• Journal of Korean Society of Industrial and Systems Engineering
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• v.44 no.2
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• pp.115-123
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• 2021

A lot of sensor and control signals is generated by an industrial controller and related internet-of-things in discrete manufacturing system. The acquired signals are such records indicating whether several process operations have been correctly conducted or not in the system, therefore they are usually composed of binary numbers. For example, once a certain sensor turns on, the corresponding value is changed from 0 to 1, and it means the process is finished the previous operation and ready to conduct next operation. If an actuator starts to move, the corresponding value is changed from 0 to 1 and it indicates the corresponding operation is been conducting. Because traditional fault detection approaches are generally conducted with analog sensor signals and the signals show stationary during normal operation states, it is not simple to identify whether the manufacturing process works properly via conventional fault detection methods. However, digital control signals collected from a programmable logic controller continuously vary during normal process operation in order to show inherent sequence information which indicates the conducting operation tasks. Therefore, in this research, it is proposed to a recurrent neural network-based fault detection approach for considering sequential patterns in normal states of the manufacturing process. Using the constructed long short-term memory based fault detection, it is possible to predict the next control signals and detect faulty states by compared the predicted and real control signals in real-time. We validated and verified the proposed fault detection methods using digital control signals which are collected from a laser marking process, and the method provide good detection performance only using binary values.

• The Journal of Information Systems
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• v.26 no.2
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• pp.105-121
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• 2017

Purpose It is a major goal to improve the product yields during production operations in the manufacturing industry. Therefore, factory is trying to keep the good quality materials and proper production resources, also find the proper condition of facilities and manufacturing environment for yields improvement. Design/methodology/approach We propose the hybrid framework to analyze to dataset extracted from MES. Those data is about the alarm information generated from equipment, both measurement and equipment process value from production and cycle/pitch time measured from production data these covered products during production. We adapt a data warehousing techniques for organizing dataset, a logistic regression for finding out the significant factors, and a association analysis for drawing the rules which affect the product yields. And then we validate the framework by applying the real data generated from the discrete process in secondary cell battery manufacturing. Findings This paper deals with challenges to apply the full potential of modeling and simulation within CPPS(Cyber-Physical Production System) and Smart Factory implementation. The framework is being applied in one of the most advanced and complex industrial sectors like semiconductor, display, and automotive industry.

• Proceedings of the Korean Society of Precision Engineering Conference
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• 2012.10a
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• pp.513-514
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• 2012

• Journal of the Korean Society of Manufacturing Technology Engineers
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• v.8 no.4
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• pp.112-122
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• 1999

In realistic control systems the nonlinear saturation attributes of the control actuator due to physical limitations should be taken into account This nonlinear saturation of actuators may cause not only deterioration of the control performance but also a large overshoot during start-up and shut-down. As the overshoot increases the system may become oscillatory unstable. in this paper the supervisor implementation which guarantees good performance for saturation operation and prevents reset wind up is presented, Moreover the sufficient conditions of the stability for saturated system using supervisory control with a dynamic controller are provided in the continuous-time and in the discrete-time domain Numerical example is illustrated to depict the efficiency of supervisory control for a typical satuaurated production-distribution system controlled by a discrete-time dynamic controller and to validate basic results by simulation.

• Journal of Korean Society of Industrial and Systems Engineering
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• v.38 no.4
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• pp.149-158
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• 2015

Up-to-date manufacturing companies have faced a market-driven environment of pull production order. There should be a difference in operating manufacturing resources according to the type, quantity, and delivery time of manufactured products, because the process situation in pull production is changed by customer orders. And it should be taken into account from the stage of preparing for production such as process design and the placement and utilization of manufacturing resources. However, the feasibility of production plans is limited because most of small manufacturing businesses make production/supply plan of the parts and products assuming that equipment abilities in scheduling is sufficient without managing process standard information systemically. In this study, a discrete event simulation system based on BOM (bill of material), that is F-OPIS (online productivity innovation system), is introduced and a case study on application of the system leading to improving productivities is presented. F-OPIS deals with a decision-problem on production management and it is specialized for small-and- medium sized manufacturing companies. The target company of this case study is a typical small-and-medium sized manufacturing company in Korea, that produces various machined parts. The target company adopts make-to-stock production management to prevent tardy delivery because of fluctuations in demand. Therefore, it is required to apply an efficient inventory control solution for improving productivities. In this paper, based on the constraints of working capacity of manufacturing resources, the bottleneck process is analyzed as production conditions are changed. Consequently, an improvement plan is proposed, that eventually enhances overall utilization rates of resources in the bottleneck process and reduces overall production lead-time and inventory level.

• Journal of Institute of Control, Robotics and Systems
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• v.2 no.3
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• pp.209-219
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• 1996

Fieldbus provides a real-time data communication among field devices in the process control and manufacturing automation systems. In this paper, a Petri Net model of the 1993 draft of IEC/ISA fieldbus which is proposed as an international standard of fieldbus network is developed. Based on the Petri Net model, discrete-event simulation model of IEC/ISA fieldbus network is developed. This paper evaluates the network induced delay in the data link layer of IEC/ISA fieldbus using the simulation model. In addition, an integrated discrete-event/continuous-time simulation model of fieldbus system and distributed control system is developed. This paper investigates the real-time data processing capability of IEC/ISA fieldbus and the effect of network-induced delay to the performance of control system.

• ETRI Journal
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• v.25 no.4
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• pp.238-246
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• 2003

This paper introduces the modeling and analysis of a discrete-time, two-phase queueing system for both exhaustive batch service and gated batch service. Packets arrive at the system according to a Bernoulli process and receive batch service in the first phase and individual services in the second phase. We derive the probability generating function (PGF) of the system size and show that it is decomposed into two PGFs, one of which is the PGF of the system size in the standard discrete-time Geo/G/1 queue without vacations. We also present the PGF of the sojourn time. Based on these PGFs, we present useful performance measures, such as the mean number of packets in the system and the mean sojourn time of a packet.

• Journal of Korean Society of Industrial and Systems Engineering
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• v.41 no.4
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• pp.59-69
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• 2018

This study deals with the case study on the pallet quantity determination problem for the flexible manufacturing system producing 32 different types of aircraft wing ribs which are major structures of an aircraft wings. A Korean company has constructed the WFMS (wing rib flexible manufacturing system) that is composed of several automated equipments such as the 5-axis machining centers, the RGV (rail guided vehicles)s, the AS/RS (automated storage and retrieval system), the loading/unloading stations, and so on. Pallets play a critical role in the WFMS to maintain high system utilization and continuous work flow between 5-axis machining machines and automated material handling devices. The discrete event simulation method is used to evaluate the performance of the WFMS under various pallet mix alternatives for wing rib manufacturing processes. Four performance measures including system utilization, throughput, lead-time and work in process inventory level are investigated to determine the best pallet mix alternative. The best pallet mix identified by the simulation study is adopted in setting up and operating a real Korean aircraft parts manufacturing shop. By comparing the real WFMS's performances with those of the simulation study, we discussed the cause of performance difference observed and the necessity of developing the CPS (cyber physical system).

• Journal of the Korea Society for Simulation
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• v.3 no.1
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• pp.75-88
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• 1994

Discrete event modeling is finding ever more application to anlysis and design of complex manufacturing, communication, computer systems, etc. This paper shows how packet network systems may be advantageously represented as DEVS (Discrete Event System Specification) models by employing System Entity structure / Model base (SES/MB) framework developed by Zeigler. DEVS models and network structure representations support a strong basis for performance analysis of packet network systems. This approach is illustated in a typical packet network example with several routing strategies.

• The Journal of Korean Institute of Communications and Information Sciences
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• v.28 no.9B
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• pp.783-792
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• 2003

We consider a finite-buffer discrete-time queueing system with fixed-size bulk-service discipline: Geo/ $G^{B}$1/K＋B. The main purpose of this paper is to present a performance analysis of this system that has a wide range of applications in Asynchronous Transfer Mode (ATM) and other related telecommunication systems. For this purpose, we first derive the departure-epoch probabilities based on the embedded Markov chain method. Next, based on simple rate in and rate out argument, we present stable relationships for the steady-state probabilities of the queue length at different epochs: departure, random, and arrival. Finally, based on these relationships, we present various useful performance measures of interest such as the moments of number of packets in the system at three different epochs and the loss probability. The numerical results are presented for a deterministic service-time distribution - a case that has gained importance in recent years.s.