The work deals with the optimization of the production system in the engineering company Prodia s.r.o. There is a review of technological design in the introduction, the methods of analysis, design methods and capacity calculations are introduced. Subsequently, using these methods, the current state of material flows are analysed, the critical points in the production defined and design of new solution options to eliminate the main weaknesses identified during the analysis. Finally, an evaluation of the best variant and its economic profitability is introduced.

Notre thèse est consacrée à l’étude de la supervision des réseaux de Petri en vue de la conception de systèmes manufacturiers flexibles. L’objectif est la définition de stratégies de pilotage en ligne pour l’évitement de conflits et d’interblocages, dans le cadre de la théorie de la supervision. Le point de départ de notre travail est d’exploiterle graphe de marquage du réseau de Petri, ce qui permet en particulier d’obtenir des stratégies de commande maximalement permissive pour des problèmes d’évitement de conflits et d’interblocages. Nous avons ainsi introduit des techniques originales, manipulations d’inégalités ou réductions d’ensembles de marquages, destinées à diminuerla complexité algorithmique d’une telle méthode. Dans premier temps, nous avons focalisé sur la synthèse de superviseurs dits purs, ce qui correspond au cas particulier où l’ensemble de marquage légaux, est convexe.Cette optimisation est ensuite considérée du point de vue de la facilité de mise en oeuvre. Nous traitons ainsi de la minimisation de la structure du superviseur et de son coût d’implémentation en préservant une structure de supervision qui offre à la fois la permissivité maximale et une complexité de calcul raisonnable en vue d’utilisationsur des installations réelles. Aussi, nous avons cherché à réduire le nombre de places de contrôle nécessaires pour réaliser un superviseur maximalement permissif, pour cela nous avons formule le calcul du nombre minimal de places de contrôle en termes d’un problème de programmation linéaire. Afin d’affaiblir la complexité de ce calcul de superviseur, deux versions de l’algorithme sont proposées. Ce problème de minimisation de la taille dusuperviseur, quoique fondamental, n’est pas abordé aussi directement dans la littérature. Il s’agit là d’une première contribution.Dans u second temps, nous nous sommes intéressés aux réseaux de Petri à boucles (self-loops). Les boucles étant représentées par une variable qui s’ajoute dans la contrainte inégalité définissant l’ensemble de marquages légaux. Après avoir proposé une méthode de réduction du nombre d’inégalités ainsi que du superviseur optimalen se basant sur les approches et résultats précédents, nous avons établi une condition suffisante d’obtention d’un superviseur maximalement permissif permettant de traiter des ensembles de marquages légaux non convexes.Enfin nous proposons une méthode de synthèse de contrôleur pour une nouvelle classe de réseaux de Petri, avec des arcs inhibiteurs correspondant à des contraintes définies par des intervalles. La taille du contrôleur ainsi obtenu et défini en termes d’arcs inhibiteurs à intervalles s’en trouve réduite ainsi que par conséquent sont coût d’implémentation. / Reachability graph analysis is an important technique for deadlockcontrol, which always suffers from a state explosion problem since it requires togenerate all or a part of reachable markings.Based on this technique, an optimal or suboptimal supervisor with high behavioralpermissiveness can always be achieved. This thesis focuses on designing liveness enforcing Petri net supervisors for FMSs by considering their behavioralpermissiveness, supervisory structure, and computationnal complexity.The following research contributions are made in this thesis.1. The design of a maximally permissive liveness-enforcing supervisor for an FMSis proposed by solving integer linear programming problems (ILPPs).2. Structural complexity is also an important issue for a maximally permissivePetri net supervisor. A deadlock prevention policy for FMSs is proposed, which canobtain a maximally permissive liveness-enforcing Petri net supervisor while thenumber of control places is compressed.3. In order to overcome the computational complexity problem in MCPP and ensurethat the controlled system is maximally permissive with a simple structure, wedevelop an iterative deadlock prevention policy and a modified version.4. We consider the hardware and software costs in the stage of controlimplementation of a deadlock prevention policy, aiming to obtain a maximallypermissive Petri net supervisor with the lowest implementation cost. A supervisorconsists of a set of control places and the arcs connecting control places totransitions. We assign an implementation cost for each control place and controland observation costs for each transition. Based on reachability graph analysis,maximal permissiveness can be achieved by designing place invariants that prohibitall FBMs but no legal markings.5. Self-loops are used to design maximally permissive supervisors. A self-loop ina Petri net cannot be mathematically represented by its incidence matrix. Wepresent a mathematical method to design a maximally permissive Petri netsupervisor that is expressed by a set of control places with self-loops. A controlplace with a self-loop can be represented by a constraint and a selfloopassociated with a transition whose firing may lead to an illegal marking.

Le contrôle de systèmes industriels à cause de l’automatisation et la réduction de nombre des opérateurs devient un enjeu crucial. Les systèmes de production automatisés (AMS) sont d’autant plus touchés car une défaillance du programme de contrôle peut réduire considérablement la productivité voire entraîner l’arrêt du système de production. Pour certains de ces systèmes où le partage des ressources est pondérant, la notion de blocage partiel ou global est fréquente et la validation avant implantation est préférable pour réduire les risques.En raison de la capacité des réseaux de Petri à décrire aisément l’exécution concurrente des processus et le partage des ressources, de nombreuses méthodes de vérification d’absence de blocage et de synthèse de contrôleurs basées sur la théorie structurelle ou le graphe d’accessibilité des réseaux de Petri ont été proposées au cours des deux dernières décennies.Traditionnellement, une méthode de prévention de blocage est évaluée selon trois critères de performance: la complexité structurelle, la permissivité comportementale, et la complexité de calcul. Les méthodes fondées sur l’espace d’état aboutissent généralement à un contrôle maximal permissif mais souffrent de l'explosion combinatoire de l'espace d'états. En revanche, les méthodes de synthèse de contrôleurs fondées sur l’analyse structurelle évitent le problème de l’explosion de l’espace d’état mais aboutissent à des superviseurs pouvant restreindre considérablement les comportements admissibles du système. De plus si la théorie structurelle de contrôle de siphons pour la synthèse des superviseurs est mature dans le cas des réseaux de Petri ordinaires, elle est en développement pour les réseaux de Petri généralises. Par ailleurs, la plupart des travaux existants partent du principe que les ressources sont constamment disponibles. Or l’indisponibilité de ressources est en réalité un phénomène ordinaire. Il serait donc judicieux de développer une politique de vérification de blocage qui soit efficace tout en considérant des ressources non fiables.Cette thèse vise principalement à faire face aux limitations mentionnées ci-dessus. Nos principales contributions à la fois théoriques et algorithmiques sont les suivantes.Premièrement, après avoir revisité les conditions de contrôlabilité des siphons (cs–propriété) et précisé les limitations de la max cs- propriété et max’ cs- propriété, nous définissons la max’’ cs-propriété et nous démontrons que cette nouvelle propriété est une condition non seulement suffisante mais aussi nécessaire pour la vivacité de la classe des GS3PR (Generalized Systems of SimpleSequential Processes with Resources).Par la suite nous montrons comment le problème de la vérification de cette propriété et donc la vivacité des GS3PR peut se ramener à la résolution d’un programme linéaire en nombre entiers.Dans une seconde partie, nous proposons une classe de réseaux de Petri appelée M-Nets dotée d’une forte capacité de modélisation des systèmes de production automatisés. En combinant la théorie du contrôle siphon avec la théorie des régions, nous développons une méthode de prévention de blocage ayant un bon compromis entre l'optimalité du comportement et la complexité de calcul. De plus, nous proposons une méthode de synthèse d'un contrôleur maximal permissif pour une sous-classe de réseaux notée b-nets.Enfin, nous proposons dans cette thèse une méthode de conception d’un superviseur de systèmes de production automatisés où les ressources ne sont pas toutes fiables et particulièrement efficace pour la classe des S3PR (Systems of Simple Sequential Processes with Resources). / Because of automation and reduction of the number of operators, the control of industrial systems is becoming a critical issue. For automated manufacturing systems (AMS) where resource sharing is preponderant, the notion of partial or total blocking is frequent and validation before implementation is preferable to reduce the risks.Due to the easy and concise description of the concurrent execution of processes and the resource sharing by Petri nets, many methods to verify deadlock-freeness and to synthesize controllers using structural theory or reachability graph have been proposed over the past two decades.Traditionally, a deadlock control policy can be evaluated by three performance criteria : structural complexity, behavioral permissiveness, and computational complexity. Generally, deadlock control policies based on the state space analysis can approach the maximal permissive behavior, but suffer from the state explosionproblem. On the contrary deadlock control policies based on the structural analysis of Petri nets avoid in general the state explosion problem successfully, but cannot lead to the maximally or near maximally permissive controller. Morover, the current Deadlock control theory based on siphons is fairly mature for ordinary Petri nets,while for generalized Petri nets, it is presently at an early stage.On the other hand, most deadlock control policies based on Petri nets for AMS proceed on the premise that the resources in a system under consideration are reliable. Actually, resource failures are inevitable and common in most AMS, which may also cause processes to halt. Therefore, it is judicious to develop an effective and robust deadlock control policy considering unreliable resources.This thesis aims to cope with the limitations mentioned above. Our main theoretical and algorithmic contributions are the following. Firstly, after revisiting the controllability conditions of siphons and limitations of max and max' controlled-siphon properties, we define the max'' cs property and we prove that this new cs-property is not only sufficient but also a necessary liveness condition forgeneralized systems of simple sequential processes with resources (GS3PR). Moreover, we show how the checking of this property and hence liveness of GS3PR nets can be translaled into resolution of an integer programming (IP) model.Secondly, we propose a class of manufacturing-oriented Petri nets, M-nets for short, with strong modeling capability. Combining siphon control and the theory of regions, we develop a deadlock prevention method that makes a good trade-off between behavioral optimality and computational tractability Moreover, this thesis proposes a maximally permissive control policy for a subclass of Petri nets (calledBéta-nets) based on the token distribution pattern of unmarked siphons.Finally, we propose a designs method for robust liveness-enforcingsupervisors for AMS with unreliable resources appropriate in particular for systems of simple sequential processes with resources(S3PR)

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The manufacturing industry has exerted a tremendous impact on the natural environment. The aim of this thesis is to evaluate the consequences of shift from linear manufacturing system to circular manufacturing system in order to decouple the environmental burden of production and consumption process in relation to quantity of carbon footprint, cumulative energy demand, natural resource consumption, waste generated and recovered presently. In response to this, life cycle assessment (LCA) is used to quantify and compare the associated environmental impact of the current manufacturing system of both Linear manufacturing system and the circular manufacturing system. The thesis therefore asserts that circular manufacturing system (CMS) is more sustainable compared to linear manufacturing system (LMS) in relation to its reduction capacity of the prevailing environmental indicators most especially global threat of natural resources depletion and climate change confronting biodiversity. The result shown that CMS seems more sustainable compared to LMS in relation to the studied environmental indicators. Further to this, the emerging circular manufacturing system, its transitional shift, challenges, and its relationships with other manufacturing dynamics for consideration are also highlighted and discussed. It was concluded that these prominent challenges are caused by organizational management in relation to leadership and communication (OLC), has the highest impact value. Similarly, the consequential effect was seen on the level of implementation of government policy (GPI) and deployment of state of the art design, knowledge and technology (DTK) for the paradigm shift. So, it is suggested that OLC should be given due consideration.

This report is a master thesis project done as a final project of Industrial design engineering with a master in production engineering, at Luleå University of Technology during the spring of 2021. The project was done as a collaboration with the company Nord-lock, based out of Mattmar, Sweden. The company produce wedge-locking washers that use tension instead of friction to secure critical bolted joints. The purpose of the project was to create a simulation model which can be used as a tool for improving production utilisation. The company do not currently use simulation within the organisation, requiring the model to be built up from scratch. The overall project structure has followed a cyclic process which divides it into three different laps. The first lap focused on mapping the production and gaining an understanding of the manufacturing and business systems. The second lap focused on the creation of the simulation model and further data collection. The third lap looked into validation and experimentation with the simulation model, creating cases to test the use and outputs of the model. The simulation model followed four key stages for conducting a simulation study, going from creating an understanding of the real world and the problems to the solutions.  The current state was mapped using different methods for data collection and further analysis of the findings. Direct observation with operators at the shop floor was used to gain an understanding of how a batch travels through the manufacturing system. Observing the human operations that are required for different activities was important for creating a map over the necessary steps in a process. The production is divided into two different flow groups, with machines and operations being placed into machine groups under these. The surface treatment is an important step in assuring the products quality and exists as a collection of machine groups under the first flow group. It became clear that the production planning of batches was separated between the two flow groups, creating a disconnection to how a batch travels through the entire manufacturing system. The simulation model would aim to allow batches to be planned from creation to finished product, observing how they behave through the system.  Due to limited experience of the simulation software within the company, the creation of the model into a tool required control of inputs being accessible to the intended users. The inputs and outputs of the system are therefore controlled using excel sheets which only requires a user to have experience with excel and the existing business systems. Data for activities within the simulation model is gathered from the business systems, which gets their data from the results of the actual manufacturing system. A user guide was created to assist users with adding new articles or change data into the simulation model. The excel sheet which displays the outputs of the system is connected to the simulation model and updates as the model is run.  The simulation model showed that the surface treatment is a big bottleneck for the throughput of the system. Subsequent cases that were created experimented with how this bottleneck react to different inputs. When increasing the throughput time of the machine groups before the surface treatment, no real increase in the throughput of the system was found. The queue time before the bottleneck decreased greatly when comparing the results to the regular model. The second case observed how the system reacts to changes in the surface treatment, comparing the results to the previous case. The final chapter discusses how the tool can be used within the company. A sustainable context is used to show how different results can affect the sustainability within the manufacturing system in all three aspects.

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Yes / The paper contributes to development of RMS through linkage with external stakeholders such as customers and suppliers of parts/raw materials to handle demand fluctuations that necessitate information sharing across the supply chain tiers. RMS is developed as an integrated supply chain hub for adjusting production capacity using a hybrid methodology of decision trees and Markov analysis. The proposed Markov Chain model contributes to evaluate and monitor system reconfigurations required due to changes of product families with consideration of the product life cycles. The simulation findings indicate that system productivity and financial performance in terms of the profit contribution of product-process allocation will vary over configuration stages. The capacity of an RMS with limited product families and/or limited model variants becomes gradually inoperative whilst approaching upcoming configuration stages due to the end of product life cycles. As a result, reconfiguration preparation is suggested quite before ending life cycle of an existing product in process, for switching from a product family to a new/another product family in the production range, subject to its present demand. The proposed model is illustrated through a simplified case study with given product families and transition probabilities.

A capacidade de reconfiguração de sistemas de manufatura tem sido procurada pelas empresas para assegurar características de agilidade, eficiência e exibilidade para atender as mudanças de tipo/quantidade de produtos, processos, recursos e, além disso, para assegurar a devida reação à ocorrência de falhas. Por outro lado, a Indústria 4.0\" impõe novos desafios para os sistemas de controle, tais como a integração de tecnologias de interação entre homem e máquina em cadeias de valor compondo uma rede de plantas industriais geograficamente dispersas. O controle de sistemas reconfiguráveis de manufatura deve considerar: (i) funcionalidades de sistemas distribuídos e dispersos, tais como agilidade de resposta às mudanças, autonomia e colaboração entre os componentes para alcançar os objetivos do sistema de forma conjunta; (ii) interfaces para sua interoperabilidade e portabilidade; (iii) modularização para facilitar a manutenção, expansão e atualização do sistema, evitando a sobreposição de escopos; e (iv) mecanismos de controle para supervisionar as ações e interações dos componentes, o diagnóstico e a tomada de decisão. O pleno atendimento a estes requisitos não é trivial e formalismos para o desenvolvimento de soluções devem ser adotados. Uma solução é combinar técnicas voltadas para sistema multiagente e holon com arquitetura orientada a serviço através de uma adequada técnica de modelagem usando extensões de rede de Petri: Production Flow Schema e Input Output Place Transition. Portanto, este trabalho prop~oe uma arquitetura de controle e o método de modelagem de seus componentes para sistemas reconfiguráveis de manufatura combinando estas técnicas e considerando os aspectos de personalização, convertibilidade, escalabilidade, modularidade, integrabilidade, diagnosticabilidade, interoperabilidade e colaboração entre os componentes do sistema de controle, inclusive do homem. Um exemplo de aplicação é apresentado para demonstrar a viabilidade da proposta e comprovar os resultados alcançados. / The reconfiguration ability of the manufacturing systems has been approached by companies to ensure agility, efficiency and exibility characteristics to address the changes of type/quantity of products, processes and resources and, furthermore, to ensure proper reaction to the fault occurrence. On the other hand, the\"Industry 4.0\" imposes new challenges for control systems, such as interaction between man and machine into value chains composing a network of geographically dispersed industrial plants. The control of reconfigurable manufacturing systems should consider: (i) functionalities requirements of distributed and disperse systems, such as responsiveness to changes, autonomy and collaboration among components to achieve the global system aim; (ii) interfaces for interoperability and portability; (iii) modularity to facilitate maintenance, expansion and upgrade of the system, avoiding the overlapping of scopes; and (iv) control mechanisms to supervise the actions and interactions among components, diagnosis and decision making. The compliance with these requirements is not trivial and formalisms to develop solutions must be adopted. A solution is combining techniques based on holonic and multi-agent system with service-oriented architecture through appropriate modeling using Petri net extensions: Production Flow Schema and Input Output Place Transition. Therefore, this paper proposes control architecture and a method to model components for reconfigurable manufacturing systems, combining these techniques and considering aspects of customization, convertibility, scalability, modularity, integrability, diagnosability, interoperability and collaboration among control system components, including humans. An application example is presented to demonstrate the feasibility of the proposal and verify the results.