Hybrid system dynamic—discrete event simulation-based architecture for hierarchical production planning

Multi-plant production planning problem deals with the determination of type and quantity of products to produce at the plants over multiple time periods. Hierarchical production planning provides a formal bridge between long-term plans and short-term schedules. A hybrid simulation-based hierarchical production planning architecture consisting of system dynamics (SD) components for the enterprise level planning and discrete event simulation (DES) components for the shop-level scheduling is presented. The architecture consists of the Optimizer, Performance Monitor and Simulator modules at each decision level. The Optimizers select the optimal set of control parameters based on the estimated behaviour of the system. The enterprise-level simulator (SD model) and shop-level simulator (DES model) interact with each other to evaluate the plan. Feedback control loops are employed at each level to monitor the performance and update the control parameters. Functional and process models of the proposed architecture are specified using IDEF. The internal mechanisms of the modules are also described. The modules are interfaced using High Level Architecture (HLA). Experimental results from a multi-product multi-facility manufacturing enterprise demonstrate the potential of the proposed approach.