Cloud-based Integrated Shop-floor Planning and Control of Manufacturing Operations for Mass Customisation

Abstract

The shift of traditional mass producing industries towards mass customisation practices is nowadays evident. However, if not implemented properly, mass customisation can lead to disturbances in material flow and severe reduction in productivity. This paper discusses the design and development of a Cloud-based production planning and control system for discrete manufacturing environments, referred to as i-MRP. The proposed approach takes into consideration capacity constraints, lot sizing and priority control in a 'bucket-less' manufacturing environment. The i-MRP system offers simultaneous shop scheduling and material planning, where material and capacity constraints are considered together in a continuous time environment. A number of feasible alternative shop schedules and material plan combinations are formed and are evaluated on the Cloud platform where the i-MRP engine is hosted. The Cloud platform enables mobility, since it is device and location independent, as well as it minimises the cost of IT infrastructure ownership, which is especially important for SMEs. The performance of the i-MRP system has been studied in an SME from the textile sector, using real production data. The system demonstrates high performance in cases of short production times, high value inventory and frequent, small deliveries by suppliers. The i-MRP can be easily integrated with legacy IT systems as an interfaced functional module under the Software as a Service (SaaS) architecture.

Design for Additive Manufacturing: Trends, opportunities, considerations, and constraints

“…The direct digital nature of AM combined with the use of cyber-physical systems will allow for cloud-based AM [186]. The benefits of cloud-based approaches have already been demonstrated in process optimization [320], adaptive process planning [235], shop-floor planning [234], scheduling [236], and maintenance [237]. The benefits of higher quality, hybrid, high DOF, cyber-physical, and cloud-based AM systems are expected to be emergent.…”

Technology enablers for the implementation of Industry 4.0 to traditional manufacturing sectors: A review

“…SMEs in traditional industries exploit the cloud infrastructure by planning and controlling the production line, mass customization, shop scheduling, material planning, and improvement of production efficiency; see (J. Liu et al, 2019;Mourtzis et al, 2015;Shang et al, 2018;Udayangani et al, 2019) and references therein. Regarding the seventh research question, cloud infrastructure upgrades small/medium enterprise model to an extended business model that includes IT technologies and smart services without the expense of an in-house acquisition (Abdollahzadegan et al, 2013;Zheng et al, 2017).…”

An integrated approach for multi-period manufacturing planning of job-shops

“…Liu et al (2011) reported an 'adaptive annealing GA' (AAGA) algorithm to deal with manufacturing planning problem of a job-shop. Mourtzis et al (2015) designed and developed i-MRP -a cloud-based manufacturing planning system for a discrete manufacturing environment. They considered capacity constraints, lot sizing and priority control in a continuous time environment.…”