Process Planning and Scheduling for Distributed Manufacturing

By: Lihui Wang (Editor), Weiming Shen (Editor)

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Hardcover | 15 May 2007

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Manufacturing has been one of the key areas that support and influence a nation's economy since the 18th century. Being the primary driving force in economic growth, manufacturing constantly serves as the foundation of and contributes to other industries with products ranging from heavy-duty machinery to hi-tech home electronics. In the past centuries, manufacturing has contributed significantly to modern civilisation and created momentum that is used to drive today's economy. Despite various revolutionary changes and innovations in the 20th century that contributed to manufacturing advancements, we are still facing new challenges when striving to achieve greater success in winning global competitions. Today, distributed manufacturing is unforeseeably coming into being due to recent business decentralisation and manufacturing outsourcing. Manufacturers are competing in a dynamic marketplace that demands short response time to changing markets and agility in production. In the 21st century, manufacturing is gradually shifting to a distributed environment with increasing dynamism. In order to win a competition, locally or globally, customer satisfaction is treated with priority. This leads to mass customisation and even more complex manufacturing processes, from shop floors to every level along manufacturing supply chains. At the same time, outsourcing has forged a multi-tier supplier structure with numerous small-- medium-sized enterprises involved, where highly-mixed products in small batch sizes are handled simultaneously in job-shop operations.

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List of Contributors	p. xvii
An Effective Approach for Distributed Process Planning Enabled by Event-driven Function Blocks	p. 1
Introduction	p. 1
Brief Literature Review	p. 2
Distributed Process Planning	p. 5
Fundamentals of DPP	p. 5
Basic Requirements	p. 6
System Architecture	p. 7
Enabling Technologies	p. 8
Decision Solutions for Supervisory Planning	p. 11
EMF for Machining Process Sequencing	p. 11
EMF Grouping	p. 14
EMF Sequencing	p. 15
Function Block Design	p. 18
Setup Merging and Monitoring	p. 22
Setup Merging	p. 23
Detailed Operation Planning	p. 25
Function Block Execution Control and Monitoring	p. 26
Conclusions	p. 27
References	p. 28
Web-based Polishing Process Planning Using Data-mining Techniques	p. 31
Introduction	p. 31
Literature Review	p. 33
Research Works in Polishing	p. 33
Web Application for Knowledge-based Planning	p. 33
Case-based Reasoning	p. 35
Fuzzy Modelling	p. 35
Genetic Algorithms	p. 36
GA-Fuzzy Systems	p. 36
Polishing Process Planning	p. 37
Purpose of Polishing Process Planning	p. 37
Design of Polishing Process Planning	p. 38
Web-based Portal System for Polishing	p. 40
Problem Definition	p. 41
Objectives	p. 41
Design of Web-based Portal System	p. 42
Implementation of Web-based Portal System	p. 45
Knowledge-base Development Methodology	p. 45
General Framework	p. 45
Case Study	p. 49
Results and Discussions	p. 55
Conclusions	p. 56
References	p. 57
Integration of Rule-based Process Selection with Virtual Machining for Distributed Manufacturing Planning	p. 61
Introduction	p. 61
IMPlanner Architecture	p. 62
Knowledge-based Process Selection	p. 64
Knowledge Representation	p. 64
Process Selection Rules	p. 67
Knowledge Base/Database	p. 71
Integration of Rule Execution Engine into IMPlanner	p. 72
Virtual Machining of Milling Operations	p. 72
Geometric Model	p. 73
Kinematic Model	p. 74
Animation Model	p. 76
Virtual Machining Scene Graph	p. 78
Integration Approaches	p. 80
Object Visualisation Paradigm	p. 80
Distributed Approach	p. 81
Integrated Application	p. 83
XML-based Web Distributed Application	p. 83
Case Study	p. 84
Related Research	p. 87
Conclusions	p. 88
References	p. 89
CyberCut: A Coordinated Pipeline of Design, Process Planning and Manufacture	p. 91
Introduction	p. 91
Conventional Approach	p. 92
Manufacturing-dependent CAD Systems	p. 93
Bidirectionally Coupled CAD Systems	p. 94
The CyberCut System	p. 95
Overview of the CyberCut System	p. 95
Definition of Features	p. 96
Architecture	p. 98
WebCAD	p. 99
Feature Recogniser	p. 99
Feature Validation	p. 100
Macroplanner and Setup Planner	p. 101
Microplanner	p. 101
Tool-path Planner	p. 104
Implementation and Results	p. 104
Conclusions	p. 106
References	p. 107
Process Planning, Scheduling and Control for One-of-a-Kind Production	p. 109
Introduction	p. 109
Literature Review	p. 113
Process Planning	p. 117
Long-term Process Planning	p. 117
Short-term Process Planning	p. 118
Process Control	p. 125
Adaptive Planning and Control	p. 127
Long-term Resource Planning	p. 131
Conclusions	p. 134
References	p. 135
Setup Planning and Tolerance Analysis	p. 137
Introduction	p. 137
Current State-of-the-art	p. 138
Manufacturing Planning System	p. 140
Feature-based Part Information Modelling	p. 140
Feature Manufacturing Strategy	p. 143
Machine Tool Capability Modelling	p. 144
Setup Planning	p. 144
Fixture Design in Computer-aided Manufacturing Planning	p. 146
Manufacturing Plan Generation	p. 147
Automated Setup Planning	p. 148
Graph Theory and Application in Setup Planning	p. 150
Feature Tolerance Relationship Graph (FTG)	p. 150
Datum and Machining Feature Relationship Graph (DMG)	p. 152
Automated Setup Planning	p. 153
A Case Study	p. 156
Information Modelling	p. 159
A Systematic Information Modelling Methodology	p. 159
Information Model of CAMP for Mass Customisation	p. 161
Summary and Discussions	p. 164
References	p. 165
Scheduling in Holonic Manufacturing Systems	p. 167
Introduction	p. 167
Background	p. 168
Holonic Systems	p. 168
Holonic Manufacturing Systems	p. 169
Applications of Holonic Manufacturing Systems	p. 170
An Approach: the Fabricare Holonic System	p. 172
General Description	p. 172
Description of Major Holons	p. 173
Negotiation Protocol	p. 176
A Prototype	p. 179
Experiments	p. 183
Conclusions	p. 185
References	p. 187
Agent-based Dynamic Scheduling for Distributed Manufacturing	p. 191
Introduction	p. 191
Complexity of Manufacturing Scheduling Problem	p. 192
Literature Review	p. 193
iShopFloor Framework	p. 195
Agent-based Dynamic Manufacturing Scheduling	p. 198
Agent Framework - AADE	p. 201
Proof-of-concept Prototypes	p. 203
Agent-based Dynamic Scheduling in iShopFloor	p. 203
Real-time Scheduling Service for Enterprise Collaboration	p. 204
Key Issues in Technology Deployment in Industry	p. 207
Conclusions and Future Work	p. 208
References	p. 210
A Multi-agent System Implementation of an Evolutionary Approach to Production Scheduling	p. 213
Introduction	p. 213
Background	p. 214
HMS Architectures and Scheduling	p. 214
Intelligent Job-shop Scheduling	p. 215
Implementing the Agent-based Scheduling System	p. 216
The Benchmark	p. 216
The System Architecture	p. 218
The Scheduling Algorithm	p. 219
Experiments	p. 225
Summary of the Experimental System	p. 225
Stochastic Scenario (Stage 2) Results	p. 229
Evolving the Mixed-heuristic Scheduler	p. 232
Conclusions	p. 237
References	p. 239
Distributed Scheduling in Multiple-factory Production with Machine Maintenance	p. 243
Introduction	p. 243
Literature Review	p. 246
Problem Background	p. 249
Optimisation Methodology: Genetic Algorithm with Dominant Genes	p. 253
Dominant Genes	p. 253
Encoding of Chromosome	p. 255
Dominant Genes Crossover	p. 256
Mutation Operator	p. 257
Elitist Strategy	p. 258
Prevention of Prematurity and Local Searching	p. 258
Example	p. 259
Conclusions	p. 264
References	p. 264
Resource Scheduling for a Virtual CIM System	p. 269
Introduction	p. 269
VCIM System	p. 270
VCIM Issues	p. 272
Need for a VCIM Architecture	p. 274
An Agent-based VCIM Architecture	p. 278
A Java Implementation Environment for a Multi-agent VCIM System	p. 280
Resource Scheduling with the VCIM Architecture	p. 283
Resource Scheduling in a VCIM System	p. 283
VCIM Resource Scheduling Process	p. 284
Conclusions	p. 291
References	p. 292
A Unified Model-based Integration of Process Planning and Scheduling	p. 295
Introduction	p. 295
Recently Related Works	p. 296
A Unified Model to Integrate Process Planning and Scheduling	p. 297
Simulated Annealing-based Optimisation Approach	p. 303
Case Studies and Discussions	p. 305
Conclusions	p. 307
References	p. 308
A Study on Integrated Process Planning and Scheduling System for Holonic Manufacturing	p. 311
Introduction	p. 311
Literature Review	p. 312
Process Planning for Holonic Manufacturing Systems	p. 313
Holonic Manufacturing Systems	p. 313
Integrated Process Planning and Scheduling	p. 315
Target System Configuration	p. 315
Process Planning by Job Holons	p. 317
Input Information	p. 317
Objective Functions	p. 318
Procedures Based on GA and DP	p. 320
Scheduling by Scheduling Holon	p. 323
Objective Functions	p. 323
Scheduling Method Based on GA and Dispatching Rules	p. 325
Process Plan Modification	p. 326
Case Studies	p. 328
Process Planning	p. 328
Verification of Dispatching Rules	p. 329
Verification of Process Plan Modification	p. 330
Conclusions	p. 332
References	p. 332
Managing Dynamic Demand Events in Semiconductor Manufacturing Chains by Optimal Control Modelling	p. 335
Introduction	p. 335
Problem Description	p. 339
Full-load Production Functions	p. 343
A Full-load Production Function Based on Alternative Routing	p. 346
A Dynamic System Model	p. 349
A Formulation of Optimal Control	p. 350
Closed Control Set	p. 354
Numerical Examples and Application	p. 356
Conclusions	p. 362
References	p. 362
A Parameter-perturbation Approach to Replanning Operations	p. 365
Introduction	p. 365
AHFM Approach	p. 366
AHFM for Production Planning	p. 367
Solution Approach to AHFM	p. 374
Scalability of AHFM	p. 379
Plan Perturbation due to New Customers Orders	p. 382
Estimation of New Order Cost	p. 382
New Order Insertion Case Study	p. 386
Extending the Applicability of AHFM	p. 389
Conclusions	p. 391
References	p. 391
STEP into Distributed Manufacturing with STEP-NC	p. 393
Introduction	p. 393
Impediments of Current CNC Technologies	p. 395
The STEP-NC Standard	p. 396
STEP-NC Implementation Methods	p. 398
Part 21 Physical File Implementation Method	p. 399
Data Access Implementation Methods	p. 400
XML Implementation Method (Part 28 Edition 1)	p. 401
XML Implementation Method (Part 28 Edition 2)	p. 402
Recap - Issues Concerning STEP-NC in XML Format	p. 402
Recent Research Publications	p. 403
A STEP-compliant CAPP System for Distributed Manufacturing	p. 403
System Model	p. 406
Native STEP-NC Adaptor and Native CNC Databases	p. 411
System Development	p. 412
Conclusions	p. 417
References	p. 419
Index	p. 423
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Process Planning and Scheduling for Distributed Manufacturing

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