APPLICATION OF IMPROVED PRODUCTION ACTIVITY CONTROL ARCHITECTURE FOR SHOP FLOOR INFORMATION SYSTEM IN DIGITAL MANUFACTURING

Shop floor control （SFC） is responsible for the coordination and control of the manufacturing physical and information flow within the shop floor in the manufacturing system. Weaknesses of the production activity control （PAC） architecture of the shop floor are addressed by the Maglica＇s new system architecture. This architecture gives rise to unlimited number of movers and producers thus evolving more complex but decentralized architecture. Beijing Institute of Technology - production activity control （BIT-PAC） architecture introduces an idea of sub-producars and sub-movers thus reducing the complexity of the architecture. All the equipments including sub-producars and sub-movers are considered to be passive in the proposed shop floor information system. The dissemination of information from sub-producers and sub-movers is done manually through a PC. Proposed BIT-PAC SFC architecture facilitates the information flow from shop floor to the other area of the organization. Effective use of interact information services （IIS） and SQL2000 is done along with the ASP.NET technology to implement the application logic. Applicability of the software based on BIT-PAC architecture is checked by running application software on a network PC that supports the dynamic flow of information from sub-producers and sub-movers to the other parts of the organization. Use of software is also shown at the end for BIT training workshop thus supporting the use of SFC architecture for similar kind of environments.

Geological characteristics and high production control factors of shale gas reservoirs in Silurian Longmaxi Formation, southern Sichuan Basin, SW China

Marine shale gas resources have great potential in the south of the Sichuan Basin in China.At present,the high-quality shale gas resources at depth of 2000–3500 m are under effective development,and strategic breakthroughs have been made in deeper shale gas resources at depth of 3500–4500 m.To promote the effective production of shale gas in this area,this study examines key factors controlling high shale gas production and presents the next exploration direction in the southern Sichuan Basin based on summarizing the geological understandings from the Lower Silurian Longmaxi Formation shale gas exploration combined with the latest results of geological evaluation.The results show that:(1)The relative sea depth in marine shelf sedimentary environment controls the development and distribution of reservoirs.In the relatively deep water area in deep-water shelf,grade-I reservoirs with a larger continuous thickness develop.The relative depth of sea in marine shelf sedimentary environment can be determined by redox conditions.The research shows that the uranium to thorium mass ratio greater than 1.25 indicates relatively deep water in anoxic reduction environment,and the uranium to thorium mass ratio of 0.75–1.25 indicates semi-deep water in weak reduction and weak oxidation environment,and the uranium to thorium mass ratio less than 0.75 indicates relatively shallow water in strong oxidation environment.(2)The propped fractures in shale reservoirs subject to fracturing treatment are generally 10–12 m high,if grade-I reservoirs are more than 10 m in continuous thickness,then all the propped section would be high-quality reserves;in this case,the longer the continuous thickness of penetrated grade-I reservoirs,the higher the production will be.(3)The shale gas reservoirs at 3500–4500 m depth in southern Sichuan are characterized by high formation pressure,high pressure coefficient,well preserved pores,good pore structure and high proportion of free gas,making them the most favorable new field for shale gas exploration;and the pressure coefficient greater than 1.2 is a necessary condition for shale gas wells to obtain high production.(4)High production wells in the deep shale gas reservoirs are those in areas where Long11-Long13 sub-beds are more than 10 m thick,with 1500 m long horizontal section,grade-I reservoirs penetration rate of over 90%,and fractured by dense cutting+high intensity sand injection+large displacement+large liquid volume.(5)The relatively deep-water area in the deep-water shelf and the area at depth of 3500–4500 m well overlap in the southern Sichuan,and the overlapping area is the most favorable shale gas exploration and development zones in the southern Sichuan in the future.With advancement in theory and technology,annual shale gas production in the southern Sichuan is expected to reach 450×108 m3.

An Improved Production Activity Control Architecture for Shop Floor Control

This paper presents a further improved Production Activity Control Architecture to deal with the complexity of information by creating Sub-Producers and Sub-Movers which will not only give a better control at workstation level but also reduce load on the Dispatcher. It also makes an analysis of the basic and improved PAC (Production Activity Control) Architecture in the Control System for Integrated Manufacturing. The PAC Architecture and the improvement will further enhance the flexibility and adaptability of the architecture in the ever changing environment of the Shop Floor Control (SFC) Systems.

Scheduling and control of failure prone systems with demand uncertainty and job overlaps

Given that the overlapping of jobs is permitted, the paper studies the scheduling and control of failure prone production systems, i.e. so-called settings with demand uncertainty and job overlaps. Because a variable demand resource is involved in the production and corrective maintenance control problems of the system, which switched randomly between zero and a maximum level, it is difficult to obtain the analytical solutions of the optimal single hedging point policy. An asymptotic optimal scheduling policy is presented and a double hedging point policy is offered to control simultaneously the production rate and the corrective maintenance rate of the system. The corresponding analytical solutions and approximate solutions are obtained. Considering the relationship of production, corrective maintenance and demand variable, an approximate optimal single hedging point control policy is proposed. Numerical results are presented.

Production Planning and Control of the Pipeline Assembly Enterprise under SCM

It is vital for pipeline assembly enterprise to respond to changing market needs quickly and keep its cost advantage. A production planning and control （PPC） model under supply chain management combining with operation characteristics of pipeline assembly enterprise was proposed. The present model can realize synchroni- zation in real-time response in production by establishing a win-win corporate model, classified regulation be- tween strategic parts and non-strategic parts, postponing the production of special modules and guaranteeing pro- duction at the bottleneck.

Productivity effect and overuse of pesticide in crop production in China

Chinese farmers are often accused of overusing pesticides that play a crucial role in enhancing crop yield by reducing losses to crop pests. Pesticide overuse has caused a series of negative health and environmental externalities. This paper quantiifes the productivity effect and the optimal amount of pesticides in rice, cotton and maize production in China from the economic perspective. Using survey data col ected in 2012 and 2013, both Cobb-Douglas and Weibul damage control speciifcations are used to estimate the production function. Results show that pesticides have statistical y signiifcant pro-ductivity effect on crop yield. On the condition of Weibul damage control speciifcations, the marginal products of 1 kg of the active ingredients of pesticides for rice, cotton and maize are 71.06, 22.73 and 98.45 kg, respectively. However, 57, 64 and 17%of the actual amount of pesticides are overused for rice, cotton and maize, respectively. Moreover, the productivity effect of pesticides would be overestimated using Cobb-Douglas speciifcation without incorporating a damage control agent.

RFID-based Production Data Analysis in an IoT-enabled Smart Job-shop

Under industry 4.0, internet of things(IoT), especially radio frequency identification(RFID) technology, has been widely applied in manufacturing environment. This technology can bring convenience to production control and production transparency. Meanwhile, it generates increasing production data that are sometimes discrete, uncorrelated, and hard-to-use. Thus,an efficient analysis method is needed to utilize the invaluable data. This work provides an RFID-based production data analysis method for production control in Io T-enabled smart job-shops.The physical configuration and operation logic of Io T-enabled smart job-shop production are firstly described. Based on that,an RFID-based production data model is built to formalize and correlate the heterogeneous production data. Then, an eventdriven RFID-based production data analysis method is proposed to construct the RFID events and judge the process command execution. Furthermore, a near big data approach is used to excavate hidden information and knowledge from the historical production data. A demonstrative case is studied to verify the feasibility of the proposed model and methods. It is expected that our work will provide a different insight into the RFIDbased production data analysis.

An Improved PAC Architecture for Shop Floor Information System in Digital Manufacturing

In order to overcome the weakness of the former production activity control （PAC） architecture, this paper presents an improved PAC architecture. The BIT-PAC architecture has been applied with the use of information technology. It facilitates the information flow from Shop Floor to other areas of the organization and makes the organizations more integrated and productive. This architecture also facilitates the expansion of the Shop Floor functions without disturbing the basic infrastructure. Effectiveness of the BIT-PAC architecture was checked by developing and running application software on a network PC which has supported the dynamic flow of information from Sub-Producers and Sub-Movers to other areas of organization.

Studies on Production Planning of Dispersion Type U3Si2-Al Fuel in Plate-Type Fuel Elements for Nuclear Research Reactors

Several fuel plants that supply nuclear research reactors need to increase their production capacity in order to meet the growing demand for this kind of nuclear fuel. After the enlargement of the production capacity of such plants, there will be the need of managing the new production level. That level is usually the industrial one, which poses challenges to the managerial staff. Such challenges come from the fact that several of those plants operate today on a laboratorial basis and do not carry inventory. The change to the industrial production pace asks for new actions regarding planning and control. The production process based on the hydrolysis of UF6 is not a frequent production route for nuclear fuel. Production planning and control of the industrial level of fuel production on that production route is a new field of studies. The approach of the paper consists in the creation of a mathematical linear model for minimization of costs. We also carried out a sensitivity analysis of the model. The results help in minimizing costs in different production schemes and show the need of inventory. The mathematical model is dynamic, so that it issues better results if performed monthly. The management team will therefore have a clearer view of the costs and of the new, necessary production and inventory levels.

Production Control of a Manufacturing System with Random Machine Breakdowns

We consider a serial production system with machine breakdowns, where the machine at each station alternates between up and down states with exponential up and down time distributions. To obtain insight about the optimal production strategy, we focus on one production station. Its production process (output) and that of the previous station (input) are modeled by point processes with stochastic intensities. Our objectives is to control both input and output intensities such that expected discounted profit is maximized. We show that the optimal control policy is of a threshold type which is characterized by two threshold values.When each station in the serial system has reliable machines, the well known Kanban production strategy, which was first developed in Toyota Motor Co. of Japan, is usually used to control the production process at each station. Our result in this paper implies that, among other things, the traditional Kanban control rule has to be modified if the production environment is random.

Shape Discrimination Analysis of Rolled Strip Based on Strip Element Method

Based on load-oriented manufacturing control theory, different combining modes and slab storage calculation method for continuous casting and hot rolling were discussed. The buffer capacity index of continuous casting-rolling was introduced, and the reasonable slab storage under different combining modes was calculated with buffer capacity index of 120.00 h for CCR, 79.20 h for HCR, 19.68 h for DHCR and 3.84 h for DR. Thin slab is 1.20 h, and the strip is zero. Theory gist was provided for steel enterprise to decrease storage.

PLANNED LEAD TIME OPTIMIZATION IN MATERIAL REQUIREMENT PLANNING ENVIRONMENT FOR MULTILEVEL PRODUCTION SYSTEMS

This paper deals with the problem of planned lead time calculation in a Material Requirement Planning （MRP） environment under stochastic lead times. The objective is to minimize the sum of holding and backlogging costs. The proposed approach is based on discrete time inventory control where the decision variables are integer. Two types of systems are considered： multi-level serial-production and assembly systems. For the serial production systems （one type of component at each level）, a mathematical model is suggested. Then, it is proven that this model is equivalent to the well known discrete Newsboy Model. This directly provides the optimal values for the planned lead times. For multilevel assembly systems, a dedicated model is proposed and some properties of the decision variables and objective function are proven. These properties are used to calculate lower and upper limits on the decision variables and lower and upper bounds on the objective function. The obtained limits and bounds open the possibility to develop an efficient optimization algorithm using, for example, a Branch and Bound approach. The paper presents the proposed models in detail with corresponding proofs and se＇~eral numerical examples. Some advantages of the suggested models and perspectives of this research are discussed.

A framework for ICT-enabled real-time production planning and control

This paper aims to develop a conceptual framework for real-time production planning and control（PPC）.Firstly,we discuss the most prominently applied contemporary information and communication technologies for PPC.Enterprise resource planning（ERP） systems that integrate the value chain in an enterprise,manufacturing execution systems that manage and control the production on shopfloor,and advanced planning and scheduling（APS）systems that develop solutions for complex planning problems are the planning and control systems that have been analyzed.We emphasize the application of radio frequency identification as the most advanced and promising emerging real-time data capture technology that is currently available to manufacturers.Having analyzed the features and shortcomings of the individual systems perse,and by considering the advantages that may be realized through effective integration of these otherwise discrete systems,we propose a framework for real-time PPC.

Slab Storage Calculation Method for Continuous Casting-Hot Rolling

Based on load-oriented manufacturing control theory,different combining modes and slab storage calculation method for continuous casting and hot rolling were discussed.The buffer capacity index of continuous casting-rolling was introduced,and the reasonable slab storage under different combining modes was calculated with buffer capacity index of 120.00 hfor CCR,79.20 hfor HCR,19.68 hfor DHCR and 3.84 hfor DR.Thin slab is 1.20 h,and the strip is zero.Theory gist was provided for steel enterprise to decrease storage.

Digital implementation and analysis of a high dynamic frequency tracking loop

In the wireless guidance system, the signals that receiver received has obvious Doppler shift for the high dynamic characteristic of the carrier. A new solution of carrier frequency tracking loop with frequency modifying system is put forward. The characteristic of cross product auto frequency control and the second order loop filter in this loop are analyzed. The simulation shows that this loop can accomplish frequency tracking well in high dynamic circumstance.

Rule based vs Optimization based Workload Control with and without Exogenous Lead Times:An Assessment by Simulation

Order release is a key production planning and control function,specifically in high variety contexts.A large literature on release methods that balance the workload consequently emerged.These Workload Control methods can be rule based,using a simple greedy heuristic,optimization based or optimization based with lead times that are exogenous.Although all three types of methods have the same objective,their performance has never been compared.Using simulation,this study shows that a better on time delivery performance of jobs can be achieved by the two optimization based release methods.Most importantly,optimization based methods that assume lead times to be exogenous significantly outperform alternative methods in terms of tardiness performance.Rule based and optimization based Workload Control without exogenous lead times overemphasize average lateness reduction,which leads to sequence deviations that offset performance improvements through balancing.In contrast,Workload Control methods that assume lead times to be exogenous limit sequence deviations,which leads to a significant reduction in dispersion of lateness.This has important implication for the future design of order release methods,and managerial practice.

How the SACI Control The Imported Auto Products

Generally speaking, all kinds of auto products (include motorcycle) exported to China shall pass the concerned certification sponsored by State Administration of Import & Export Commodity Inspection (SACI), the following is the procedure for

LOT SIZING WITH NON-ZERO SETUP TIMES FOR REWORK

In this paper we consider a single machine multi-product lot scheduling problem in which defective items are produced in any production run of each product. In each cycle after the normal production of each product the machine is setup for the rework of the defectives of the same product and then the rework process starts. We assume that the setup time for the normal production process as well as the rework process is non-zero. Further we consider the waiting time cost of defectives for rework. This paper has two objectives. The first objective is to obtain the economic batch quantity （EBQ） for a single product. The second objective is to extend the result of the first objective to the multi-product case. Adopting the common cycle scheduling policy we obtain optimal batch sizes for each product such that the total cost of the system per unit time is minimized.

The fit of Industry 4.0 applications in manufacturing logistics： a multiple case study

The fourth industrial revolution, Industry 4.0, is expected to cause disruptive changes in industrial produc- tion. It is driven by rapid technological developments and the need for manufacturing companies to make themselves independent of high labor costs. Industry 4.0 concerns several aspects of industrial production, including manu- facturing logistics, business models and products and ser- vices. The applications of Industry 4.0 have been vastly outlined. However, the fit of Industry 4.0 applications in different production environments is not clear. The purpose of this paper is to identify and investigate the Industry 4.0 technologies that are applicable to manufacturing logistics, and how the production environment influences the appli- cability of these technologies. This is done through a multiple case study of four Norwegian manufacturing companies. The findings from the study indicate that the applicability of Industry 4.0 in manufacturing logistics is dependent on the production environment. Companies with a low degree of production repetitiveness see less potential in applying Industry 4.0 technologies in manufacturing logistics, while companies with a highly repetitive pro- duction see a higher potential.

STEP-NC Based High-level Machining Simulations Integrated with CAD/CAPP/CAM

With the development of manufacturing,numerical control(NC) machining simulation has become a modern tool to obtain safe and reliable machining operations.Although some research and commercial software about NC machining simulations is available,most of them is oriented for G&M code.It is a low-level data model for computer numerical control(CNC),which has inherent drawbacks such as incomplete data and lack of accuracy.These limitations hinder the development of a real simulation system.Whereas,standard for the exchange of product data-compliant numerical control(STEP-NC) is a new and high-level data model for CNC.It provides rich information for CNC machine tools,which creates the condition for an informative and real simulation.Therefore,this paper proposes STEP-NC based high-level NC machining simulations solution integrated with computer-aided design/computeraided process planning/computer-aided manufacturing(CAD/CAPP/CAM).It turned out that the research provides a better informed simulation environment and promotes the development of modern manufacturing.