Cloud-based integrated shop-floor planning and control of manufacturing operations for mass customisation

Mourtzis D.a*, Doukas M.a, Lalas C.a, Papakostas N.a

aLaboratory for Manufacturing Systems and Automation (LMS),

Department of Mechanical Engineering and Aeronautics, University of Patras, Rio Patras, Greece, 26500

* Corresponding author. Tel.: +30 2610 997262; fax: +30 2610 997744.

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MRPII 37

Abstract

The shift of traditional mass producing industries towards mass customisation practices is nowadays evident. However, if not implemented properly, mass customisation can lead to disturbances in material flow and severe reduction in productivity.

This paper discusses the design and development of a Cloud-based production planning and control system for discrete manufacturing environments, referred to as i-MRP. The proposed approach takes into consideration capacity constraints, lot sizing and priority control in a ‘bucket-less’ manufacturing environment.

The i-MRP system offers simultaneous shop scheduling and material planning, where material and capacity constraints are considered together in a continuous time environment. A number of feasible alternative shop schedules and material plan combinations are formed and are evaluated on the Cloud platform where the i-MRP engine is hosted.

The Cloud platform enables mobility, since it is device and location independent, as well as it minimises the cost of IT infrastructure ownership, which is especially important for SMEs. The performance of the iMRP system has been studied in an SME from the textile sector, using real production data.

The system demonstrates high performance in cases of short production times, high value inventory and frequent, small deliveries by suppliers. The i-MRP can be easily integrated with legacy IT systems as an interfaced functional module under the Software as a Service (SaaS) architecture.

Keywords: Production Planning and Control; Mass Customisation; Decision-making; Software as a Service, Cloud Manufacturing