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

The synergistic effect of operational research and big data analytics in greening container terminal operations: a review and future directions

Container Terminals (CTs) are continuously presented with highly interrelated, complex, and uncertain planning tasks. The ever-increasing intensity of operations at CTs in recent years has also resulted in increasing environmental concerns, and they are experiencing an unprecedented pressure to lower their emissions. Operational Research (OR), as a key player in the optimisation of the complex decision problems that arise from the quay and land side operations at CTs, has been therefore presented with new challenges and opportunities to incorporate environmental considerations into decision making and better utilise the ‘big data’ that is continuously generated from the never-stopping operations at CTs. The state-of-the-art literature on OR's incorporation of environmental considerations and its interplay with Big Data Analytics (BDA) is, however, still very much underdeveloped, fragmented, and divergent, and a guiding framework is completely missing. This paper presents a review of the most relevant developments in the field and sheds light on promising research opportunities for the better exploitation of the synergistic effect of the two disciplines in addressing CT operational problems, while incorporating uncertainty and environmental concerns efficiently. The paper finds that while OR has thus far contributed to improving the environmental performance of CTs (rather implicitly), this can be much further stepped up with more explicit incorporation of environmental considerations and better exploitation of BDA predictive modelling capabilities. New interdisciplinary research at the intersection of conventional CT optimisation problems, energy management and sizing, and net-zero technology and energy vectors adoption is also presented as a prominent line of future research

The synergistic effect of operational research and big data analytics in greening container terminal operations: A review and future directions

Container Terminals (CTs) are continuously presented with highly interrelated, complex, and uncertain planning tasks. The ever-increasing intensity of operations at CTs in recent years has also resulted in increasing environmental concerns, and they are experiencing an unprecedented pressure to lower their emissions. Operational Research (OR), as a key player in the optimisation of the complex decision problems that arise from the quay and land side operations at CTs, has been therefore presented with new challenges and opportunities to incorporate environmental considerations into decision making and better utilise the ‘big data’ that is continuously generated from the never-stopping operations at CTs. The state-of-the-art literature on OR's incorporation of environmental considerations and its interplay with Big Data Analytics (BDA) is, however, still very much underdeveloped, fragmented, and divergent, and a guiding framework is completely missing. This paper presents a review of the most relevant developments in the field and sheds light on promising research opportunities for the better exploitation of the synergistic effect of the two disciplines in addressing CT operational problems, while incorporating uncertainty and environmental concerns efficiently. The paper finds that while OR has thus far contributed to improving the environmental performance of CTs (rather implicitly), this can be much further stepped up with more explicit incorporation of environmental considerations and better exploitation of BDA predictive modelling capabilities. New interdisciplinary research at the intersection of conventional CT optimisation problems, energy management and sizing, and net-zero technology and energy vectors adoption is also presented as a prominent line of future research

Manufacturing Management and Decision Support using Simulation-based Multi-Objective Optimisation

A majority of the established automotive manufacturers are under severe competitive pressure and their long term economic sustainability is threatened. In particular the transformation towards more CO2-efficient energy sources is a huge financial burden for an already investment capital intensive industry. In addition existing operations urgently need rapid improvement and even more critical is the development of highly productive, efficient and sustainable manufacturing solutions for new and updated products. Simultaneously, a number of severe drawbacks with current improvement methods for industrial production systems have been identified. In summary, variation is not considered sufficient with current analysis methods, tools used are insufficient for revealing enough knowledge to support decisions, procedures for finding optimal solutions are not considered, and information about bottlenecks is often required, but no accurate methods for the identification of bottlenecks are used in practice, because they do not normally generate any improvement actions. Current methods follow a trial-and-error pattern instead of a proactive approach. Decisions are often made directly on the basis of raw static historical data without an awareness of optimal alternatives and their effects. These issues could most likely lead to inadequate production solutions, low effectiveness, and high costs, resulting in poor competitiveness. In order to address the shortcomings of existing methods, a methodology and framework for manufacturing management decision support using simulation-based multi-objective optimisation is proposed. The framework incorporates modelling and the optimisation of production systems, costs, and sustainability. Decision support is created through the extraction of knowledge from optimised data. A novel method and algorithm for the detection of constraints and bottlenecks is proposed as part of the framework. This enables optimal improvement activities with ranking in order of importance can be sought. The new method can achieve a higher improvement rate, when applied to industrial improvement situations, compared to the well-established shifting bottleneck technique. A number of “laboratory” experiments and real-world industrial applications have been conducted in order to explore, develop, and verify the proposed framework. The identified gaps can be addressed with the proposed methodology. By using simulation-based methods, stochastic behaviour and variability is taken into account and knowledge for the creation of decision support is gathered through post-optimality analysis. Several conflicting objectives can be considered simultaneously through the application of multi-objective optimisation, while objectives related to running cost, investments and other sustainability parameters can be included through the use of the new cost and sustainability models introduced. Experiments and tests have been undertaken and have shown that the proposed framework can assist the creation of manufacturing management decision support and that such a methodology can contribute significantly to regaining profitability when applied within the automotive industry. It can be concluded that a proof-of-concept has been rigorously established for the application of the proposed framework on real-world industrial decision-making, in a manufacturing management context.Volvo Car Corporation, Sweden University of Skövde, Swede

Expanding the Horizons of Manufacturing: Towards Wide Integration, Smart Systems and Tools

This research topic aims at enterprise-wide modeling and optimization (EWMO) through the development and application of integrated modeling, simulation and optimization methodologies, and computer-aided tools for reliable and sustainable improvement opportunities within the entire manufacturing network (raw materials, production plants, distribution, retailers, and customers) and its components. This integrated approach incorporates information from the local primary control and supervisory modules into the scheduling/planning formulation. That makes it possible to dynamically react to incidents that occur in the network components at the appropriate decision-making level, requiring fewer resources, emitting less waste, and allowing for better responsiveness in changing market requirements and operational variations, reducing cost, waste, energy consumption and environmental impact, and increasing the benefits. More recently, the exploitation of new technology integration, such as through semantic models in formal knowledge models, allows for the capture and utilization of domain knowledge, human knowledge, and expert knowledge toward comprehensive intelligent management. Otherwise, the development of advanced technologies and tools, such as cyber-physical systems, the Internet of Things, the Industrial Internet of Things, Artificial Intelligence, Big Data, Cloud Computing, Blockchain, etc., have captured the attention of manufacturing enterprises toward intelligent manufacturing systems

Application of lean scheduling and production control in non-repetitive manufacturing systems using intelligent agent decision support

This thesis was submitted for the degree of Doctor of Philosophy and awarded by Brunel University.Lean Manufacturing (LM) is widely accepted as a world-class manufacturing paradigm, its currency and superiority are manifested in numerous recent success stories. Most lean tools including Just-in-Time (JIT) were designed for repetitive serial production systems. This resulted in a substantial stream of research which dismissed a priori the suitability of LM for non-repetitive non-serial job-shops. The extension of LM into non-repetitive production systems is opposed on the basis of the sheer complexity of applying JIT pull production control in non-repetitive systems fabricating a high variety of products. However, the application of LM in job-shops is not unexplored. Studies proposing the extension of leanness into non-repetitive production systems have promoted the modification of pull control mechanisms or reconfiguration of job-shops into cellular manufacturing systems. This thesis sought to address the shortcomings of the aforementioned approaches. The contribution of this thesis to knowledge in the field of production and operations management is threefold: Firstly, a Multi-Agent System (MAS) is designed to directly apply pull production control to a good approximation of a real-life job-shop. The scale and complexity of the developed MAS prove that the application of pull production control in non-repetitive manufacturing systems is challenging, perplex and laborious. Secondly, the thesis examines three pull production control mechanisms namely, Kanban, Base Stock and Constant Work-in-Process (CONWIP) which it enhances so as to prevent system deadlocks, an issue largely unaddressed in the relevant literature. Having successfully tested the transferability of pull production control to non-repetitive manufacturing, the third contribution of this thesis is that it uses experimental and empirical data to examine the impact of pull production control on job-shop performance. The thesis identifies issues resulting from the application of pull control in job-shops which have implications for industry practice and concludes by outlining further research that can be undertaken in this direction