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Risultati finali
The Static Scheduler Module developed within the IS-OPTIMUS project attempts to make up for the shortfalls of traditional production plans, which are mainly derived from the complexity of the problem, an ever changing production environment and a non-existent optimum solution. This module allows the user to generate a plan that satisfies all the manufacturing constraints, taking into account the available resources in the factory. On the other hand, the system provides several rules to the user, so he can select the most suitable one for generating the schedule in order to obtain a plan according to the goals defined in each factory. The static scheduler will anticipate short term planning operations in two stages:
-Static: Firstly, a manufacturing plan is created, based on the existing restrictions, available resources and goals to reach, which is composed by the set of operations to be accomplished by each assigned machine, placed in a time frame and in order.
-Interactive: A graphic presentation of the plan is provided, where it will be possible to make modifications such as the movements in the time frame of the same machine, with various different reaction policies due to the inconsistencies generated by such actions.
The use of SOAP technique platform for the communication between the client and the server sides of the Shop Floor Data Capture module has permitted us to know better this technique for potential analysis, studies and design of future projects, and in the meantime to optimise the performances of our module in IS-OPTIMUS system. This choice is been made thinking also about the possible future developments of the system, because SOAP is the emerging standard for application communication (the Microsoft .NET framework web services are totally based on SOAP messages managing XML streams through http). The adoption of the WEB platform over the main functions of the data capture allows to system to catch the followings main important distinctiveness:
-From the technical point of view it permits to minimise the software installations in the clients at the shop floor (in fact it is sufficient only the installation of a common browser, that is MS Internet Explorer or Netscape Communicator, beyond to the client side of the Shop Floor Data Capture module);
-From the commercial point of view the WEB based characteristic gives to the system an important and strategic distinctive mark respect to the others concurrencies products.
The Material Optimisation module developed within the IS-OPTIMUS allows the user to generate the best cutting pattern solution for the material in question, minimising waste, and with appropriate regard to other enterprise specific constraints (due date, material cost, customer priority, delivery schedules, capacity, resources available). The material optimisation module functions within the general IS-OPTIMUS system as follows. A Master Production Schedule is generated based on the static or dynamic schedule. A manufacturing order release status will inform the user of the number of orders available to the optimiser and the line items to be included as well as the material or stock available to optimise. The jobs to be processed are organised and run through the material optimiser to prepare a cutting solution for each board type. The solution is determined from the available stock. The board types are assessed and the waste is evaluated. The cutting pattern solution can be viewed, reviewed, accepted/rejected and printed. The user can use the material optimiser in an interactive manner. For example should the waste on any particular board exceed a critical point the cutting pattern can be viewed to determine the nature of the waste. If the waste is of a shape that can be used again, the program is accepted. However, if the waste is excessive and of a nature that cannot be re-used then line items of a similar material are combined and included in the spatial optimisation software to attempt to reduce or re-structure the waste. The loop is continued until either the system operator determines no better solution can be found or the waste is reduced under the critical point. The cutting solution is printed out onto an A4 sheet outlining the arrangement of each sheet type and the line items to be cut from it.
The General IS-OPTIMUS system is composed of several software components that have been integrated in one application. This application provides finite capacity scheduling capabilities (both off-line and real-time) for discrete manufacturing production and material optimisation for 2D cutting operations. These software components address general industrial user requirements and can be exploited as basic components for the development of new application in other industrial and services market sectors. For instance these software components may be reused to address the following market sectors:
- Manufacture of plastic products
- Manufacture of tubes
- Manufacture of fabricated metal products
- Manufacture of machinery and mechanical equipment
- Automotive
- Aeronautics
- Furniture
- Packaging industry
Most of the partners involved in the project have contributed to the development of this set of components, which have been designed in the aim of working together but also as independent applications. Although these software components need to be modified in order to address a new market sector, the modular and open approach followed during the design and development phases assure an easy reuses of them.
The Dynamic Scheduling Module (DS) developed within the IS-OPTIMUS project aims to solve possible conflicts derived from deviations between the assumptions made by off-line production schedules and real data, either coming from the shop floor, or requested by the user. Nowadays, these deviations are usually fixed either manually or through costly re-planning processes, but these approaches often lead to long production stoppages diminishing productivity. In short, the main function of the DS is to provide reaction to some real-time exceptions, thus deriving in solutions of higher performance. Once a production schedule is launched to the shop floor, this module will supervise it. In practice, although traditional scheduling systems work with highly idealized conditions including permanent availability of resources or stability of production orders, disruptions are frequent (e.g. changes in production orders, machine breakdowns, material shortage, or absence of operator). If an off-line generated schedule is affected by some unforeseen events arising during the production stage leading to insurmountable conflicts, the DS will try to repair the original production schedule. Since during the off-line operation time is not such critical issue, more attention can be given to optimality goals, but the DS will make use of scheduling strategies of low computational cost, for the sake of timeliness.
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