Event-based receding horizon control for two-stage multi-product production plants

In this paper a receding horizon control approach for multi-product production plants is presented. Specifically two-stage plants are considered. In the first stage, a set of parallel production lines generates intermediate products from raw materials. In the second stage, the intermediate products are assembled into final products. A set of buffers for the intermediate products connects the production lines and the assembly line thus allowing a continuous production flow. The focus is on plants where the switch between product types is less frequent than in the assembly line. The latter is mostly dictated by the external demand, while the first one is the main scheduling variable. A systematic event-based control approach using receding horizon control (RHC) techniques is proposed; specifically the production line flow is controlled in order to satisfy the time-varying request from the assembly line while minimizing the intermediate products storage and processing time. Experimental results underline the benefits resulting from the application of the proposed approach to a car engine manufacturing process. © 2007 Elsevier Ltd. All rights reserved.