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Using simulation as a proxy for a real shop floor and data collection system

Introduction Increasing shop floor efficiency has always been a major concern of manufacturing companies. Scheduling applications have been successfully employed to create optimized schedules that manufacturers can use to run their operations. But it is a common occurrence in today’s dynamic manufacturing environment that the information upon which a schedule is based changes after the schedule has been created. Running shop floor operations based on this out-ofdate information can lead to increased shop floor inefficiency. Systems need to be developed which not only provide good initial schedules, but also create new schedules in reaction to important changes in the state of operations of the shop floor. Research is underway at the National Institute of Standards and Technology (NIST) to develop standards and procedures that facilitate the development of reactive scheduling systems [1]. A reactive scheduling system is one that not only produces initial schedules for production, but also: 1) monitors the shop floor events and evaluates compliance to the schedule and other shop floor performance related criteria; 2) collects shop floor status information to enable the creation of updated schedules based on current information; and 3) produces new schedules based on the collected information. A key area of research in developing this approach is the use of a discrete event simulation system as a proxy for a real shop floor and a real shop floor data collection system. A prototype is being developed at NIST that uses Deneb QuestTM in these roles[]. In this paper, the characteristics of the Shop Floor and Data Collection component of a reactive scheduling system and the modifications that were made to QuestTM to incorporate it into the NIST reactive scheduling system prototype are discussed.