Research Papers

Event-Based Production Control for Energy Efficiency Improvement in Sustainable Multistage Manufacturing Systems

[+] Author and Article Information
Yang Li

Department of Industrial Engineering,
School of Mechanical Engineering,
Northwestern Polytechnical University,
Xi'an 710072, Shaanxi, China;
Performance Analysis Center of Production
and Operations Systems (PacPos),
Northwestern Polytechnical University,
Xi'an 710072, Shaanxi, China
e-mail: yangmli@outlook.com

Jun-Qiang Wang

Department of Industrial Engineering,
School of Mechanical Engineering,
Northwestern Polytechnical University,
Xi'an 710072, Shaanxi, China;
Performance Analysis Center of Production
and Operations Systems (PacPos),
Northwestern Polytechnical University,
Xi'an 710072, Shaanxi, China
e-mail: wangjq@nwpu.edu.cn

Qing Chang

Department of Mechanical and
Aerospace Engineering,
The University of Virginia,
Charlottesville, VA 22904
e-mail: qing.chang@stonybrook.edu

Manuscript received April 18, 2018; final manuscript received November 1, 2018; published online December 24, 2018. Assoc. Editor: Sara Behdad.

J. Manuf. Sci. Eng 141(2), 021006 (Dec 24, 2018) (8 pages) Paper No: MANU-18-1258; doi: 10.1115/1.4041926 History: Received April 18, 2018; Revised November 01, 2018

There has been an increasing trend for manufacturers to shift toward sustainable manufacturing strategies in response to an ever-growing pressure from fluctuating energy price and environmental crisis. Reducing energy consumption is considered as an important step to achieve the sustainability of a production system. This paper proposes an event-based control methodology to improve the production energy efficiency through strategically switching appropriate stations to energy saving mode. Based on an event-based analysis of production dynamics, an analytical approach is developed to quantitatively predict the system level production loss resulted from an energy saving control event (ESCE). A genetic-based control algorithm is proposed to balance the trade-off between the gain from energy saving and the expense of throughput loss. The energy improvement analysis results in a fundamental understanding of production energy dynamics and a significant decrease of energy cost for a manufacturing facility. Numerical case studies are performed to validate the effectiveness of the proposed method. It is found that the control method can effectively reduce energy cost, while only slightly impacting production.

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Grahic Jump Location
Fig. 1

A multistage serial production system

Grahic Jump Location
Fig. 2

The flowchart of PPLEM

Grahic Jump Location
Fig. 3

The production system consisting of six stations and five buffers

Grahic Jump Location
Fig. 4

The learning curve of an EBECM control



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