Skip to main content

Advertisement

SpringerLink
Log in

Design of integrated manufacturing planning, scheduling and control systems: a new framework for automation

  • Original Article
  • Published:
The International Journal of Advanced Manufacturing Technology Aims and scope Submit manuscript

Abstract

The automation and integration of manufacturing planning, scheduling and control functions have, for a long while, been targeted in computer-integrated manufacturing (CIM) and artificial intelligence (AI) approaches. Current systems, however, are human-based and they can only be characterised as decision support systems (DSS) rather than automated systems. Global competition and the need for improved responsiveness, particularly in low-volume, high-variety manufacturing industries, necessitate further integration and automation in planning, scheduling and control functions. We consider that, to achieve automation, the concepts and techniques from operations research (OR), control theory (CT), and computer science (CS) should be integrated, enriched and unified to provide a platform for automation. This paper presents a fresh perspective for understanding the design issues involved and proposes a new framework for the automation and integration of planning, scheduling and control functions. A fully automated flow shop production system is presented to illustrate the applicability of the new framework.

This is a preview of subscription content, log in via an institution to check access.

Access this article

Log in via an institution

Price excludes VAT (USA)
Tax calculation will be finalised during checkout.

Instant access to the full article PDF.

Institutional subscriptions

Similar content being viewed by others

References

  1. Abdelhameed MM, Tolbah FA (2002) Design and implementation of a flexible manufacturing control system using neural network. Int J Flex Manuf Systems 14(3):263–279

    Article  Google Scholar 

  2. Akella R (1990) Guest editorial. IEEE Trans Robot Autom 6(6):605–607

    Article  Google Scholar 

  3. Akturk MS, Ozkan S (2001) Integrated scheduling and tool management in flexible manufacturing systems. Int J Prod Res 39:(12):2697–2722

    Article  Google Scholar 

  4. Artiba A, Aghezzaf E-H (1997) An architecture of a multi-model system for planning and scheduling. Int J Comput Integr Manuf 10(5):380–393

    Article  Google Scholar 

  5. Askin RG, Standridge CR (1993) Modelling and analysis of manufacturing systems. Wiley, New York

    Google Scholar 

  6. Bai SX, Gershwin SB (1994) Scheduling manufacturing systems with work-in-process inventory control: multiple-part-type systems. Int J Prod Res 32(2):365–385

    MATH  Google Scholar 

  7. Bodington CE (1995) Planning, scheduling, and control integration in the process industries. McGraw-Hill, New York

    Google Scholar 

  8. Brandimarte P, Ukoviche W, Villa A (1995) Continuous flow models for batch manufacturing: a basis for a hierarchical approach. Int J Prod Res 33(6):1635–1660

    MATH  Google Scholar 

  9. Cervin A, Eker J, Bernhardsson B, Karl-Erik Årzén (2002) Feedback-feedforward scheduling of control tasks. Real-Time Syst 23(1–2):25–53

    Article  MATH  Google Scholar 

  10. Cho H (1993) An intelligent workstation controller for computer integrated manufacturing. PhD dissertation, University of Michigan, Ann Arbour, Michigan

  11. Choi BK, Kim BH (2002) MES (manufacturing execution system) architecture for FMS compatible to ERP (enterprise planning system). Int J Comput Integr Manuf 15(3):274–284

    Article  Google Scholar 

  12. Conway RW, Maxwell WL, Miller LW (1967) Theory of scheduling. Addison-Wesley, Reading, Massachusetts

    MATH  Google Scholar 

  13. Deb RK, Serfozo RF (1973) Optimal control of batch service queues. Adv Appl Prob 5(2):340–361

    Article  MATH  MathSciNet  Google Scholar 

  14. Devedzic V, Radovic D (1999) A framework for building intelligent manufacturing systems. IEEE Trans Syst Man Cybern C—Appl Rev 29(3):402–419

    Google Scholar 

  15. Fukunaga AS, Rabideau G, Chien S, Yan D (1997) ASPEN: a framework for automated planning and scheduling of spacecraft control and operations. In: Proceedings of the 4th International Symposium on AI, Robotics and Automation in Space (i-SAIRAS), Tokyo, Japan, July 1997

  16. Gershwin SB, Hildebrandt RR, Suri R, Mitter SK (1986) A control perspective on recent trends in manufacturing systems. IEEE Control Syst Mag 6(2):3–15

    Article  Google Scholar 

  17. Gershwin SB (1989) Hierarchical flow control: a framework for scheduling and planning discrete events in manufacturing systems. Proc IEEE 77(1):195–209

    Article  Google Scholar 

  18. Gershwin SB (1994) Manufacturing systems engineering. Prentice Hall, Englewood Cliffs, New Jersey

    Google Scholar 

  19. Gershwin SB (1999) Design and operations of manufacturing systems—the control-point policy. IIE Trans32(2):93–103

    Google Scholar 

  20. Ghez C (1991) Principles of neural science, 3rd edn. Elsevier, New York

    Google Scholar 

  21. Gong DC, Hsieh YW (1997) Conceptual design of a shop floor control information system. Int J Comput Integr Manuf 10(1–4):4–16

    Google Scholar 

  22. Grant H (1987) Controlling the shop floor. CIM Technology, November

  23. Haouba A, Xie X (1999) Flow control of multi-level assembly systems. Int J Comput Integr Manuf 12(1):84–95

    Article  Google Scholar 

  24. Ho YC (1989) Dynamics of discrete event systems. Proc IEEE 77(1):3–6

    Article  Google Scholar 

  25. Hsu C, Lester G, Spooner D, Rubenstein A (1994) Adaptive integrated manufacturing enterprises: information technology for the next decade. IEEE Trans Syst Man Cybern 24(5):828–837

    Article  Google Scholar 

  26. Ishii N, Talavage JJ (1991) A transient-based real-time scheduling algorithm in FMS. Int J Prod Res 29(12):2501–2520

    MATH  Google Scholar 

  27. Jackson JR (1963) Job shop-like queuing systems. Manage Sci 10:131–142

    Google Scholar 

  28. Kogan K, Khmelnitsky E (2000) Scheduling: control-based theory and polynomial-time algorithms, vol 43. Kluwer, Dordrecht, The Netherlands

    Google Scholar 

  29. Kusiak A (1990) Intelligent manufacturing systems. Prentice-Hall, Englewood Cliffs, New Jersey

    Google Scholar 

  30. Rajaram K, Jaikumar R (2002) An interactive decision support system for on-line process control. Eur J Oper Res 138(3): 554–568

    Article  MATH  Google Scholar 

  31. Leon VJ, Wu SD, Storer RH (1994) A game-theoretic control approach for job shops in the presence of disruptions. Int J Prod Res 32(6):1451–1476

    MATH  Google Scholar 

  32. Little D, Rollins R, Peck M, Porter JK (2000) Integrated planning and scheduling in the engineer-to-order sector. Int J Comput Integr Manuf 13(6):545–554

    Article  Google Scholar 

  33. Lu C (2001) Feedback control real-time scheduling. PhD thesis, Department of Computer Science & Electrical Engineering, University of Virginia, Charlottesville, Virginia

  34. Mckay KN, Safayeni RR, Buzacott JA (1988) Job-shop scheduling theory: what is relevant? Interfaces 18(4):84–90

    Article  Google Scholar 

  35. Mejabi OO, Singh N (1997) A framework for enterprise-wide integration. Int J Comput Integr Manuf 10(1–4):212–220

    Google Scholar 

  36. MESA (1997) MES explained: a high level vision. White paper 6, Manufacturing Execution Systems Association (MESA), Pittsburgh, Pennsylvania

  37. Monfared MAS, Steiner SJ (1995) Intelligent manufacturing systems: a case in production control. In: Proceedings of the 11th International Conference on Computer-Aided Production Engineering, London, UK, September 1995, pp 115–121

  38. Monfared MAS, Yang JB, Steiner SJ (1996) Field survey from experts: a perspective on automation of scheduling and control activities. Technical report, School of Manufacturing and Mechanical Engineering, the University of Birmingham, Birmingham, UK

  39. Monfared MAS (1997) A study of control algorithms for some classes of intelligent manufacturing systems. PhD dissertation, School of Manufacturing and Mechanical Engineering, the University of Birmingham, UK

  40. Monfared MAS, Steiner SJ (2000) Fuzzy adaptive scheduling and control systems. Fuzzy Set Syst 115(2):231–246

    Article  MATH  MathSciNet  Google Scholar 

  41. Monfared MAS, Yang JB (2004) Design of an intelligent manufacturing scheduling and control system using fuzzy logic: sensitivity analysis and parameter optimization. Int J Intell Fuzzy Syst 15(2):89–104

    MATH  Google Scholar 

  42. Monfared MAS, Yang JB (2005) Multilevel intelligent scheduling and control system for an automated flow shop manufacturing environment. Int J Prod Res 43(1):147–168

    Article  MATH  Google Scholar 

  43. Prabhu VV, Duffie NA (1999) Nonlinear dynamics in distributed arrival time control of heterarchical manufacturing systems. IEEE Trans Control Syst Technol 7(6):724–730

    Article  Google Scholar 

  44. Rogers RV, Whites KP (1991) Algebraic mathematical programming, and models of the deterministic job-shop scheduling problem. IEEE Trans Man Syst Cybern 21(3):693–697

    Article  Google Scholar 

  45. Roy D, Anciaux D (2001) Shop-floor control: a multi-agents approach. Int J Comput Integr Manuf 14(6):535–544

    Article  Google Scholar 

  46. Senehi MK, Kramer TR (1998) A framework for control architectures. Int J Comput Integr Manuf 11(4):347–363

    Article  Google Scholar 

  47. Shantikumar JG, Buzacott JA (1981) Open queuing network models of dynamic job shops. Int J Prod Research 19(3):255–266

    Google Scholar 

  48. Shobrys DE, White DC (2000) Planning, scheduling and control systems: why can’t they work together. PSE Conference, July 2000

  49. Suarez OA, Foronda JLA, Abreu FM (1998) Standard based framework for the development of manufacturing control systems. Int J Comput Integr Manuf 11(5):401–415

    Article  Google Scholar 

  50. Sun H, Frick J (1999) A shift from CIM to CHIM. Int J Comput Integr Manuf 12(5):461–469

    Article  Google Scholar 

  51. Suresh V, Chaudhuri D (1993) Dynamic scheduling—a survey of research. Int J Prod Econ 32(1):53–63

    Article  Google Scholar 

  52. Tata (2002) Manufacturing execution systems, a concept note. Tata Consultancy Services, India

  53. Trentesaux D, Pesin P, Tahan C (2000) Distributed artificial intelligence for FMS scheduling, control and design support. J Intell Manuf 11(6):573–589

    Article  Google Scholar 

  54. Wu B (2000) Manufacturing and supply systems management: a unified framework of systems design and operation. Springer, London

    Google Scholar 

  55. Wu B (2001) Strategy analysis and system design within an overall framework of manufacturing system management. Int J Comput Integr Manuf 14(3):319–341

    Article  Google Scholar 

  56. Zimmemann HJ (1988) Fuzzy mathematical programming. In: Vilaplana GP (ed) Investigacion Operativa Universidal del Parsvasco

  57. Zweben M, Fox M (1994) Intelligent scheduling. Morgan Kaufmann. Author’s response to the review of paper no. 10144

Download references

Acknowledgement

The authors sincerely appreciate the valuable insights and encouraging comments expressed by our two anonymous referees.

Author information

Authors and Affiliations

  1. School of Engineering, Alzahra University, Vanak St., Tehran, 1993891176, Iran

    M. A. S. Monfared

  2. Decision Sciences and Operations Management Group, Manchester Business School (East), The University of Manchester, P.O. Box 88, Manchester, M60 1QD, UK

    J. B. Yang

Authors
  1. M. A. S. Monfared
    View author publications

    You can also search for this author in PubMed Google Scholar

  2. J. B. Yang
    View author publications

    You can also search for this author in PubMed Google Scholar

Corresponding author

Correspondence to M. A. S. Monfared.

Rights and permissions

Reprints and permissions

About this article

Cite this article

Monfared, M.A.S., Yang, J.B. Design of integrated manufacturing planning, scheduling and control systems: a new framework for automation. Int J Adv Manuf Technol 33, 545–559 (2007). https://doi.org/10.1007/s00170-006-0476-8

Download citation

  • Received:

  • Accepted:

  • Published:

  • Issue Date:

  • DOI: https://doi.org/10.1007/s00170-006-0476-8

Keywords

Search

Navigation