Tuesday 10 January 2012

Holonic Manufacturing - An Introduction

I want to introduce the concept of Holonic Manufacturing, as I believe Computer Integrated Manufacturing (CIM) will continue to move in this direction now that connectivity, interoperability and cloud-based networking are present. Areas of security, rules based systems and distributed architecture will be addressed in later blogs as we develop this Holonic theme.

HOLONIC MANUFACTURING

Manufacturing has changed a lot since its beginning, especially for the last decades. These changes are not only technology-related, but also concern the way customers interact with the manufacturing system, the environment that must be preserved, the shorter product's life-cycle, etc.

Until a few years ago, the Computer Integrated Manufacturing concept was considered satisfactory enough for treating enterprise/manufacturing requirements. However, taking into account a new set of organizational and economic concepts, it becomes clear that the centralized CIM approach is not the answer. On the contrary, the requirements for today's and future manufacturing systems suggest autonomy, distribution, and flexibility, while stressing the need for co-ordination amongst production units. It is expected that rigid, static and hierarchical manufacturing systems will give way to systems that are more adaptable to rapid change.
 
It is at this point that agent technology is adequate. An agent is an autonomous entity, maybe intelligent, that pursuits its own goals and, eventually, it may cater for the user's ones. Some authors would like to augment this definition in order to incorporate social ability, mental behavior (e.g. knowledge, beliefs, desires, and intentions), and learning.
 
A Multi-Agent System (MAS) is a population of agents that exhibit social behavior and are capable of interacting with each other in a co-operative fashion, while simultaneously each agent may pursue individual objectives. This interaction assumes some kind of communication language (e.g. KQML  and perception of the surrounding environment. The use of a multi-agent architecture will make the decisions be taken in a decentralized way.
 
Agent-based systems are "best suited for applications that are modular, decentralized, changeable, ill-structured and complex", and with a "great number of interactions among components".
 
On the other hand, a manufacturing system may be characterized by:
  • Its functions (e.g. production planning, production scheduling, inventory, etc.), which can be seen as modules;
  • As it was already referred, the traditional CIM centralized architecture is not satisfactory for today's manufacturing requirements; new manufacturing systems must be decentralized manufacturing systems;
  • Physically, a manufacturing system is based on resources (e.g. numeric control machines, robots, AGVs, conveyors). The number and configuration of these resources may change during the system's life time;
  • Since the manufacturing process is a dynamic one (e.g. suppliers and consumers in a supply chain may change many times) it is impossible to know the exact structure or topology of the system, thus being ill-structured;
  • The number of products and orders, as well as different alternative production routes, count for the highly complex nature of the manufacturing systems.
Therefore, it seems that a framework based on the principles which the Distributed Artificial Intelligence (DAI) and Multi-Agent Systems (MAS) paradigms were built on, appears as the most natural solution for the new generation of manufacturing systems. This methodology will allow the modelling of a system as a set of intelligent, autonomous and co-operative elements in order to achieve reconfigurable and extensible architectures.
 
On the manufacturing arena, these two paradigms (DAI and MAS) are best represented by the concept of Holonic Manufacturing Systems (HMSs). The idea behind HMSs is to provide a dynamic and decentralised manufacturing process, in which humans are effectively integrated, so that changes can be made dynamically and continuously.

As Agent-based Manufacturing relies on the notion of agent, HMSs are based on the notion of Holon. Arthur Koestler coined the term "Holon" from a combination of Greek holos (whole) with the suffix on which, as in proton or neutron, suggests a particle or part. A Holon means simultaneously a whole (to their subordinated parts) and a dependent part when seen from the inverse direction. Thus, a Holon can be made up of other holons.
 
This aggregation of holons inside other holons is called holarchy. An HMS is a holarchy that integrates the entire range of manufacturing activities from order booking through design, production, and marketing to achieve the agile manufacturing enterprise.

This article (and image) are quoted from a good resource paper on the Holonic Manufacturing subject (see http://sic.ici.ro/sic2000_2/art02.htm.) My source acknowledgement goes to:

Paulo Sousa & Carlos Ramos
Departamento de Engenharia Informática
Instituto Superior de Engenharia do Porto (ISEP/IPP)
Rua São Tomé, s/n, 4200 Porto,
Portugal

Wednesday 4 January 2012

MTConnect Needs/Usage Survey Results

A few weeks ago, I posted an MTConnect needs/usage survey and I thought I would list some of the preliminary results now. Here is a quick summary of the answers, for those that are interested:

1. What would you use MTConnect for?

Our answers found more or less equal interest in OEE, Machine Monitoring, Production Planning, Lights Out Manufacturing, Operator Management & Flexible Manufacturing Systems. I expected OEE and machine monitoring, but the others are interesting extensions that have been largely lacking on the factory floor probably due to their high cost and the complexity of previous solutions.

2. What is holding you back from adoption of MTConnect?

People answered that they didn't know what MTConnect was yet...

3. Do you have anything for real-time monitoring now?

Yes - but it looks like MTConnect will do a better job.

4. Do you have a DNC system?

All do...


5. Do you have LAN or WiFi on the factory floor now?

50% do and 50% don't


6. Talk further about this?

Yes - keep the conversation going - there is interest here...

Anyway, these are interesting results. It shows that MTConnect is still an unknown entity, but people are looking to use this for some substantial applications that up until now have been a challenge to successfully implement. The tracking of production is not quite the same as machine tool monitoring. MTConnect can basically enable quite a bit, but the real issue is connectivity. It always comes down to the value equation - what pay-back do you get for the investment in MTConnect. Obviously, more discussion is needed here - so we will make that happen this blog in future entries.

Happy New Year all...