TOC And Conwip/Pull Based Simulation And Optimization For Manufacturing Execution Control System

Manufacturing system control and optimization is the key to achieve enterprises and their production goals, Bottleneck resources which are the main factors to affect system resources, load balancing and production efficiency. To identify and effective control bottlenecks equipment on the production system, which is the important task for ensuring a smooth production system and improving the rate of orders for delivery to meet. Therefore, this paper studied the bottlenecks problem on Conwip /pull control system, proposed a control method on manufacturing systems bottleneck resources and manufacturing process optimization based on the Theory of Constraints (TOC), on the basis of simulation studies, it is given the optimization algorithm about circulation cards number in the integrated control system and bottleneck resource scheduling algorithm based on improved simulated annealing algorithm (VFSA). It has provided an indemnification to implement the system foe enterprises.Firstly, taking into account the problems in dealing with the system bottleneck in the Conwip / pull control system, the hybrid control system model is formulated with respect to DBR (Drum-Buffer-Rope) technique and a novel TOC based bottleneck resources discovery and scheduling mechanism is presented. After a detailed analysis of the integrated system control structure and operation mechanism, proposed Conwip / pull production control system based on TOC to identify bottlenecks processes.Secondly, most of the literatures has merely introduced or explained the concept of the hybrid model, the system parameters optimization or other related problem have not yet been studied in-depth. It is established an integrated control system based on discrete event system modeling and simulation and its various modules of the integrated control system simulation model. The optimal parameters allocation method is given about the circulation cards number and buffering coefficient of the integrated control system. Thirdly, taking into account the simulation system run-time is relatively long and in order to improve the efficiency of the simulation system, hence, it has adopted a fast simulated annealing algorithm (VFSA), which is proposed by Ingber to replace the traditional simulated annealing algorithm, make the improved simulated annealing algorithm embed into the simulation system, it greatly improved the efficiency of the system simulation and obtained the optimal solution.Finally, for the purpose of verifying the validity of above methods, simulations under witness environment were done and the comparison among the Conwip, Conwip/pull and integrated control system was given. The simulation results showed that the proposed hybrid system can solve the bottleneck problem effectively and enhanced the productivity of the system and reduced the delay time greatly by the TOC based novel bottleneck resources discovery and scheduling mechanism.