The Computational Complexity Of The Manufacturing Job Shop And Reentrant Flow Line

This paper presents a comparison study of the computational complexity of the general job shop protocol and the flow line protocol in a flexible manufacturing system. It is shown that a certain representative problem of finding resource invariants is NP-complete in the case of the job shop, while in the flow line case it admits a closed-form solution. The importance of correctly selecting part flow and job routing protocols in flexible manufacturing systems to reduce complexity is thereby conclusively demonstrated. 1 Introduction In a general flexible manufacturing system (FMS) where resources are shared, a key role in part routing, job selection, and resource assignment is played by the FMS controller. Given the same resources of machines, robots, fixtures, tooling, and so on, different structures result under different routing/assignment strategies by the controller. Unstructured strategies are generally classified as the so-called job shop organization, while structured protocols ..

Makespan Minimization of Machines and Automated Guided Vehicles Schedule Using Binary Particle Swarm Optimization

An efficient and optimized Automated Guided Vehicles (AGVs) operation plays a critical role in improving the performance of a Flexible Manufacturing System (FMS). Among the main elements in the implementation of AGV is task scheduling. This is due to the fact that efficient scheduling would enable the increment of productivity and reducing delivery cost whilst optimally utilizes the entire fleet. In this research, Binary Particle Swarm Optimization (BPSO) is used to optimize simultaneous machines and AGVs scheduling process with makespan minimization function. It is proven that the method is capable to provide better solution compared to others