Simulation assisted optimization and real-time control aspects of flexible production systems subject to disturbances

Several types of production systems have been studied and researched in the past using either simulation and\or optimization methods. In this paper we describe the design and development of a simulation assisted predictive-reactive system for scheduling and rescheduling a typical flexible production system configuration. Aspects like the combined use of simulation and optimization to solve complex scheduling and rescheduling tasks are described in view of system stability and some of the broader production system elements like buffer sizing and material handling equipment. Results show that combining simulation and optimization for predictive scheduling resulted in better and valid performance measures for a typical example. Results also show that some newly addressed aspects of stability and real-time control can be handled efficiently using a combination of simulation and optimization. Our discussions only bolster the claim that simulation is an indispensable tool in managing complex production systems.