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SMS : a Spinning Mill Simulator made in Swarm. Matteo Morini. http://www.labor-torino.it. Centre for Employment Studies “LABORatorio R. Revelli”. m.morini@labor-torino.it. GANTT DIAGRAM. Filatoio 4. Filatoio 3. Filatoio 2. Filatoio 1. 0. 5. 10. 15. 20.
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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
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
Production Constraints • Timely delivery • “Soft” technical constraints • “Hard” technical constraints SwarmFest 2002
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
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
Fitness evaluation (in-depth) • Delay costs • Setup costs • Misplacing order costs • Average count costs • Overlaying setups costs SwarmFest 2002
Fitness evaluation (in-depth) • Delay costs • Setup costs • Misplacing order costs • Average count costs • Overlaying setups costs SwarmFest 2002
Fitness evaluation(Delay & setup) Cost Total cost Delay ‘cost’ Setup cost Lot size SwarmFest 2002
1 to 3 days 4 to 8 days 9+ days Late deliveries’ ‘cost’ Cost Delay SwarmFest 2002
Cost (time) Rotor & Card substitution Card substitution Rotor substitution Perfect matching Set-up costs Set-up SwarmFest 2002
Fitness evaluation (in-depth) • Delay costs • Setup costs • Misplacing order costs • Average count costs • Overlaying setups costs SwarmFest 2002
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
Fitness evaluation (in-depth) • Delay costs • Setup costs • Misplacing order costs • Average count costs • Overlaying setups costs SwarmFest 2002
Average count costs ‘Cost’ Optimal average count Preceeding and subsquent departments saturation Preceeding and subsequent departments shortage Count SwarmFest 2002
Fitness evaluation (in-depth) • Delay costs • Setup costs • Misplacing order costs • Average count costs • Overlaying setups costs SwarmFest 2002
5 6 4 0 to 3 Overlapping (interfering)setup costs ‘Cost’ # simultaneous setups SwarmFest 2002
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
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
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
Solutions’ evolution graph SwarmFest 2002
SMS in action (w/GUI) SwarmFest 2002
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
SMS is ERA compliant SwarmFest 2002
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