SMS : a Spinning Mill Simulator made in Swarm

1. SMS:a Spinning Mill Simulatormade in Swarm Matteo Morini http://www.labor-torino.it Centre for Employment Studies “LABORatorio R. Revelli” m.morini@labor-torino.it SwarmFest 2002

2. GANTT DIAGRAM Filatoio 4 Filatoio 3 Filatoio 2 Filatoio 1 0 5 10 15 20 Production management:the problem • Matching orders and production units (PU) • Appropriate sequencing of each chain • Who is supposed to do what AND in which sequence? SwarmFest 2002

3. Production Constraints • Timely delivery • “Soft” technical constraints • “Hard” technical constraints SwarmFest 2002

4. Solutions’ evaluation • Modelling the firm’s supply chain • Simulating the production process for each order • Accounting for: • Set-ups • Lead times • Technical similarity of products in a row • Speed of heterogeneous PUs SwarmFest 2002

5. Search for good production plans • GA (G. Ferraris’ Genetic Manipulator) • Each solution is coded in form of a binary string • The SCN model can evaluate each plan’s fitness in terms of –tC (minus total costs) SwarmFest 2002

6. Fitness evaluation (in-depth) • Delay costs • Setup costs • Misplacing order costs • Average count costs • Overlaying setups costs SwarmFest 2002

7. Fitness evaluation (in-depth) • Delay costs • Setup costs • Misplacing order costs • Average count costs • Overlaying setups costs SwarmFest 2002

8. Fitness evaluation(Delay & setup) Cost Total cost Delay ‘cost’ Setup cost Lot size SwarmFest 2002

9. 1 to 3 days 4 to 8 days 9+ days Late deliveries’ ‘cost’ Cost Delay SwarmFest 2002

10. Cost (time) Rotor & Card substitution Card substitution Rotor substitution Perfect matching Set-up costs Set-up SwarmFest 2002

11. Fitness evaluation (in-depth) • Delay costs • Setup costs • Misplacing order costs • Average count costs • Overlaying setups costs SwarmFest 2002

12. Misplaced orders costs • Different yarns need different bobbins • Cylinder-shaped, ready for dyeing • Cone-shaped, ready for weaving • Extremely urgent deliveries may end being made on the wrong kind of PU • Re-winding a certain amount of product has a known cost, epxressed in money/kg. SwarmFest 2002

13. Fitness evaluation (in-depth) • Delay costs • Setup costs • Misplacing order costs • Average count costs • Overlaying setups costs SwarmFest 2002

14. Average count costs ‘Cost’ Optimal average count Preceeding and subsquent departments saturation Preceeding and subsequent departments shortage Count SwarmFest 2002

15. Fitness evaluation (in-depth) • Delay costs • Setup costs • Misplacing order costs • Average count costs • Overlaying setups costs SwarmFest 2002

16. 5 6 4 0 to 3 Overlapping (interfering)setup costs ‘Cost’ # simultaneous setups SwarmFest 2002

17. The planner:evolution and working modes • RANDOM planner (1) • Explicit rules (failed attempt) (2) • Optimizing by Genetic Algorithms (3) • Applying a human-made program (4) SwarmFest 2002

18. Comparing results • Total costs obtained on test case: • (1): random 100.00 • (3): GA (5’ run) 68.75 • (3): GA (30’ run) 62.25 • (3): GA (6h run) 60.62 • (4): hand made by human planner 82.27 SwarmFest 2002

19. 5 2 1 8 10 2 7 3 11 6 9 3 4 Encoding sequences intobinary strings [8 1] [7 2] [4 3] [5 1] [3 2] [6 3] [2 1] [11 2] [9 3] • From base10 into base2 (using enough bits) [1000 01] [0111 10] [0100 11] [0101 01] [0011 10] [0110 11]... • Semantics is lost from the GA perspective 100001011110010011010101001110011011... SwarmFest 2002

20. Solutions’ evolution graph SwarmFest 2002

21. SMS in action (w/GUI) SwarmFest 2002

22. SMS’ batch mode: sms –b • EC grant (project Penelope): • Cordis Fifth Framework IST programme • http://www.cordis.lu/fp5/home.html • SMS to become part of a bigger framework • SMS as the engine of a web-based production planning service SwarmFest 2002

23. SMS is ERA compliant SwarmFest 2002

24. Matteo Morini m.morini@labor-torino.it http://www.labor-torino.it Centre for Employment Studies “LABORatorio R. Revelli” SMS:a Spinning Mill Simulatormade in Swarm SwarmFest 2002