A hybrid shop-floor control system for food manufacturing

Moreno-Lizaranzu, Manuel J.; Wysk, Richard A.; Hong, Joonki; Prabhu, Vittaldas V.

doi:10.1080/07408170108936822

Cited by 5 publications

(5 citation statements)

References 5 publications

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“…The control approach attempts to control the planning, scheduling, and execution activities on the shop floor based on process planning. The previous approach was modified and applied with the aid of simulation to control hybrid manufacturing systems in MorenoLizaeanzu et al [17]. A distributed control approach has been also used for a manufacturing systems scheduling problem Ioannidis et al [12].…”

Section: Literature Reviewmentioning

confidence: 99%

Agile MPC system linking manufacturing and market strategies

Deif

ElMaraghy

2007

Journal of Manufacturing Systems

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a b s t r a c tIncreasing complexity and interdependency in manufacturing enterprises require an agile manufacturing paradigm. This paper considers a dynamic control approach for linking manufacturing strategy with market strategy through a reconfigurable manufacturing planning and control (MPC) system to support agility in this context. A comprehensive MPC model capable of adopting different MPC strategies through distributed controllers of inventory, capacity, and WIP is presented. A hierarchical supervisory controller (referred to as decision logic unit, DLU) that intakes the high-level strategic market decisions and constraints together with feedback of the current manufacturing system state (WIP, production, and inventory levels) and optimally manages the distributed controllers is introduced. The DLU architecture with its three layers and their different functionalities is discussed showing how they link the higher management level to the operational level to satisfy the required demand. A case study for an automatic PCB assembly factory is implemented to demonstrate the applicability of the whole approach. In addition, a comparative cost analysis study is carried out to compare between the developed agile MPC system and classical-inventory-and capacity-based MPC policies in response to different demand patterns. Results showed that the developed agile MPC policy is as cost effective as the inventory-based MPC policy in demand patterns with steady trends, as cost effective as capacity-based MPC in turbulent demand patterns, and far superior than both classical MPC polices in mixed-demand patterns.

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Section: Literature Reviewmentioning

confidence: 99%

Agile MPC system linking manufacturing and market strategies

Deif

ElMaraghy

2007

Journal of Manufacturing Systems

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“…Even though the solution inspired many research projects e.g. Moreno-Lizaranzu et al (2001), Ramakrishnan and Thakur (2005), Son and Wysk (2001), Son, Wysk, and Jones (2003), Mousavi et al (2007Mousavi et al ( , 2008Mousavi et al ( , 2011, Mousavi and Tavakoli (2009), Lee, Son, and Wysk (2007), Gupta et al (2002) and De Ugarte et al 2006but the solutions remained localised. To the best knowledge of the authors, a standard solution that could be implemented in day-to-day control of plants has never become available.…”

Section: Performance Evaluation and Performance Modellingmentioning

confidence: 99%

Automatic translation of plant data into management performance metrics: a case for real-time and predictive production control

Mousavi

Siervo

2016

International Journal of Production Research

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A scalable and repeatable solution for linking shop-floor control system to a discrete event simulation (DES) model is presented. The key objective is to automatically translate the real-time data from the control system (e.g. supervisory control and data acquisition, SCADA) into KPI transfer functions of the production process. Such a seamless translation allows for the integration of engineering data emitted at plant level to higher level information system for decision-making. The solution provides a platform for researchers and practitioners to utilise the capabilities of realtime DAQ and control with that of discrete event simulation to accurately measure the key manufacturing systems performance metrics. In addition to the real-time capabilities, the predictive capabilities of the solution provide the managers to look ahead and to conduct What-if scenarios. Such capability enables line management to optimise performance and predict destabilising factors in the system ahead of time. A fully operational version of the designed solution has been deployed in a brewery's live production system for the first time. The brewhouse production line model measures the utilisation of resources, Overall Equipment Effectiveness, and Overall Line Effectiveness in real-time and fast-forward mode simulation. The results of the predictive models (What-if-Scenarios) have been validated and verified by statistical means and direct observations. The accuracy of the estimated parameters is highly satisfactory.

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“…The above data aggregation concept is not unfamiliar to the well established Hierarchical Object-Oriented Design (HOOD) [10]. This structure forms the basis for the Flexible Data Input Layer of the data fusion concept in our generic methodology.…”

Section: Bmentioning

confidence: 99%

“…Reference [10] developed a hybrid shop floor control system for food manufacturing. They implemented National Instruments' Labview DAQ software and hardware in order to retrieve sensor data from an ice cream freezer process.…”

Section: Methodsmentioning

confidence: 99%

Flexible Data Input Layer Architecture (FDILA) for Quick-Response Decision Making Tools in Volatile Manufacturing Systems

Tavakoli

Mousavi

Komashie

2008

2008 IEEE International Conference on Communications

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Abstract-This paper proposes the foundation for a flexible data input management system as a vital part of a generic solution for quick-response decision making. Lack of a comprehensive data input layer between data acquisition and processing systems has been realized and thought of. The proposed FDILA is applicable to a wide variety of volatile manufacturing environments. It provides a generic platform that enables systems designers to define any number of data entry points and types regardless of their make and specifications in a standard fashion. This is achieved by providing a variable definition layer immediately on top of the data acquisition layer and before data pre-processing layer. For proof of concept, National Instruments' Labview data acquisition software is used to simulate a typical shop floor data acquisition system. The extracted data can then be fed into a data mining module that builds cost modeling functions involving the plant's

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A hybrid shop-floor control system for food manufacturing

Cited by 5 publications

References 5 publications

Agile MPC system linking manufacturing and market strategies

Agile MPC system linking manufacturing and market strategies

Automatic translation of plant data into management performance metrics: a case for real-time and predictive production control

Flexible Data Input Layer Architecture (FDILA) for Quick-Response Decision Making Tools in Volatile Manufacturing Systems

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