RETRACTED: Data-driven model predictive control for real-time planned lead time optimization in a reconfigurable flow line

Abstract

Mass customization has enabled smart manufacturing systems to develop reconfigurable machines and fixtures to fulfill customized products with high process variety. Coupled with these reconfigurable components, diversified design and operational problems should be dealt with such that the efficiency of reconfigurations can be maximized. This paper investigates a planned lead time (PLT) optimization problem after addressing the pre-determined reconfigurations and real-time disruptions in a flow line. A data-driven model predictive control (d-MPC) is developed for this problem such that the total expected cost for work-in-process inventory, final-product inventory, and tardiness penalty can be minimized. Considering the predictive multi-stage transitions and reconfigurable behaviors, d-MPC utilizes max-plus algebra to generate a time-varying state-space equation for a flow line. In this regard, a systematic method for permanent production loss identification can be formulated for real-time disruption diagnosis. This identification is useful in providing feedback signals for d-MPC and thus a closed-loop feedback control for PLT optimization can be achieved. A case study of an industrial welding line is reported to illustrate the operational benefits of d-MPC. The results demonstrate that d-MPC can efficiently cooperate with PLT optimization with machine reconfiguration such that the total expected cost can be minimized. Compared with continuous re-optimization, d-MPC adopts an event-driven mechanism to respond to real-time disruptions and can decrease the nervousness of flow lines with lower operational costs.