A Data-Driven Simulation-Based Optimisation Approach for Adaptive Scheduling and Control of Dynamic Manufacturing Systems

Abstract

The increasing customisation of products, which leads to higher numbers of product variants with smaller lot sizes, requires a high flexibility of manufacturing systems. These systems are subject to dynamic influences and need increasing effort for the generation of the production schedules and for the control of the processes. This paper presents an approach that addresses these challenges. First, scheduling is done by coupling an optimisation heuristic with a simulation model to handle complex and stochastic manufacturing systems. Second, the simulation model is continuously adapted by real-time data from the shop floor. If, e.g., a machine breakdown or a rush order appears, the simulation model and consequently the scheduling model is updated and the optimisation heuristic adjusts an existing schedule or generates a new one. This approach uses real-time data provided by future cyber-physical systems to integrate scheduling and control and to manage the dynamics of highly flexible manufacturing systems.