AI helps factories design better production lines faster, cutting costly simulations
Researchers developed a machine learning system that predicts how manufacturing changes will affect production before costly real-world tests. The approach cuts design time for complex factories and could help manufacturers respond faster to demand swings and quality issues—a significant advantage in competitive sectors like marine engine production.
Originaltitel: Predictive model-based multi-objective optimization with life-long meta-learning for designing unreliable production systems
<p>Owing to the realization of advanced manufacturing systems, manufacturers have more flexibility in improving their processes through design decisions. Design decisions in production lines primarily involve two complex problems: buffer and resource allocation (B&RA). The main aim of B&RA is to determine the best location and size of buffers in the production line and optimally allocate production resources, such as operators and machines, to workstations. Inspired by a real-world case from the marine engine production industry, this study addresses B&RA in high-mix, low-volume hybrid flow shops (HFSs) with feed-forward quality inspection. These HFSs can be characterized by uncertainties in demand, material handling, processing times, and quality control. In this study, the production environment is modeled via discrete-event simulation, which reflects the features of the actual system without requiring unreasonable or restrictive assumptions. To replace the expensive simulation runs, five widely used regressor machine learning algorithms in manufacturing are trained on data sampled from the simulation model, and the best-performing algorithm is selected as the predictive model. To obtain high-quality solutions, the predictive model is coupled with an enhanced non-dominated sorting genetic algorithm (En-NSGA-II) that incorporates lifelong meta-learning and features a customized representation and a variable neighborhood search. Additionally, a post-optimality analysis using a pattern-mining algorithm is performed to generate knowledge for allocating buffers and operators based on the optimization results, thus providing promising managerial insights.</p>