Modeling Manufacturing Systems. From Aggregate Planning to Real-Time Control

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1 Modeling Manufacturing Systems From Aggregate Planning to Real-Time Control

2 Springer-Verlag Berlin Heidelberg GmbH

3 Paolo Brandimarte. Agostino Villa (Eds.) Modeling Manufacturing Systems From Aggregate Planning to Real-Time Control With 54 Figures and 16 Tables Springer

4 Professor Paolo Brandimarte Professor Agostino Villa Technical University of Torino Dipartimento di Sistemi di Produzione ed Economia dell' Azienda Corso Duca degli Abruzzi Torino, Italy ISBN Cataloging-in-Publication Data applied for Die Deutsche Bibliothek - CIP-Einheitsaufnahme Modeling manufacturing systems : from aggregate planning to real time control 1 ed.: Paolo Brandimarte; Agostino Villa. ISBN ISBN (ebook) DOI / This work is subject to copyright. All rights are reserved. whether the whole or part of the material is concerned. specifically the rights of translation. reprinting. reuse of illustrations. recitation. broadcasting. reproduction on microfilm or in any other way. and storage in data banks. Duplication of this publication or parts thereof is permitted only under the provisions of the German Copyright Law of September in its current version. and permission for use must always be obtained from Springer-Verlag Berlin Heidelberg GmbH. Violations are liable for prosecution under the German Copyright Law. Springer-Verlag Berlin Heidelberg 1999 Originally published by Springer -Verlag Berlin Heidelberg New York in 1999 Softcover reprint of the hardcover 1 st edition 1999 The use of registered names. trademarks. etc. in this publication does not imply. even in the absence of a specific statement. that such names are exempt from the relevant protective laws and regulations and therefore free for general use. Hardcover design: Erich Kirchner. Heidelberg SPIN / o - Printed on acid-free paper

5 Preface Four years ago the International Federation of Automatic Control (IFAC) set up a Technical Committee on Manufacturing Modelling, Management and Control. Among the goals of this committee were: the development, the comparison, and the classification of formal models, both descriptive and prescriptive, of Computer Integrated Manufacturing Systems; the integration among optimization methods, simulation models and knowledgebased procedures; the specification of requirements for new models, including discrete-event and continuous representations, to be used in simulating and designing the management strategies for manufacturing plants. The technical areas of interest included: at the system level, models for plant layout design, process planning, production planning and scheduling; at the component level, models for the functional description of flexible manufacturing and assembly systems, and for the design of strategies for production activity control, process supervision, and maintenance. The Technical Committee is going on with the organization of Workshops and International Symposia under IFAC sponsorship. This volume collects some contributions from members of the IFAC Technical Committee on Manufacturing Modelling, Management and Control. We wish to thanks the members for their valuable contributions and the anonymous reviewers for their cooperation in making this book possible. The editors.

6 Contents o Modeling Manufacturing Systems: an Introduction P. Brandimarte, A. Villa 0.1 Introduction and overview of the contributions 0.2 For further reading 0.3 References From the Aggregate Plan to Lot-Sizing in Multi-level Production Planning J.-C. Hennet Introduction The planning process The Aggregate Planning Problem (APP) The detailed planning level The multi-stage planning problem The Lot-Sizing Problem Problem description A decomposed technique for cost evaluation Example Conclusion References Shop Floor Scheduling in Discrete Parts Manufacturing G.J. Meester, J.M.J. Schutten, S.L. van de Velde, W.H.M. Zijm 2.1 Introduction Basic decomposition approach. 2.3 Multi-resource scheduling Set-up times Convergent and divergent job routings 2.6 Further extensions and practical aspects Transportation times Unequal transfer and production batches Open shops JOBPLANNER Components of JOBPLANNER Practical experiences with JOB PLANNER. 2.8 Conclusions References.... Appendix A: Derivation of set-up jobs

7 viii Contents 3 Integrating Layout Design and Material Flow Management in Assembly Systems M.Lucertini, D.Pacciarelli, A.Pacifici Introduction Statement of the problem Problem data Decision variables A numerical example Problem statement Feasibility properties Feasibility graph Feasibility given 'IT" Feasibility given,\ Optimization properties Completion time minimization Cycle time minimization Part transfer minimization Conclusions References Appendix: proofs of theorems Proof of theorem Proof of theorem Proof of theorem Proof of theorem Proof of theorem Reactive Scheduling in Real Time Production Control E. Szelke, L. Monostori Reactive operation management - Predictive, reactive and proactive scheduling Objectives of reactive operation management - reactivej proactive scheduling Monitoring - A basis of RSjPS in real-time production control RS problem complexity - IT requirements against solution approaches Models of reactive and proactive scheduling problems Graphical modelling techniques Simulation Concurrent Modelling Language (CML) Graph theoretic modelling used for RS as a Constraint Satisfaction (CS) problem Neural network models Genetic algorithm based models Stochastic models of proactive scheduling Distributed agent architectures Solution approaches - methods, techniques, tools AI-based methods and heuristic search techniques of RS

8 Contents ix Combined methods of reactive scheduling 4.4 Conclusions: future research issues in the field. 4.5 References Simulation within CAD-Environment P. Kopacek, G. Kronreif, T. Perme Introduction Simulation and CAD Simulation system LASIMCO Formulation of requirements Conceptual solution and applied theory Developed tools Examples Simulation in robotics - ROMOBIL/SITAR Introduction Simulation system SITAR Modelling of robot cells in ROMOBIL Application example Conclusion References Model of Material Handling and Robotics C.- Y. Huang, S. Y. No! Introduction Traditional models of material handling and robotics Traditional approaches Concerns with traditional modeling approaches A Comparison of models of material handling and robotics with the tool perspective Facility Description Language (FDL) Concurrent Flexible Specifications (CFS) for material handling and robotics CFS using data/control flow diagram and Petri nets Overview of specification software tools Case study application Flexibility of specification Discussion and conclusion References A Simultaneous Approach for IMS Design: a Possibility Based Approach G. Perrone, S. Noto La Diega Introduction The decisional environment for Strategic IMS Design The Strategic IMS Design Decision-Making Tool: the possibilistic programming theory The possibilistic framework for strategic FMS design Market

9 x Contents Production Redditivity and risk Framework optimisation model 7.5 Numerical example 7.6 Conclusions 7.7 References... 8 Adaptive Production Control In Modern Industries K.N. McKay, J.A. Buzacott 8.1 Introduction Motivation - inherent uncertainty Applying production control methods - a perspective Production control Production control Production control Production control present. 8.4 Production control concepts for immaturity or uncertainty Organizational design Plan generation Plan execution 8.5 Conclusion Acknowledgments. 8.7 References

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