Simulation and optimization based flexible job scheduling of powder coating lines

Abstract

The Paper will present a new approach to use simulation methods combined with intelligent optimization algorithms in an operative scheduling and monitoring application for powder coating lines. Powder Coating lines are built usually as a closed loop “power and free” chain system that transports the products on carriers from a starting point through the different production stages. Due to the closed loop, efficiency and the overall output of the system is highly dependent on the sequence of the production orders entering the line. Inefficient sequences can cause deadlocks, significant decrease of the production output or even scrap production. The presented application architecture is based on a 3D simulation platform working together with a closed loop heuristic sequence scheduling algorithm. The paper will also introduce the system architecture design with full integration to an enterprise IT structure comprising ERP, real time PLC communication and a Warehouse Management System.