Identification of Moving Bottlenecks in Production Systems

Manufacturing sector have been plagued by bottlenecks from time immemorial, leading to loss of productivity and profitability, various research effort has been expended towards identifying and mitigating the effects of bottlenecks on production lines. However, traditional approaches often fail in identifying moving bottlenecks. The current data boom and giant strides made in the machine learning field proffers an alternative means of using the large volume of data generated by machines in identifying bottlenecks. In this study, a hierarchical agglomerative clustering algorithm is used in identifying potential groups of bottlenecks within a serial production line. A serial production line with five workstations and zero buffer was simulated in ARENA® with data regarding blocked, producing and starvation time extracted. The extracted data was preprocessed using Python 3.7 to obtain a matrix of ones and zeros. The resultant matrix was fed into a complete linkage hierarchical agglomerative clustering algorithm to obtain clusters containing potential bottleneck workstations. Results obtained was validated using results obtained from simulation and an Elbow plot

A Modeling and Analysis Framework To Support Monitoring, Assessment, and Control of Manufacturing Systems Using Hybrid Models

The manufacturing industry has constantly been challenged to improve productivity, adapt to continuous changes in demand, and reduce cost. The need for a competitive advantage has motivated research for new modeling and control strategies able to support reconfiguration considering the coupling between different aspects of plant floor operations. However, models of manufacturing systems usually capture the process flow and machine capabilities while neglecting the machine dynamics. The disjoint analysis of system-level interactions and machine-level dynamics limits the effectiveness of performance assessment and control strategies. This dissertation addresses the enhancement of productivity and adaptability of manufacturing systems by monitoring and controlling both the behavior of independent machines and their interactions. A novel control framework is introduced to support performance monitoring and decision making using real-time simulation, anomaly detection, and multi-objective optimization. The intellectual merit of this dissertation lies in (1) the development a mathematical framework to create hybrid models of both machines and systems capable of running in real-time, (2) the algorithms to improve anomaly detection and diagnosis using context-sensitive adaptive threshold limits combined with context-specific classification models, and (3) the construction of a simulation-based optimization strategy to support decision making considering the inherent trade-offs between productivity, quality, reliability, and energy usage. The result is a framework that transforms the state-of-the-art of manufacturing by enabling real-time performance monitoring, assessment, and control of plant floor operations. The control strategy aims to improve the productivity and sustainability of manufacturing systems using multi-objective optimization. The outcomes of this dissertation were implemented in an experimental testbed. Results demonstrate the potential to support maintenance actions, productivity analysis, and decision making in manufacturing systems. Furthermore, the proposed framework lays the foundation for a seamless integration of real systems and virtual models. The broader impact of this dissertation is the advancement of manufacturing science that is crucial to support economic growth. The implementation of the framework proposed in this dissertation can result in higher productivity, lower downtime, and energy savings. Although the project focuses on discrete manufacturing with a flow shop configuration, the control framework, modeling strategy, and optimization approach can be translated to job shop configurations or batch processes. Moreover, the algorithms and infrastructure implemented in the testbed at the University of Michigan can be integrated into automation and control products for wide availability.PHDMechanical EngineeringUniversity of Michigan, Horace H. Rackham School of Graduate Studieshttps://deepblue.lib.umich.edu/bitstream/2027.42/147657/1/migsae_1.pd

Efficient Data Streaming Analytic Designs for Parallel and Distributed Processing

Today, ubiquitously sensing technologies enable inter-connection of physical\ua0objects, as part of Internet of Things (IoT), and provide massive amounts of\ua0data streams. In such scenarios, the demand for timely analysis has resulted in\ua0a shift of data processing paradigms towards continuous, parallel, and multitier\ua0computing. However, these paradigms are followed by several challenges\ua0especially regarding analysis speed, precision, costs, and deterministic execution.\ua0This thesis studies a number of such challenges to enable efficient continuous\ua0processing of streams of data in a decentralized and timely manner.In the first part of the thesis, we investigate techniques aiming at speeding\ua0up the processing without a loss in precision. The focus is on continuous\ua0machine learning/data mining types of problems, appearing commonly in IoT\ua0applications, and in particular continuous clustering and monitoring, for which\ua0we present novel algorithms; (i) Lisco, a sequential algorithm to cluster data\ua0points collected by LiDAR (a distance sensor that creates a 3D mapping of the\ua0environment), (ii) p-Lisco, the parallel version of Lisco to enhance pipeline- and\ua0data-parallelism of the latter, (iii) pi-Lisco, the parallel and incremental version\ua0to reuse the information and prevent redundant computations, (iv) g-Lisco, a\ua0generalized version of Lisco to cluster any data with spatio-temporal locality\ua0by leveraging the implicit ordering of the data, and (v) Amble, a continuous\ua0monitoring solution in an industrial process.In the second part, we investigate techniques to reduce the analysis costs\ua0in addition to speeding up the processing while also supporting deterministic\ua0execution. The focus is on problems associated with availability and utilization\ua0of computing resources, namely reducing the volumes of data, involving\ua0concurrent computing elements, and adjusting the level of concurrency. For\ua0that, we propose three frameworks; (i) DRIVEN, a framework to continuously\ua0compress the data and enable efficient transmission of the compact data in the\ua0processing pipeline, (ii) STRATUM, a framework to continuously pre-process\ua0the data before transferring the later to upper tiers for further processing, and\ua0(iii) STRETCH, a framework to enable instantaneous elastic reconfigurations\ua0to adjust intra-node resources at runtime while ensuring determinism.The algorithms and frameworks presented in this thesis contribute to an\ua0efficient processing of data streams in an online manner while utilizing available\ua0resources. Using extensive evaluations, we show the efficiency and achievements\ua0of the proposed techniques for IoT representative applications that involve a\ua0wide spectrum of platforms, and illustrate that the performance of our work\ua0exceeds that of state-of-the-art techniques

Overall Equipment Effectiveness: Systematic Literature Review and Overview of Different Approaches

Overall equipment effectiveness (OEE) is a key performance indicator used to measure equipment productivity. The purpose of this study is to review and analyze the evolution of OEE, present modifications made over the original model and identify future development areas. This paper presents a systematic literature review; a structured and transparent study is performed by establishing procedures and criteria that must be followed for selecting relevant evidences and addressing research questions effectively. In a general search, 862 articles were obtained; after eliminating duplicates and applying certain inclusion and exclusion criteria, 186 articles were used for this review. This research presents three principal results: (1) The academic interest in this topic has increased over the last five years and the keywords have evolved from being related to maintenance and production, to being related to lean manufacturing and optimization; (2) A list of authors who have developed models based on OEE has been created; and (3) OEE is an emerging topic in areas such as logistics and services. To the best of our knowledge, no comparable review has been published recently. This research serves as a basis for future relevant studies

Intelligent Energy-Savings and Process Improvement Strategies in Energy-Intensive Industries

S tím, jak se neustále vyvíjejí nové technologie pro energeticky náročná průmyslová odvětví, stávající zařízení postupně zaostávají v efektivitě a produktivitě. Tvrdá konkurence na trhu a legislativa v oblasti životního prostředí nutí tato tradiční zařízení k ukončení provozu a k odstavení. Zlepšování procesu a projekty modernizace jsou zásadní v udržování provozních výkonů těchto zařízení. Současné přístupy pro zlepšování procesů jsou hlavně: integrace procesů, optimalizace procesů a intenzifikace procesů. Obecně se v těchto oblastech využívá matematické optimalizace, zkušeností řešitele a provozní heuristiky. Tyto přístupy slouží jako základ pro zlepšování procesů. Avšak, jejich výkon lze dále zlepšit pomocí moderní výpočtové inteligence. Účelem této práce je tudíž aplikace pokročilých technik umělé inteligence a strojového učení za účelem zlepšování procesů v energeticky náročných průmyslových procesech. V této práci je využit přístup, který řeší tento problém simulací průmyslových systémů a přispívá následujícím: (i)Aplikace techniky strojového učení, která zahrnuje jednorázové učení a neuro-evoluci pro modelování a optimalizaci jednotlivých jednotek na základě dat. (ii) Aplikace redukce dimenze (např. Analýza hlavních komponent, autoendkodér) pro vícekriteriální optimalizaci procesu s více jednotkami. (iii) Návrh nového nástroje pro analýzu problematických částí systému za účelem jejich odstranění (bottleneck tree analysis – BOTA). Bylo také navrženo rozšíření nástroje, které umožňuje řešit vícerozměrné problémy pomocí přístupu založeného na datech. (iv) Prokázání účinnosti simulací Monte-Carlo, neuronové sítě a rozhodovacích stromů pro rozhodování při integraci nové technologie procesu do stávajících procesů. (v) Porovnání techniky HTM (Hierarchical Temporal Memory) a duální optimalizace s několika prediktivními nástroji pro podporu managementu provozu v reálném čase. (vi) Implementace umělé neuronové sítě v rámci rozhraní pro konvenční procesní graf (P-graf). (vii) Zdůraznění budoucnosti umělé inteligence a procesního inženýrství v biosystémech prostřednictvím komerčně založeného paradigmatu multi-omics.Zlepšení průmyslových procesů, Model založený na datech, Optimalizace procesu, Strojové učení, Průmyslové systémy, Energeticky náročná průmyslová odvětví, Umělá inteligence.

Best matching processes in distributed systems

The growing complexity and dynamic behavior of modern manufacturing and service industries along with competitive and globalized markets have gradually transformed traditional centralized systems into distributed networks of e- (electronic) Systems. Emerging examples include e-Factories, virtual enterprises, smart farms, automated warehouses, and intelligent transportation systems. These (and similar) distributed systems, regardless of context and application, have a property in common: They all involve certain types of interactions (collaborative, competitive, or both) among their distributed individuals—from clusters of passive sensors and machines to complex networks of computers, intelligent robots, humans, and enterprises. Having this common property, such systems may encounter common challenges in terms of suboptimal interactions and thus poor performance, caused by potential mismatch between individuals. For example, mismatched subassembly parts, vehicles—routes, suppliers—retailers, employees—departments, and products—automated guided vehicles—storage locations may lead to low-quality products, congested roads, unstable supply networks, conflicts, and low service level, respectively. This research refers to this problem as best matching, and investigates it as a major design principle of CCT, the Collaborative Control Theory. The original contribution of this research is to elaborate on the fundamentals of best matching in distributed and collaborative systems, by providing general frameworks for (1) Systematic analysis, inclusive taxonomy, analogical and structural comparison between different matching processes; (2) Specification and formulation of problems, and development of algorithms and protocols for best matching; (3) Validation of the models, algorithms, and protocols through extensive numerical experiments and case studies. The first goal is addressed by investigating matching problems in distributed production, manufacturing, supply, and service systems based on a recently developed reference model, the PRISM Taxonomy of Best Matching. Following the second goal, the identified problems are then formulated as mixed-integer programs. Due to the computational complexity of matching problems, various optimization algorithms are developed for solving different problem instances, including modified genetic algorithms, tabu search, and neighbourhood search heuristics. The dynamic and collaborative/competitive behaviors of matching processes in distributed settings are also formulated and examined through various collaboration, best matching, and task administration protocols. In line with the third goal, four case studies are conducted on various manufacturing, supply, and service systems to highlight the impact of best matching on their operational performance, including service level, utilization, stability, and cost-effectiveness, and validate the computational merits of the developed solution methodologies

STAY FLEXIBLE: A PRESCRIPTIVE PROCESS MONITORING APPROACH FOR ENERGY FLEXIBILITY-ORIENTED PROCESS SCHEDULES

The transition of energy supply from fossil fuels to renewable energy sources poses major challenges for balancing increasingly weather-dependent energy supply and demand. Demand-side energy flexibility, offered particularly by companies, is seen as a promising and necessary approach to address these challenges. Process mining provides significant potential to prevent a deterioration of product quality or process flows due to flexibilization and allows for exploiting monetary benefits associated with flexible process operation. Hence, we follow the design science research paradigm to develop PM4Flex, a prescriptive process monitoring approach, that generates recommendations for pending process flows optimized under fluctuating power prices by implementing established energy flexibility measures. Thereby, we consider company- and process-specific constraints and historic event logs. We demonstrate and evaluate PM4Flex by implementing it as a software prototype and applying it to exemplary data from a heating and air conditioning company, observing considerable cost-savings of 1.42ct per kWh or 7.89%

Dynamics in Logistics

This open access book highlights the interdisciplinary aspects of logistics research. Featuring empirical, methodological, and practice-oriented articles, it addresses the modelling, planning, optimization and control of processes. Chiefly focusing on supply chains, logistics networks, production systems, and systems and facilities for material flows, the respective contributions combine research on classical supply chain management, digitalized business processes, production engineering, electrical engineering, computer science and mathematical optimization. To celebrate 25 years of interdisciplinary and collaborative research conducted at the Bremen Research Cluster for Dynamics in Logistics (LogDynamics), in this book hand-picked experts currently or formerly affiliated with the Cluster provide retrospectives, present cutting-edge research, and outline future research directions

A New methodology to identify supply chains sustainability bottlenecks

The world globalization has been creating a very strong competition amongst companies. To maintain their market position, companies need to guarantee that all their activities are performed with high efficacy and efficiency standards, allowing not only a business profit but also a good company image among their stakeholders. Such reputation is not definitely related only to the service level and the economic performance but also to the way environmental and social aspects are treated within the companies’ strategy. This thesis explores these concerns and presents a simple and systematic methodology (SustainSCVSM) for supply chain analyses. SustainSC-VSM is composed of a value stream map and a complementary analysis which is based on the Sustain-Pro methodology. SustainSC-VSM will screen and identify the main bottlenecks, regarding sustainable factors (economic, environmental and social) in any supply chain. Moreover, SustainSC-VSM proposes an information factor in order to improve the coordination among the supply chain actors and their sustainable performance. A set of new indicators is applied during the analysis; these indicators aims to identify the bottlenecks in terms of sustainability of the supply chain. The analysis of these indicators points out the issues to be improved, when the future state Value Stream Map is designed. A set of best practises is also presented as a guideline to undertake this last step. A case study is presented to highlight the applicability of the developed methodology. The obtained results point out the direction to harmonize business efficiency standards and sustainability in the supply chain