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Potential Applicability of Intelligent P&S in Production & Logistics

Potential Applicability of Intelligent P&S in Production & Logistics. Prof. dr. Tim Grant Atos Origin Nederland / University of Pretoria, RSA Tim.Grant@atosorigin.com / tgrant@cs.up.ac.za. Overview. Goal:

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Potential Applicability of Intelligent P&S in Production & Logistics

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  1. Potential Applicability of Intelligent P&S in Production & Logistics Prof. dr. Tim Grant Atos Origin Nederland / University of Pretoria, RSA Tim.Grant@atosorigin.com / tgrant@cs.up.ac.za PLANET Bilbao I-day

  2. Overview • Goal: • To identify industrial sectors & activities that can benefit from intelligent planning & scheduling • Structure: • Introduction • What is IP&S • Industrial sectors & activities • IP&S features & benefits • Key case studies in production & logistics • IP&S products & services PLANET Bilbao I-day

  3. Introducing myself • Qualifications: • BSc Aeronautical Engineering, Univ. Bristol, UK • Chartered Engineer, UK • PhD Artificial Intelligence, Univ. Maastricht, NL • Experience: • 1966-87: Royal Air Force officer • UK & Singapore: Aircraft maintenance & logistics • 1987-date: Principal Consultant, Atos Origin • NL: Aerospace, defence, motorway traffic control • 2001-date: Professor Extraordinary, Univ. Pretoria • RSA: Advanced ICT in Planning & Control PLANET Bilbao I-day

  4. Introducing Atos Origin http://www.atosorigin.com\ • Atos Origin: • Leading European IT services supplier: • 28K staff worldwide (50K from 1 Jan 04) • 50% Dutch (Origin), 50% French (Atos) • Financially stable • Technical Automation (TA) business unit: • Co-creating next-generation of intelligent, software-intensive systems & products together with our clients • In Utrecht (NL): • Aerospace, Defence, Road & Rail Traffic, Telecoms • In Veldhoven (NL): • Consumer & industrial electronics, Semiconductors, Medical equipment, Document processing PLANET Bilbao I-day

  5. Introducing University of Pretoria • University of Pretoria (“Tukkies”): • Front-rank South African university • Computer Science: • Java, .NET, AI • Swarm intelligence • Information & computer security • Risk management • My research interests: • Decentralised planning & control • Generation of Standard Operating Procedures • Mixed-initiative, collaborative planning • Dynamic risk management http://www.cs.up.ac.za\ PLANET Bilbao I-day

  6. Machining Raw materials Product Planning & Scheduling Monitoring & Control Schedule Current state & past experience Sensor data Instructions What is IP&S (1) Need Requirements Specification Design Design Production Products Usage Obsolete products Decommission PLANET Bilbao I-day

  7. Planning & Scheduling Monitoring & Control Schedule Current state & past experience Sensor data Instructions Loading, driving & unloading Package at A Package at B What is IP&S (2) Transportation & logistics PLANET Bilbao I-day

  8. Domain knowledge (in human planner’s head) Domain Planning & Scheduling Monitoring & Control Schedule Current state & past experience What is IP&S (3) Generalising: Goals / objectives + domain model Sensor data Instructions Action Initial state Goal state PLANET Bilbao I-day

  9. Term: Domain Action Changing domain Planning Defining valid action-sequence Scheduling Allocate resources & time to actions Example: Factory / fleet of trucks Machining / loading & driving Changes product / truck Constructing recipe / route Make plan (action-sequence) for machining / driving Resource allocation Allocate machines & times / trucks+drivers & times What is IP&S (4) PLANET Bilbao I-day

  10. Industrial sectors & activities (1) • Potential industrial sectors: • Industry: • Construction & civil engineering • Capital & household goods • Automotive, rail, shipping • Aerospace • Machine tools & equipment • Logistics & transportation • Utilities (electricity, water, gas) • Telecommunications • Agriculture • Finance & banking • Medical • Other services PLANET Bilbao I-day

  11. Industrial sectors & activities (2) • Potential activities: • In complex processes: • Wherever there are human planners: • Industrial • E.g. production, logistics, & transportation • Military & emergency services • Police, fire-fighting, ambulance • In products with autonomous capabilities: • Lifts / elevators • Driverless trains • Spacecraft • Unmanned air vehicles • Mobile robots PLANET Bilbao I-day

  12. Current methods: Action-sequence Schedule Planning Scheduling • Done manually (+ office software) • No tools • Very time-consuming & inflexible • Supported by products (eg ARTEMIS, MS-Project) • Based on PERT / CPA algorithms (1950s technology) • Slow & inflexible IP&S methods: Input Action-sequence Schedule Planning Scheduling Planning & Scheduling Monitoring & Control Output • Supported by tools (eg PRODIGY) • Based on 1990s/2000s technology • Fast & flexible • Supported by products (eg ILOG Scheduler) • Based on CSP algorithms (1990s technology) • Fast & flexible Schedule Current state & past experience IP&S features & benefits (1) PLANET Bilbao I-day

  13. P&S knowledge Domain knowledge (on factory floor or in control room) IP&S features & benefits (2) Why planners have grey hair: Age (years) 40 30 20 Common-sense knowledge 10 PLANET Bilbao I-day

  14. IP&S features & benefits (3) • Where does benefit come from? • Capturing knowledge in planner’s head • Applying it to support human planner: • Automate boring routine problems • Free human planner to work on difficult problems: • Where creativity & ingenuity needed • Remind human planner of domain constraints: • So human planner avoids errors • Conventional software: • Either “hard-codes” industry-specific knowledge: • Inflexible & very expensive (limited market) • Or unable to capture or apply domain knowledge: • Cheaper, but cannot give intelligent support PLANET Bilbao I-day

  15. IP&S features & benefits (4) • IP&S approach: • Capture, apply & maintain domain knowledge: • Knowledge engineering tool • Can be interfaced to related software, e.g. CADCAM • N.B. Significant effort needed = the price you pay for the gains in the planning & scheduling processes • Planning: • Provide support for human planner: • “Mixed-initiative” planning tool • 1990s/2000s technology • Scheduling: • Replace 1950s algorithm with 1990s technology: • CSP-based scheduling tool / engine PLANET Bilbao I-day

  16. IP&S features & benefits (5) • Expected benefits: • Planning: • Increased productivity of human planner • Better quality plans: • Makes “what-if” possible • More consistent plans • Scheduling: • Faster scheduling process: • Runs inside production cycle • Less idle time & overtime • Better-quality schedules: • More “what-if” within same time • More robust schedules PLANET Bilbao I-day

  17. Key case studies (1) • Production (1): • Aircraft assembly: • 570 tasks, 17 resources • Conventional method: • ARTEMIS • 20 hours to generate schedule • IP&S method: • Replace ARTEMIS by CSP • 30 mins to generate optimum schedule • 10 to 15% shorter makespan • Saving: • 4 to 6 days floor-time per aircraft • US$ 0.2 to 1 million per day PLANET Bilbao I-day

  18. Key case studies (2) • Production (2): • Submarine construction: • 1.4 million tasks per boat • Conventional method: • ARTEMIS • 6 weeks to generate schedule • Highly non-uniform profiles • IP&S method: • Replace ARTEMIS by CSP • 1 day to generate schedule • More uniform profiles • Savings: • 30% reduction in overtime & sub-contracting PLANET Bilbao I-day

  19. Key case studies (2) • Logistics: • Military build-up to 1991 Gulf War: • Conventional method: • Hundreds of human planners • Months to generate plans/schedules • IP&S method: • Aid planners with O-PLAN2 • Savings: • Faster logistics build-up • Fewer airlift missions • Financial pay-back >> all US Government AI research: • From 1956 • Not just IP&S research – all AI research PLANET Bilbao I-day

  20. IP&S products & services (1) • List of European products on following slides: • Commercial vs. academic products • Planning vs. scheduling products • Sources: • PLANET & UK PlanSIG web-sites • Conclusions: • No commercial planning product • Schedulers: • Twice as many commercial as academic • Academic focus: • More than twice as many planners as schedulers PLANET Bilbao I-day

  21. Product CHIP V5 ILOG Solver ILOG Scheduler CPLEX Evolver/Blue Kaizen - optimisation iBundler iAuctionMaker Constraint optimisation toolkit XpressMP – optimization suite Electrical power generation INORDA - APS for production JOBWISE - APS for manpower Supplier Cosytec (FR) ILOG (FR) ILOG (FR) ILOG (FR) MASA (FR) iSOCO (E) iSOCO (E) BT (UK) Dash Optimization (UK/US) Power Optimisation (UK) Workplace Systems (UK) Workplace Systems (UK) IP&S products & services (2) Commercial scheduling products (1): PLANET Bilbao I-day

  22. Product HARMONY – shift scheduling PEARL SHORTREC – routing & scheduling ModelEnterprise – plant design SERVICEPower scheduler Timetabling software Scheduling software DAYSY – flight scheduling Prescient5 – production scheduling TASKFORCE – workforce scheduler Ximes PDC Staffplan Supplier ORTEC (NL/US) ORTEC (NL/US) ORTEC (NL/US) Process Systems Enterprise (UK) ServicePower (UK) Lantiv (?) COMSEC (?) SEMA Group (UK/FR) Prescient (?) APSolve (UK) XIMES (AU) PDC (DK) IP&S products & services (3) Commercial scheduling products (2): PLANET Bilbao I-day

  23. Product ChariTime – dynamic appointment ConBATT – timetabling INTERDIP – nurse scheduling WISPRO CSP-Lab & CS-Lib PAVE – patient scheduling ECOPT – vehicle & crew scheduling LiSA – scheduling algorithms TOSCA – factory scheduling (job-shop) Supplier U. Humboldt (GE) U. Humboldt (GE) U. Munich (GE) GMD First (GE) U. Strathclyde (UK) Demokritos (GR) Erasmus (?) U. Magdeburg (GE) U. Edinburgh (UK) IP&S products & services (4) Academic scheduling products: PLANET Bilbao I-day

  24. Product IxTET IPP Fast-Forward GRT & MO-GRT DDPLAN Model-Based Planner (MBP) Prodigy IMPLAN MACHINE – manufacturing TRP-Planner – temporal planning MIME – mixed-initiative modeller & planner University/Institute LAAS-CNRS (FR) U. Freiburg (GE) U. Freiburg (GE) UoM (GR) U. Perugia (IT) IRST (IT) UC3M (E) U. Humboldt (GE) UGR (E) U. Piraeus (GR) Mid Sweden U. (SE) IP&S products & services (5) Academic planning products (1): PLANET Bilbao I-day

  25. Product STAN TIM – domain analysis tool O-PLAN PLANFORM – planning environment GIPO CAPplan INT-OP – operating procedure synthesis MACTA – planning for interacting robots Plan 95 – distributed planner CHARADE – interactive planning I-Rescue –disaster relief planning University/Institute U. Durham (UK) U. Durham (UK) U. Edinburgh (UK) U. Huddersfield (UK) U. Huddersfield (UK) U. Kaiserlautern (GE) U. Salford (UK) U. Salford (UK) U. Uppsala (SE) U. UGR (E) U. Edinburgh (UK) IP&S products & services (6) Academic planning products (2): PLANET Bilbao I-day

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