Development of a Simulation-Based Intelligent Decision Support System for the Adaptive Real-Time Control of Flexible Manufacturing Systems

Babak Shirazi; Iraj Mahdavi; Maghsud Solimanpur

doi:10.4236/jsea.2010.37076

Journal of Software Engineering and Applications > Vol.3 No.7, July 2010

Development of a Simulation-Based Intelligent Decision Support System for the Adaptive Real-Time Control of Flexible Manufacturing Systems

Babak Shirazi, Iraj Mahdavi, Maghsud Solimanpur
DOI: 10.4236/jsea.2010.37076 PDF HTML 6,042 Downloads 11,490 Views Citations

Abstract

This paper describes a simulation-based intelligent decision support system (IDSS) for real time control of a flexible manufacturing system (FMS) with machine and tool flexibility. The manufacturing processes involved in FMS are complicated since each operation may be done by several machining centers. The system design approach is built around the theory of dynamic supervisory control based on a rule-based expert system. The paper considers flexibility in operation assignment and scheduling of multi-purpose machining centers which have different tools with their own efficiency. The architecture of the proposed controller consists of a simulator module coordinated with an IDSS via a real time event handler for implementing inter-process synchronization. The controller’s performance is validated by benchmark test problem.

Keywords

Intelligent Decision Support System, Real Time Control, Flexible Manufacturing System, Multi-Purpose Machining Centers

Share and Cite:

Shirazi, B. , Mahdavi, I. and Solimanpur, M. (2010) Development of a Simulation-Based Intelligent Decision Support System for the Adaptive Real-Time Control of Flexible Manufacturing Systems. Journal of Software Engineering and Applications, 3, 661-673. doi: 10.4236/jsea.2010.37076.

Conflicts of Interest

The authors declare no conflicts of interest.

References

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[2] J. R. Dixon, “Measuring Manufacturing Flexibility: An Empirical Investigation,” European Journal of Operational Research, Vol. 60, 1992, pp. 131-143.

[3] R. Jaikumar, “Flexible Manufacturing Systems: Manage- ment Perspective,” Division of Research, Harvard Business School, 1984.

[4] J. S. Edghill and A. Davies, “Flexible Manufacturing Systems—The Myth and Reality,” International Journal of Advanced Manufacturing Technology, Vol. 1, No. 3, 1985, pp. 37-54.

[5] M. D. Byrne and P. Chutima, “Real-Time Operational Control of an FMS with Full Routing Flexibility,” International Journal of Production Economics, Vol. 51, No. 2, 1997, pp. 109-113.

[6] Y. M. Moon, “Reconfigurable Machine Tool Design,” In: A. I. Dashchenko, Ed., Reconfigurable Manufacturing Systems and Transformable Factories, Springer, 2006, pp. 112-139.

[7] R. Tawegoum, E. Castelain and J. C. Gentina, “Real- Time Piloting of Flexible Manufacturing Systems,” Euro- pean Journal of Operational Research, Vol. 78, No. 2, 1994, pp. 252-261.

[8] K. E. Stecke and L. Kim, “A Flexible Approach to Part Type Selection in Flexible Flow Systems Using Part Mix Ratios,” International Journal of Production Research, Vol. 29, No. 1, 1991, pp. 53-75.

[9] C. Basnet and J. H. Mize, “Scheduling and Control of Flexible Manufacturing Systems: A Critical Review,” International Journal of Computer Integrated Manufacturing, Vol. 7, No. 6, 1994, pp. 340-355.

[10] J. Ayel, “Supervising Conflicts in Production Management,” International Journal of Computer Integrated Manufacturing, Vol. 8, No. 1, 1995, pp. 54-63.

[11] H. Seifoddini and J. Zhang, “Application of Simulation and Petri Net Modelling in Manufacturing Control Systems,” International Journal of Production Research, Vol. 34, No. 1, 1996, pp. 191-207.

[12] E. Szelke and L. Monostori, “Reactive Scheduling in Real-Time Production Control,” Modeling Manufacturing Systems, Springer, New York, 1999.

[13] Z. Guo, W. Wong, S. Leung, J. Fan and S. Chan, “A Genetic-Algorithm-Based Optimization Model for Scheduling Flexible Assembly Lines,” International Journal of Advanced Manufacturing Technology, Vol. 36, No. 1-2, 2006, pp. 156-168.

[14] D. J. Van der Zee, “Modeling Decision Making and Control in Manufacturing Simulation,” International Journal of Production Economics, Vol. 100, No. 1, 2006, pp. 155-167.

[15] F. T. S. Chan, R. Bhagwat and S. Wadhwa, “Comparative Performance Analysis of a Flexible Manufacturing System (FMS): A Review-Period-Based Control,” Interna- tional Journal of Production Research, Vol. 46, No. 1, 2006, pp. 1-24.

[16] G. Habchi and C. Berchet, “A Model for Manufacturing Systems Simulation with a Control Dimension,” Simulation Modelling Practice and Theory, Vol. 11, No. 1, 2003, pp. 21-44.

[17] B. P. Douglass, “Real-Time Design Patterns: Robust Scalable Architecture for Real-Time Systems,” Addison- Wesley, 2003.

[18] L. Yao, W. Browne, I. Postlethwaite, T. Ozen, P. Atack, M. Mar and S. Lowes, “Architecture for Intelligent Knowledge-Based Supervisory Control of Rolling Mills,” IFAC Workshop on New Technologies for Automation of Metallurgical Industry, Shanghai, China, 2003, pp. 162- 167.

[19] G. Guariso, M. Hitz and H. Werthner, “An Integrated Simulation and Optimization Modelling Environment for Decision Support,” Decision Support Systems, Vol. 16, No. 2, 1996, pp. 103-117.

[20] C. Gertosio, N. Mebarki and A. Dussauchoy, “Modeling and Simulation of the Control Framework on a Flexible Manufacturing System,” International Journal of Production Economics, Vol. 64, No. 1-3, 2000, pp. 285- 293.

[21] J. W. Fowler and O. Rose, “Grand Challenges in Modeling and Simulation of Complex Manufacturing Systems,” SIMULATION—Transactions of the Society for Modelling and Simulation International, Vol. 80, No. 9, 2004, pp. 469-476.

[22] F. T. S. Chan and H. Chan, “A Comprehensive Survey and Future Trend of Simulation Study on FMS Scheduling,” Journal of Intelligent Manufacturing, Vol. 15, No. 1, 2004, pp. 87-102.

[23] G. R. Drake, J. S. Smith and B. A. Peters, “Simulation as a Planning and Scheduling Tool for Flexible Manufacturing Systems,” Proceedings of the 1995 Winter Simulation Conference, 1995, pp. 805-812.

[24] F. T. S. Chan, H. K. Chan and H. C. W. Lau, “The State of the Art in Simulation Study on FMS Scheduling: A Comprehensive Survey,” International Journal of Advanced Manufacturing Technology, Vol. 19, No. 11, 2002, pp. 830-849.

[25] S. Chong, A. Sivakumar and R. Gay, “Simulation-Based Scheduling for Dynamic Discrete Manufacturing,” Proceedings of the 2003 Winter Simulation Conference, New Orleans, Louisiana, USA, 2003.

[26] R. W. Brennan and O. William, “Performance Analysis of a Multi-Agent Scheduling and Control System for Manufacturing,” Production Planning Control, Vol. 15, No. 2, 2004, pp. 225-235.

[27] R. Schelasin and J. Mauer, “Creating Flexible Simulation Models,” IEE Solutions, Vol. 5, 1995, pp. 50-67.

[28] A. Anglani, A. Grieco, M. Pacella and T. Tolio, “Object- Oriented Modeling and Simulation of Flexible Manufacturing Systems: A Rule-Based Procedure,” Simulation Modelling Practice and Theory, Vol. 10, No. 3-4, 2002, pp. 209-234.

[29] D. Arnott and G. Pervan, “A Critical Analysis of Decision Support Systems Research,” Journal of Information Technology, Vol. 20, No. 2, 2005, pp. 67-87.

[30] R. W. Brennan, “Towards Real-Time Distributed Intelligent Control: A Survey of Research Themes and Applications,” IEEE Transactions on Systems, Man, and Cybernetics, Vol. 37, No. 5, 2007, pp. 744-765.

[31] G. E. Vieira, J. W. Herrmann and E. Lin, “Rescheduling Manufacturing Systems: A Framework of Strategies, Policies, and Methods,” Journal of Scheduling, Vol. 6, No. 1, 2003, pp. 39-62.

[32] J. A. Ventura, F. F. Chen and C. H. Wu, “Grouping Parts and Tools in FMS Production Planning,” International Journal of Production Research, Vol. 28, No. 6, 1990, pp. 1039-1056.

[33] R. Beach, A. Muhlemann, D. Price, A. Paterson and J. Sharp, “A Review of Manufacturing Flexibility,” European Journal of Operational Research, Vol. 122, No. 1, 2000, pp. 41-57.

[34] P. Kouvelis, “An Optimal Tool Selection Procedure for the Initial Design Phase of a Flexible Manufacturing System,” European Journal of Operational Research, Vol. 55, No. 2, 1991, pp. 201-210.

[35] P. Tomek, “Tooling Strategies Related to FMS Management,” FMS Magazine, Vol. 4, 1986, pp. 102-107.

[36] D. Veeramani, D. Upton and M. Barash, “Cutting Tool Management in Computer Integrated Manufacturing,” The International Journal of Flexible Manufacturing Systems, Vol. 3, No. 4, 1992, pp. 237-265.

[37] M. Wahab, “Measuring Machine and Product Mix Flexibilities of a Manufacturing System,” International Journal of Production Research, Vol. 43, No. 18, 2005, pp. 3773-3786.

[38] J. Browne, D. Dubois, K. Rathmill, S. Sethi and K. Stecke, “Classification of Flexible Manufacturing Systems,” The FMS Magazine, Vol. 2, No. 2, 1984, pp. 114- 117.

[39] J. A. Buzacott, “The Fundamental Principles of Flexibility in Manufacturing Systems,” Proceedings of the 1st International Conference on Flexible Manufacturing Systems, 1982, pp. 13-22.

[40] S. K. Das and P. Nagendra, “Investigation into the Impact of Flexibility on Manufacturing Performance,” International Journal of Production Research, Vol. 31, No. 10, 1993, pp. 2337-2354.

[41] A. Gray, A. Seidmann and K. Stecke, “A Synthesis of Decision Models for Tool Management in Automated Manufacturing,” Management Science, Vol. 39, No. 5, 1993, pp. 549-567.

[42] N. Buyurgan, C. Saygina and E. Kilic, “Tool Allocation in Flexible Manufacturing Systems with Tool Alternatives,” Robotics and Computer-Integrated Manufacturing, Vol. 20, No. 4, 2004, pp. 341-349.

[43] S. C. Sarin and C. S. Chen, “The Machine Loading and Tool Allocation in a Flexible Manufacturing System,” International Journal of Production Research, Vol. 25, No. 7, 1987, pp. 1081-1094.

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[1]	J. A. Buzacott and D. D. Yao, “Flexible Manufacturing Systems: A Review of Analytical Models,” Management Science, Vol. 32, No. 7, 1986, pp. 890-905.
[2]	J. R. Dixon, “Measuring Manufacturing Flexibility: An Empirical Investigation,” European Journal of Operational Research, Vol. 60, 1992, pp. 131-143.
[3]	R. Jaikumar, “Flexible Manufacturing Systems: Manage- ment Perspective,” Division of Research, Harvard Business School, 1984.
[4]	J. S. Edghill and A. Davies, “Flexible Manufacturing Systems—The Myth and Reality,” International Journal of Advanced Manufacturing Technology, Vol. 1, No. 3, 1985, pp. 37-54.
[5]	M. D. Byrne and P. Chutima, “Real-Time Operational Control of an FMS with Full Routing Flexibility,” International Journal of Production Economics, Vol. 51, No. 2, 1997, pp. 109-113.
[6]	Y. M. Moon, “Reconfigurable Machine Tool Design,” In: A. I. Dashchenko, Ed., Reconfigurable Manufacturing Systems and Transformable Factories, Springer, 2006, pp. 112-139.
[7]	R. Tawegoum, E. Castelain and J. C. Gentina, “Real- Time Piloting of Flexible Manufacturing Systems,” Euro- pean Journal of Operational Research, Vol. 78, No. 2, 1994, pp. 252-261.
[8]	K. E. Stecke and L. Kim, “A Flexible Approach to Part Type Selection in Flexible Flow Systems Using Part Mix Ratios,” International Journal of Production Research, Vol. 29, No. 1, 1991, pp. 53-75.
[9]	C. Basnet and J. H. Mize, “Scheduling and Control of Flexible Manufacturing Systems: A Critical Review,” International Journal of Computer Integrated Manufacturing, Vol. 7, No. 6, 1994, pp. 340-355.
[10]	J. Ayel, “Supervising Conflicts in Production Management,” International Journal of Computer Integrated Manufacturing, Vol. 8, No. 1, 1995, pp. 54-63.
[11]	H. Seifoddini and J. Zhang, “Application of Simulation and Petri Net Modelling in Manufacturing Control Systems,” International Journal of Production Research, Vol. 34, No. 1, 1996, pp. 191-207.
[12]	E. Szelke and L. Monostori, “Reactive Scheduling in Real-Time Production Control,” Modeling Manufacturing Systems, Springer, New York, 1999.
[13]	Z. Guo, W. Wong, S. Leung, J. Fan and S. Chan, “A Genetic-Algorithm-Based Optimization Model for Scheduling Flexible Assembly Lines,” International Journal of Advanced Manufacturing Technology, Vol. 36, No. 1-2, 2006, pp. 156-168.
[14]	D. J. Van der Zee, “Modeling Decision Making and Control in Manufacturing Simulation,” International Journal of Production Economics, Vol. 100, No. 1, 2006, pp. 155-167.
[15]	F. T. S. Chan, R. Bhagwat and S. Wadhwa, “Comparative Performance Analysis of a Flexible Manufacturing System (FMS): A Review-Period-Based Control,” Interna- tional Journal of Production Research, Vol. 46, No. 1, 2006, pp. 1-24.
[16]	G. Habchi and C. Berchet, “A Model for Manufacturing Systems Simulation with a Control Dimension,” Simulation Modelling Practice and Theory, Vol. 11, No. 1, 2003, pp. 21-44.
[17]	B. P. Douglass, “Real-Time Design Patterns: Robust Scalable Architecture for Real-Time Systems,” Addison- Wesley, 2003.
[18]	L. Yao, W. Browne, I. Postlethwaite, T. Ozen, P. Atack, M. Mar and S. Lowes, “Architecture for Intelligent Knowledge-Based Supervisory Control of Rolling Mills,” IFAC Workshop on New Technologies for Automation of Metallurgical Industry, Shanghai, China, 2003, pp. 162- 167.
[19]	G. Guariso, M. Hitz and H. Werthner, “An Integrated Simulation and Optimization Modelling Environment for Decision Support,” Decision Support Systems, Vol. 16, No. 2, 1996, pp. 103-117.
[20]	C. Gertosio, N. Mebarki and A. Dussauchoy, “Modeling and Simulation of the Control Framework on a Flexible Manufacturing System,” International Journal of Production Economics, Vol. 64, No. 1-3, 2000, pp. 285- 293.
[21]	J. W. Fowler and O. Rose, “Grand Challenges in Modeling and Simulation of Complex Manufacturing Systems,” SIMULATION—Transactions of the Society for Modelling and Simulation International, Vol. 80, No. 9, 2004, pp. 469-476.
[22]	F. T. S. Chan and H. Chan, “A Comprehensive Survey and Future Trend of Simulation Study on FMS Scheduling,” Journal of Intelligent Manufacturing, Vol. 15, No. 1, 2004, pp. 87-102.
[23]	G. R. Drake, J. S. Smith and B. A. Peters, “Simulation as a Planning and Scheduling Tool for Flexible Manufacturing Systems,” Proceedings of the 1995 Winter Simulation Conference, 1995, pp. 805-812.
[24]	F. T. S. Chan, H. K. Chan and H. C. W. Lau, “The State of the Art in Simulation Study on FMS Scheduling: A Comprehensive Survey,” International Journal of Advanced Manufacturing Technology, Vol. 19, No. 11, 2002, pp. 830-849.
[25]	S. Chong, A. Sivakumar and R. Gay, “Simulation-Based Scheduling for Dynamic Discrete Manufacturing,” Proceedings of the 2003 Winter Simulation Conference, New Orleans, Louisiana, USA, 2003.
[26]	R. W. Brennan and O. William, “Performance Analysis of a Multi-Agent Scheduling and Control System for Manufacturing,” Production Planning Control, Vol. 15, No. 2, 2004, pp. 225-235.
[27]	R. Schelasin and J. Mauer, “Creating Flexible Simulation Models,” IEE Solutions, Vol. 5, 1995, pp. 50-67.
[28]	A. Anglani, A. Grieco, M. Pacella and T. Tolio, “Object- Oriented Modeling and Simulation of Flexible Manufacturing Systems: A Rule-Based Procedure,” Simulation Modelling Practice and Theory, Vol. 10, No. 3-4, 2002, pp. 209-234.
[29]	D. Arnott and G. Pervan, “A Critical Analysis of Decision Support Systems Research,” Journal of Information Technology, Vol. 20, No. 2, 2005, pp. 67-87.
[30]	R. W. Brennan, “Towards Real-Time Distributed Intelligent Control: A Survey of Research Themes and Applications,” IEEE Transactions on Systems, Man, and Cybernetics, Vol. 37, No. 5, 2007, pp. 744-765.
[31]	G. E. Vieira, J. W. Herrmann and E. Lin, “Rescheduling Manufacturing Systems: A Framework of Strategies, Policies, and Methods,” Journal of Scheduling, Vol. 6, No. 1, 2003, pp. 39-62.
[32]	J. A. Ventura, F. F. Chen and C. H. Wu, “Grouping Parts and Tools in FMS Production Planning,” International Journal of Production Research, Vol. 28, No. 6, 1990, pp. 1039-1056.
[33]	R. Beach, A. Muhlemann, D. Price, A. Paterson and J. Sharp, “A Review of Manufacturing Flexibility,” European Journal of Operational Research, Vol. 122, No. 1, 2000, pp. 41-57.
[34]	P. Kouvelis, “An Optimal Tool Selection Procedure for the Initial Design Phase of a Flexible Manufacturing System,” European Journal of Operational Research, Vol. 55, No. 2, 1991, pp. 201-210.
[35]	P. Tomek, “Tooling Strategies Related to FMS Management,” FMS Magazine, Vol. 4, 1986, pp. 102-107.
[36]	D. Veeramani, D. Upton and M. Barash, “Cutting Tool Management in Computer Integrated Manufacturing,” The International Journal of Flexible Manufacturing Systems, Vol. 3, No. 4, 1992, pp. 237-265.
[37]	M. Wahab, “Measuring Machine and Product Mix Flexibilities of a Manufacturing System,” International Journal of Production Research, Vol. 43, No. 18, 2005, pp. 3773-3786.
[38]	J. Browne, D. Dubois, K. Rathmill, S. Sethi and K. Stecke, “Classification of Flexible Manufacturing Systems,” The FMS Magazine, Vol. 2, No. 2, 1984, pp. 114- 117.
[39]	J. A. Buzacott, “The Fundamental Principles of Flexibility in Manufacturing Systems,” Proceedings of the 1st International Conference on Flexible Manufacturing Systems, 1982, pp. 13-22.
[40]	S. K. Das and P. Nagendra, “Investigation into the Impact of Flexibility on Manufacturing Performance,” International Journal of Production Research, Vol. 31, No. 10, 1993, pp. 2337-2354.
[41]	A. Gray, A. Seidmann and K. Stecke, “A Synthesis of Decision Models for Tool Management in Automated Manufacturing,” Management Science, Vol. 39, No. 5, 1993, pp. 549-567.
[42]	N. Buyurgan, C. Saygina and E. Kilic, “Tool Allocation in Flexible Manufacturing Systems with Tool Alternatives,” Robotics and Computer-Integrated Manufacturing, Vol. 20, No. 4, 2004, pp. 341-349.
[43]	S. C. Sarin and C. S. Chen, “The Machine Loading and Tool Allocation in a Flexible Manufacturing System,” International Journal of Production Research, Vol. 25, No. 7, 1987, pp. 1081-1094.