LEARNING OUTCOMES

The course aims at providing the modeling and methodological tools for the formalization and resolution of some important decision-making and management problems in the context of industrial systems. During the course, planning, scheduling and control problems will be formalized and solved according to the framework proposed by the ANSI/ISA-95 international standard. Special focus will be devoted to the primary and support functions given by the Manufacturing Execution System (MES). At the end of the course, the student will be able to position an industrial automation problem in the context of ANSI/ISA-95 and to formalize and to solve decision-making problems, using proper methods and tools.

AIMS AND LEARNING OUTCOMES

AIMS: make the student aware of the complex work done on the information related to a production process, starting from the control at shopfloor level, passing through the different functionalities of the manufactiring operation management (MES/MOM), to get to the final planning activities of an ERP.

At the end of the course, the student will be aware of the different methodological and technological aspects of such information processes.

PREREQUISITES

No prerequisite

TEACHING METHODS

Lessons and exercises in different software environments (among which Matlab)

SYLLABUS/CONTENT

1. Introduction (4h + 2h):

1. 1. Introduction to the Course
   2. Architectural Models in Industrial Automation
   3. Manufacturing Methods: Batch production, Job Production, Flow Production
   4. Improvement Methods (Lean Manufacturing, Reliability-centered Maintenance, Zero Defects…)
   5. Information and Communication Standards (ISA-88, ISA-95, ERP, IEC 62264, B2MML …)
   6. Matlab Basic Exercise 1.1 

1. Field Level and Direct Control (8h + 4h):

   1. Shopfloor Description and Examples
   2. SCADA, PLC, DCS
   3. Linear quadratic optimal control, Linear Quadratic Tracking, PID
   4. Matlab Exercise 2.1: Generate Ladder Logic Diagrams (https://www.plcfiddle.com/)
   5. Matlab Exercise 2.2: LQ control in discrete time system, tracking, and PID

1. Manufacturing Execution Systems (24h + 12h):

1. 1. Definition and Models
   2. Who’s Who in MES
   3. MES Primary Functions: Planning System Interface; Work Orders; Work Stations; Inventory / Materials; Material Movement; Data Collection; Exception Management
   4. MES Support Functions: Maintenance; Time and Attendance; Statistical Process Control; Quality Assurance; Process Data; Documentation Management; Genealogy; Supplier Management.
   5. Scheduling methods
   6. Process control and quality control
   7. Matlab Exercise 3.1: Single Machine Scheduling: SPT, EDD
   8. Matlab Exercise 3.2: Single Machine Scheduling: Moore; Flow Shop Scheduling: Johnson
   9. Matlab Exercise 3.3: Job Shop Scheduling
   10. Matlab Exercise 3.4: Dynamic Programming for Scheduling
   11. Matlab Exercise 3.5: Stochastic Scheduling
   12. Matlab Exercise 3.6: Run and Trend Charts, Time Plots in Statistical Process Control. Scatter Diagrams and Control Charts in Statistical Process Control

1. MRP, MRPII and ERP Systems (8h + 4h):

1. 1. Definition and Models (Make to Order, Make to Stock)
   2. Introduction to Basic Problems at Planning Level
   3. Exercise 4.1: Inventory Control Basic Example
   4. Exercise 4.2: Demand Prediction Basic Example

1. Use Cases (6h):

1. 1. Definition of Use Cases by a MES/ERP developer

Total: 72h

• Lectures: 44 hours; Hands-on: 28 hours

RECOMMENDED READING/BIBLIOGRAPHY

Lecture slides and recorded lessons.

Students with learning disorders ("disturbi specifici di apprendimento", DSA) will be allowed to use specific modalities and supports that will be determined on a case-by-case basis in agreement with the delegate of the Engineering courses in the Committee for the Inclusion of Students with Disabilities.