Date of Award

2019

Degree Type

Thesis

Degree Name

Master of Science in Systems Engineering

Department

Mechanical, Industrial and Systems Engineering

First Advisor

Manbir S Sodhi

Abstract

Today’s dilemma of realizing an efficient production schedule, minimizing downtime of a production system, and work overload for the production workers concerns almost every profit-oriented organization. Nowadays, manufacturers are faced with the challenge of providing a rich product variety at a low-cost level. Most companies have reacted to these disruptive changes by increasing internal flexibility and accelerating business processes. The growing penetration of advanced planning and scheduling systems, as well as the use of innovative and smart technology, promises synergy effects of combining physical and computational aspects of a manufacturing system.

This paper proposes a cyber-physical production system utilizing the communication technology of Radio Frequency Identification. Moreover, the philosophy of lean manufacturing is examined. The traditional Kanban concept, which is an essential part of a Just-in-time production, implies desirable characteristics enabling lean production. These assets are considered in the development of a flow shop production scenario. As a significant part of research in job scheduling, the particular problem of non-permutation flow shop scheduling is examined and applied to the scenario. With Radio Frequency Identification as an enabler of real-time information availability and the exploitation of valuable characteristics of a Kanban system, a mixed integer program is applied to use the bundled data and allow the generation of knowledge to install a production steering mechanism.

The efficient assignment of n jobs to m machines is a complex and widely discussed topic. As an essential part of a complete cyber-physical production system, feedback loops improve the system’s capacity to act in challenging situations such as machine delays or undesired machine idle time. At that, the technical enrichment through Radio Frequency Identification technology as well as the consideration of lean aspects deriving from the original Kanban philosophy, enable a flexible reschedule of the flow shop sequence in order to optimize the makespan of the production system proposed. This study conducts a simulation of several situation-based schemes and compares the efficiency between a reschedule with or without the integration of a flexible, real-time enabled feedback loop.

Available for download on Friday, July 31, 2020

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