Skip to main content
Log in

The state of the art in intelligent real-time FMS control: a comprehensive survey

  • Published:
Journal of Intelligent Manufacturing Aims and scope Submit manuscript

Flexible manufacturing systems (FMS) have been developed with the hope that they would provide a means to tackle a threefold challenge — better quality, lower cost and shorter lead times — by integrating machine tools, robots, material handling and storage systems, and computers. Control of the integrated system presented a new set of problems as well as challenges, which have been receiving considerable attention from the academic community as well as from industrial system users. Intelligent control, which involves using computers to assist in decision making at various stages of the control process, has been advocated by many researchers as a possible avenue to reach a solution to these problems. This paper provides a review of the state of the art in intelligent control of FMS, in an attempt to supplement earlier general reviews via a more focused perspective. The principles of several techniques, namely simulation, knowledge based, example based, petri nets, and hybrid approaches are briefly introduced, and publications are reviewed, followed by discussions ontheir potential. Suggestions for further research and development are also enumerated.

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

Access this article

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

Instant access to the full article PDF.

Similar content being viewed by others

Bibliography

  • Aytug, H., Bhattacharya, S., Koehler, G. J. and Snowdon, J. L. (1994) A review of machine learning in scheduling. IEEE Transactions on Engineering Management, 41(2), 165–171.

    Google Scholar 

  • Basnet, C. and Mize, J. H. (1994) Scheduling and control of flexible manufacturing systems: a critical review. International Journal of Computer Integrated Manufacturing, 7(6), 340–355.

    Google Scholar 

  • Blackstone, J. H. Jr, Phillips, D. T. and Hogg, G. L. (1982) A state-of-the-art survey of dispatching rules for manufacturing job shop operations. International Journal of Production Research, 20(1), 27–45.

    Google Scholar 

  • Bu-Hulaiga, M. I. and Chakravarty, A. K. (1988) An object oriented knowledge representation for hierarchical real-time control of flexible manufacturing, International Journal of Production Research, 26(5), 777–793.

    Google Scholar 

  • Camurri, A., Franchi, P., Gandolfo, F. and Zacearia, R. (1993) Petri net based process scheduling: a model of the control system of flexible manufacturing systems. Journal of Intelligent and Robotic Systems, 8, 99–123.

    Google Scholar 

  • Chang, Y.-L., Sullivan, R. S. and Bagchi, U. (1985) Experimental investigation of real-time scheduling in FMS. Annals of Operations Research, 3, 355–377.

    Google Scholar 

  • Cheng, C. W., Sun, T. H. and Fu, L. C. (1994) Petri-net based modeling and scheduling of a flexible manufacturing system, in Proceedings of the IEEE International Conference on Robotics and Automation, pp. 513–518. IEEE, Piscataway, NJ.

    Google Scholar 

  • Cho, H. and Wysk, R. A. (1995) Intelligent workstation controller for computer-integrated-manufacturing: problems and models. Journal of Manufacturing Systems, 4(4), 252–263.

    Google Scholar 

  • Choi, J., Hitomi, K and Econ, P. (1994) A method of flexible scheduling for flexible manufacturing systems. International Journal of Production Economics, 33, 247–255.

    Google Scholar 

  • Choi, R. H. and Malstrom, E. M. (1988) Evaluation of traditional work scheduling rules in a flexible manufacturing system with a physical simulator. Journal of Manufacturing Systems, 7(1), 33–45.

    Google Scholar 

  • Choobineh, F. and Shivani, M. (1992) A dynamic process planning and scheduling algorithm, in Japan/USA Symposium on Flexible Automation, San Francisco, CA, 13–15 July, 1, pp. 429–432.

  • Chryssolouris, G., Pierce, J. E. and Cobb, W. (1989) A decision-making approach to the operation of FMS, in Proceedings of the Third ORSA/TIMS Conference on Flexible Manufacturing Systems, MIT, Cambridge, MA, 14–16 August, pp. 355–360.

    Google Scholar 

  • Chu, C. and Portmann M.-C. (1993) Job-shop scheduling to minimize total waiting time. Applied Stochastic and Data Analysis, 9, 177–185.

    Google Scholar 

  • Davis, W. J. and Jones, A. T. (1989) On-line concurrent simulation in production scheduling, in Proceedings of the Third ORSA/ TIMS Conference on Flexible Manufacturing Systems, MIT, Cambridge, MA, 14–16 August, pp. 253–258.

    Google Scholar 

  • Dhingra, J. S., Musser, K. L. and Blankenship, G. L. (1992) Realtime operations scheduling for flexible manufacturing systems, in Proceedings of the 1992 Winter Simulation Conference, IEEE, Piscataway, NJ, pp. 849–855.

    Google Scholar 

  • D'Souza, K. A. and Khator, S. K. (1994) A survey of petri net applications in modeling controls for automated manufacturing systems. Computers in Industry, 24(1), 5–16.

    Google Scholar 

  • Duan, N. and Kumara, S. R. T. (1993) A distributed hierarchical control model for highly autonomous flexible manufacturing systems, in Intelligent Autonomous Systems-3, Proceedings of the International Conference, Pittsburgh, PA, 15–18 February, pp. 532–541.

  • Duffie, N. A. and Piper R. S. (1987) Non-hierarchical control of a flexible manufacturing cell. Robotics and Computer Integrated Manufacturing, 3(2), 175–179.

    Google Scholar 

  • Duffie, N. A. and Prabhu, V V (1994) Real-time distributed scheduling of hetrarchical manufacturing systems. Journal of Manufacturing Systems, 13(2), 94–107.

    Google Scholar 

  • Dupont-Gatelmand, C. (1982) A survey of flexible manufacturing systems. Journal of Manufacturing Systems, 1(1), 1–16.

    Google Scholar 

  • Evans, G. W., Karwowski, W. and Wilhelm, M. R. (1989) Application of Fuzzy Set Methodologies in Industrial Engineering, Elsevier Science, Amsterdam, pp. 3–11.

    Google Scholar 

  • Ferreira, P. M., Menon, S. R. and Kapoor, S. G. (1991) Simulation and control of FMSs using a data-configurable colored petri net system, in Proceedings of the Winter Annual Meeting of the ASME, Planning and Control of Material Handling Systems, MH-1, pp. 67–83. ASME, New York.

    Google Scholar 

  • Fox, M. S. and Smith, S. F., (1984) ISIS: a knowledge-based system for factory scheduling. Expert Systems, 1(1), 25–49.

    Google Scholar 

  • Gentina, J. C. and Corbeel, D. (1987) Colored adaptive structured petri-net: a tool for the automatic synthesis of hierarchical control of flexible manufacturing systems, in IEEE International Conference on Robotics and Automation, 2, 1166–1173. IEEE, Piscataway, NJ.

    Google Scholar 

  • Gershwin, S. B., Hildebrant, R. R., Suri, R. and Mitter, S. K. (1986) A control perspective on recent trends in manufacturing systems. IEEE Control Systems Magazine, 4(4), 3–15.

    Google Scholar 

  • Gonzalez, A. J. and Dankel, D. D. (1993) The Engineering of Knowledge Based Systems, Prentice-Hall, Englewood Cliffs, NJ.

    Google Scholar 

  • Graves, S. C. (1981) A review of production scheduling. Operations Research, 29(4), 646–675.

    Google Scholar 

  • Gupta, Y. P., Gupta, M. C. and Bector, C. R. (1989) A review of scheduling rules in flexible manufacturing systems. International Journal of Computer Integrated Manufacturing, 2(6), 356–377.

    Google Scholar 

  • Haddock, J. (1988) A simulation generator for flexible manufacturing systems design and control. IIE Transactions, 20(1), 22–31.

    Google Scholar 

  • Hao, G., Shang, J. S. and Vargas, L. G. (1994) A neural network approach for real time control of a FMS, in Proceedings of the Twenty-Seventh Annual Hawaii International Conference on System Sciences, pp. 641–648. IEEE, Los Alamitos, CA.

    Google Scholar 

  • Harmonosky, C. M. and Robohn, S. R. (1991) Real-time scheduling in computer integrated manufacturing: a review of recent research. International Journal of Computer Integrated Manufacturing, 4(6), 331–340.

    Google Scholar 

  • Harmonosky, C. M. and Robohn, S. F. (1995) Investigating the application potential of simulation to real-time control decisions. International Journal of Computer Integrated Manufacturing, 8, 126–132.

    Google Scholar 

  • Hatono, I., Suzuka, T. and Umano, M. (1992) Toward intelligent scheduling for flexible manufacturing: application of fuzzy inference to realizing high variety of objectives, in Proceedings of the Japan/USA Symposium on Flexible Automation, 1, pp. 433–440. ASME, New York.

    Google Scholar 

  • Heikkila, A., Virtanen, T. and Majapuro, R. (1994) Modular control system with expert scheduling for flexible manufacture, in Proceedings of IEEE Conference on Control Applications, 3, pp. 1751–1754. IEEE, Piscataway, NJ.

    Google Scholar 

  • Hildebrant, R. R. and Suri, R. (1980) Methodology and multi-level algorithm structure for scheduling and real-time control of flexible manufacturing systems, in Proceedings of Third International Symposium on Large Engineering Systems, Memorial University of Newfoundland, Canada, July, pp. 1–6.

    Google Scholar 

  • Huang, H. P. and Chang, P. C. (1992) Specification, modeling and control of a flexible manufacturing cell. International Journal of Production Research, 30(11), 2515–2543.

    Google Scholar 

  • Huang, H. S. and Zhang, H.-C. (1994) Artificial neural networks in manufacturing: concepts, applications, and perspectives, IEEE Transactions on Components, Packaging, and Manufacturing Technology - Part A, 17(2), 212–228.

    Google Scholar 

  • IFAC (1984) Artificial intelligence in manufacturing. Computers in Industry, 5, 159.

    Google Scholar 

  • Jones, A., Rabelo, L. and Yih, Y. (1995) A hybrid approach for real-time sequencing and scheduling. International Journal of Computer Integrated Manufacturing, 8(2), 145–154.

    Google Scholar 

  • Joshi, S. B., Mettala, E. G. and Wysk, R. A. (1992) CIMGEN - a computer aided software engineering tool for development of FMS control software. IIE Transactions, 24(3), 85–97.

    Google Scholar 

  • Kachitvichyanukul, V., Cheng, S.-W. J. and Denzler, D. R. (1986) KBSIM: a knowledge based simulator for FMS scheduling and dispatching, in Proceedings of the Summer Simulation Conference, pp. 696–698. IEEE, Piscataway, NJ.

    Google Scholar 

  • Karabuk, S. and Sabuncouglu, I. (1993) A beam search based algorithm for scheduling machines and AGVs in a FMS, in Proceedings of the 2nd Industrial Engineeering Research Conference, Los Angeles, CA, 26–28 May, pp. 308–312.

  • Kim, M. H. and Kim, Y.-D. (1994) Simulation-based real-time scheduling in a flexible manufacturing system. Journal of Manufacturing Systems, 13(2), 85–93.

    Google Scholar 

  • Kohonen, T. (1988) An introduction to neural computing. Neural Networks, 1, 4.

    Google Scholar 

  • Kusiak, A. (1986) Application of operational research models and techniques in flexible manufacturing systems. European Journal of Operational Research, 24, 336–345.

    Google Scholar 

  • Kusiak, A. (1989) Scheduling automated manufacturing systems: a knowledge-based approach, in Proceedings of the Third ORSA/TIMS Conference on Flexible Manufacturing Systems, MIT, Cambridge, MA, 14–16 August, pp. 377–382.

    Google Scholar 

  • Law, A. M., Carson, J. S., Musselman, K. J., Fox, J. G., Halladin, S. K. and Ulgen, O. M. (1993) A forum on critical issues in the simulation of manufacturing systems, in Proceedings of the Winter Simulation Conference, pp. 916–922. IEEE, Piscataway, NJ.

    Google Scholar 

  • Lee, D. Y. and DiCesare, F. (1992) FMS scheduling using petri nets and heuristic search, in Proceedings of the IEEE International Conference on Robotics and Automation, Nice, France, pp. 1057–1062.

    Google Scholar 

  • Lefrancois, P. and Montreuil, B. (1994) An object-oriented knowledge representation for intelligent control of manufacturing workstations. IIE Transactions, 26(1), 11–26.

    Google Scholar 

  • Liang, M. and Dutta, S. P. (1993) An integrated approach to the part selection and machine loading problem in a class of flexible manufacturing systems. European Journal of Operational Research, 67, 387–404.

    Google Scholar 

  • Lin, L.-E. S. and Chung, S. L. (1986) A systematic FMS model for real-time on-line control and question-answer simulation using artificial intelligence, in Proceedings of the Second ORSA/TIMS Conference on Flexible Manufacturing Systems, Ann Arbor, MI, 12–15 August, pp. 567–579.

  • Maimon, O. Z. (1987) Real-time operational control of flexible manufacturing systems. Journal of Manufacturing Systems, 6(2), 125–136.

    Google Scholar 

  • Maley, J. G., Ruiz-Mier, S. and Solberg, J. J. (1988) Dynamic control in automated manufacturing: a knowledge integrated approach. International Journal of Production Research, 26(11), 1739–1748.

    Google Scholar 

  • Manivannan, S. and Banks, J. (1991) Real-time control of a manufacturing cell using knowledge-based simulation, in Proceedings of the Winter Simulation Conference, pp. 251–260. IEEE, Piscataway, NJ.

    Google Scholar 

  • Manivannan, S. and Banks, J. (1992) Design of a knowledge-based on-line simulation system to control a manufacturing shop floor. IIE Transactions, 24(3), 72–83.

    Google Scholar 

  • Masory, O. (1994) An integrated approach to simulation, control and real-time diagnostic of manufacturing systems based on adaptive augmented timed petri nets. Transactions of NAMRI/ SME, 22, 351–355.

    Google Scholar 

  • McConnell, P. G. and Medeiros, D. J. (1992) Real-time simulation for decision support in continuous flow manufacturing systems, in Proceedings of the Winter Simulation Conference, pp. 936–944. IEEE, Piscataway, NJ.

    Google Scholar 

  • O'Grady, P. and Lee, K. H. (1988) An intelligent cell control system for automated manufacturing. International Journal of Production Research, 26(5), 845–861.

    Google Scholar 

  • Panwalkar, S. S. and Iskander, W. (1977) A survey of scheduling rules. Operations Research, 25(1), 45–61.

    Google Scholar 

  • Rabelo, L. C. and Alptekin, S. (1989) Synergy of neural networks and expert systems for FMS scheduling, in Proceedings of the Third ORSA/TIMS Conference on Flexible Manufacturing Systems, MIT, Cambridge, MA, 14–16 August, pp. 361–366.

    Google Scholar 

  • Raju, K. R. and Chetty, O. V K. (1993a) Priority nets for scheduling flexible manufacturing systems. Journal of Manufacturing Systems, 12(2), 326–340.

    Google Scholar 

  • Raju, K. R. and Chetty, O. V. K. (1993b) Addressing design and control issues of AGV-based FMSs with petri net aided simulation. Computer Integrated Manufacturing Systems, 6(2), 125–134.

    Google Scholar 

  • Ralston, P. A. S. and Ward, T. L. (1990) Fuzzy logic control of machining. Manufacturing Review, 3(3), 147–154.

    Google Scholar 

  • Ranky, P. G. (1992) Intelligent planning and dynamic scheduling of flexible manufacturing cells and systems, in Proceedings of the Japan/USA Symposium on Flexible Automation, 1, pp. 415–422. ASME, New York.

    Google Scholar 

  • Ravichandran, R. and Chakravarty, A. K. (1986) Decision support in flexible manufacturing systems using timed petri nets. Journal of Manufacturing Systems, 5(2), 89–101.

    Google Scholar 

  • Rodammer, E A. and White, K. P. (1988) A recent survey of production scheduling. IEEE Transactions on Systems, Man, and Cybernetics, SMC-18(6), 841–851.

    Google Scholar 

  • Rogers, P. and Gordon, R. J. (1993) Simulation for real-time decision making in manufacturing systems, in Proceedings of the Winter Simulation Conference, Los Angeles, CA, 12–15 December, pp. 866–874.

  • Sabuncuoglu, I. and Hommertzheim, D. L. (1989) Expert simulation systems – recent developments and applications in flexible manufacturing systems. Computers and Industrial Engineering, 16(4), 575–585.

    Google Scholar 

  • Sagi, S. R., Chen, F. F. and Wu, D. (1994) An intelligent real-time shop floor control system, in Proceedings of the Sixth International Conference on AI and Expert Systems Applications, Houston, TX, December, pp. 245–250.

  • Saleh, A., Odrey, N. G. and Wilson, G. R. (1991) Design and algorithmic implementation of a real-time controller for a manufacturing cell. Design, Analysis, and Control of Manufacturing Cells, PED-53, 205–229.

    Google Scholar 

  • Schroer, B. J. (1989) A simulation assistant for modeling manufacturing systems. Simulation, November, 201–206.

  • Seidmann, A. and Schweitzer, P. J. (1983) Real-time on-line control of a FMS cell, in Annual Industrial Engineering Research Conference Proceedings, pp. 562–563. IIE, Norcross, GA.

    Google Scholar 

  • Shaw, M. J. (1986) A pattern directed approach to FMS scheduling, in Proceedings of the Second ORSA/TIMS Conference on Flexible Manufacturing Systems, Ann Arbor, MI, 12–15 August, pp. 545–554.

  • Shaw, M. J. (1988) Knowledge-based scheduling in flexible manufacturing systems: an integration of pattern-directed inference and heuristic search. International Journal of Production Research, 26(5), 821–844.

    Google Scholar 

  • Shaw, M. J. and Whinston, A. B. (1989) An artificial intelligence approach to scheduling of flexible manufacturing systems. IIE Transactions, 21(2), 170–183.

    Google Scholar 

  • Shen, S. and Chang, Y.-L. (1986) An AI approach to schedule generation in a FMS, in Proceedings of the Second ORSA/ TIMS Conference on Flexible Manufacturing Systems, Ann Arbor, MI, 12–15 August, pp. 581–592.

  • Shih, H. M. and Sekiguchi, T. (1991) A timed petri net and beam search based on-line FMS scheduling system with routing flexibility, in Proceedings of the IEEE International Conference on Robotics and Automation, Sacramento, CA, April, pp. 2548–2553.

  • Smith, J. S. and Joshi, S. B. (1993) A formal model for shop floor control in automated manufacturing, in Proceedings of the Second Industrial Engineering Research Conference, 26–28 May, pp. 31–35. IIE, Norcross, GA.

    Google Scholar 

  • Smith, J. S., Wysk, R. A., Sturrock, D. T., Ramaswamy, S. E., Smith, G. D. and Joshi, S. B. (1994) Discrete event simulation for shop floor control, in Proceedings of the Winter Simulation Conference, Buena Vista, FL, 11–14 December, pp. 962–969.

  • Smith, M. L., Ramesh, R., Dudek, A. and Blair, E. L. (1986) Characteristics of US flexible manufacturing systems - a survey, in Proceedings of the Second ORSA/TIMS Conference on Flexible Manufacturing Systems, Ann Arbor, MI, August, pp. 477–485.

  • Sodhi, S. B., Askin, R. G. and Sen, S. (1994) A hierarchical model for control of flexible manufacturing systems. Journal of Operational Research Society, 45(10), 1185–1196.

    Google Scholar 

  • Solmo, J. and Watanabe, T. (1992) Intelligent scheduling of FMS: the optimization approach, in Japan/USA Symposium on Flexible Automation, ASME, 1, pp. 447–454. ASME, New York.

    Google Scholar 

  • Steffen, M. S. (1986) A survey of artificial intelligence based scheduling systems, in Proceedings of the Fall Industrial Engineering Conference, pp. 395–405. IIE, Norcross, GA.

    Google Scholar 

  • Subramanyam, S. and Askin, R. G. (1986) An expert systems approach to scheduling in flexible manufacturing systems, in Flexible Manufacturing Systems; Methods and Studies, Kusiak, A. (ed.), pp. 243–256. Elsevier, Amsterdam.

    Google Scholar 

  • Teltz, R. and Elbestawi, M. A. (1992) On the design of knowledge based control systems in manufacturing, in Proceedings of the Japan/USA Symposium on Flexible Automation, 2, pp. 1441–1446. ASME, New York.

    Google Scholar 

  • Tempelmeier, H. and Kuhn, H. (1993) Flexible Manufacturing Systems: Decision Support for Design and Operation, John Wiley & Sons, New York.

    Google Scholar 

  • Uzsoy, R., Lee, C.-Y. and Martin-Vega, L. A. (1994) A review of production planning and scheduling models in the semiconductor industry part II: shop-floor control, IIE Transactions, 26(5), 44–55.

    Google Scholar 

  • Valavanis, K. P., Ramaswamy, S. and Landry, S. P. (1994) Extended petri net-based modelling, analysis and simulation of an intelligent materials handling system. Journal of Intelligent and Robotic Systems, 10, 79–108.

    Google Scholar 

  • Watanabe, T., Tokumaru, H. and Hashimoto, Y. (1993) Job-shop scheduling using neural networks. Control Engineering Practice, 1(6), 957–961.

    Google Scholar 

  • Whitney, C. K. (1985) Control principles in flexible manufacturing. Journal of Manufacturing Systems, 4(2), 157–167.

    Google Scholar 

  • Wu, H.-J. and Joshi, S. B. (1994) Error recovery in MPSG- based controllers to shop floor control, in IEEE International Conference on Robotics and Automation, San Diego, CA, 8–13 May, pp. 1374–1379.

  • Wu, S.-Y. D. and Wysk, R. A. (1988) Multi-pass expert control system - a control/scheduling structure for flexible manufacturing cells. Journal of Manufacturing Systems, 7(2), 107–119.

    Google Scholar 

  • Wu, S.-Y. D. and Wysk, R. A. (1989) An application of discreteevent simulation to the on-line control and scheduling in flexible manufacturing. International Journal of Production Research, 27(9), 1603–1623.

    Google Scholar 

  • Wu, Z. (1992) Combining of expert system and simulator for FMS rescheduling, in Proceedings of the Japan/USA Symposium on Flexible Automation, 2, pp. 1127–1130. ASME, New York.

    Google Scholar 

  • Wysk, R. A., Smith, J. S., Joshi, S. B. and Pegden, C. D. (1994) Shop floor control for CIM, in Proceedings of the Third Industrial Engineering Research Conference, pp. 382–387. IIE, Norcross, GA.

    Google Scholar 

  • Young, R. E. and Rossi, M. A. (1988) Toward knowledge-based control of flexible manufacturing systems. IIE Transactions, 20(1), 36–43.

    Google Scholar 

  • Zadeh, L. A. (1988) Fuzzy logic. Computer, 21(4), 83–93.

    Google Scholar 

  • Zurawski, R. and Zhou, M. (1994) Petri nets and industrial applications: a tutorial. IEEE Transactions on Industrial Electronics, 41(6), 557–583.

    Google Scholar 

Download references

Author information

Authors and Affiliations

Authors

Rights and permissions

Reprints and permissions

About this article

Cite this article

Shukla, C.S., Frank Chen, F. The state of the art in intelligent real-time FMS control: a comprehensive survey. J Intell Manuf 7, 441–455 (1996). https://doi.org/10.1007/BF00122834

Download citation

  • Issue Date:

  • DOI: https://doi.org/10.1007/BF00122834

Keywords

Navigation