Journal of Textile Research ›› 2024, Vol. 45 ›› Issue (08): 225-233.doi: 10.13475/j.fzxb.20230703801

• Machinery & Equipment • Previous Articles     Next Articles

Advanced planning and scheduling system and scheduling algorithm for intelligent warp knitting workshop

HUANG Chao1,2, ZHANG Jianming2,3(), CHEN Hao2,3, LIU Weiqi2, ZHANG Haoyu2, GUO Meng2   

  1. 1. College of Mechanical and Electrical Engineering, Fujian Agriculture and Forestry University, Fuzhou, Fujian 350100, China
    2. Fujian Institute of Research on the Structure, Chinese Academy of Sciences, Fuzhou, Fujian 350100, China
    3. Fujian Provincial Key Laboratory of Intelligent Identification and Control of Complex Dynamic System, Quanzhou, Fujian 362000, China
  • Received:2023-07-17 Revised:2024-01-16 Online:2024-08-15 Published:2024-08-21
  • Contact: ZHANG Jianming E-mail:zhangjianming@fjirsm.ac.cn

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Abstract:

Objective The textile industry gradually shifts towards multi-variety, small-batch, and order-based production, and the traditional production management models no longer meet the demands for flexible customization management in large-scale production environments. This issue is particularly prominent in warp knitting production enterprises with complex and diverse products. To address the issues of low efficiency and incomplete consideration factors in traditional manual scheduling in the warp knitting industry, this paper reports an advanced planning and scheduling (APS) for warp knitting, aiming to effectively improving production continuity and order delivery efficiency.

Method APS system based on microservices architecture for warp knitting workshops is proposed. After elaborating in detail the production planning and scheduling operation mechanism based on APS, a multi-objective warp knitting workshop scheduling model was constructed to minimize the maximum completion time and the number of raw material changes. An optimization algorithm based on Non-dominated Sorting Genetic Algorithm II (NSGAⅡ) is designed and implemented to solve the intelligent allocation problem for large-scale equipment and orders.

Results It is found that APS system can effectively make up for the shortcomings of traditional enterprise resource planning (ERP) and manufacturing execution system (MES) single production planning management mode, which is separated from actual production, lack of production planning and decision support. Through the integration with MES, ERP and other systems, comprehensive data analysis and mining, the development of detailed production plans, to provide decision support for production management. According to the actual production situation, the production process is dynamically adjusted and optimized. Experimental verification shows that the optimization effect of NSGA-II based warp knitting shop scheduling optimization method can reach more than 200% as the scale increases in terms of maximum completion time and the number of raw material changes between orders. Compared with the traditional multi-objective genetic algorithm, the scheduling results of this algorithm for small-scale problems are not much different. However, with the expansion of the problem scale, the optimization ability of the traditional multi-objective genetic algorithm decreases significantly, which may lead to longer optimization time, local optimal solution, loss of excellent properties, and even worse scheduling results than manual scheduling.

Conclusion This paper proposes a warp knitting production APS system based on microservice architecture according to actual production needs. It can meet the complex business processes of warp knitting production and future business expansion, and can monitor and coordinate the management of orders and resources in the warp knitting production process in real time, better meeting the actual needs of the warp knitting workshop. In addition, this paper also uses the NSGA-Ⅱ algorithm to optimize scheduling problems, which can significantly improve production efficiency and continuity, effectively solve the problem of effective allocation of large-scale orders and equipment, and can adapt to further expansion in the future. In summary, the warp knitting production APS system reported in this paper is an efficient and intelligent production management tool with a wide range of application prospects and promotional value.

Key words: micro service architecture, advanced planning and scheduling system, warp knitting shop, workshop scheduling optimization method, non-dominated sorting genetic algorithm, intelligent production

CLC Number: 

  • TP181

Fig.1

APS microservice architecture diagram"

Fig.2

Production planning and scheduling flow chart based on APS"

Fig.3

Warp knitting production process"

Tab.1

Warp knitting shop scheduling parameter"

调度参数 参数描述
i 订单编号,i=1,2,3,…,n
j 经编机编号,j=1,2,3,…,m
n 订单数量
m 经编机台数
u j 机台j上有u个订单
O j k 机台j上的第k个订单
w i j 订单i是否分配到机台j上,   w i j = 0或1
M O j k O j ( k - 1 ) 机台j上第k个订单与第 k - 1个订单需要更换原料的次数
L i 订单i的长度,单位为m
P i 订单i的生产速度,单位为m/min
S i 订单i在经编机j上加工时长,单位为min
C j 机台j加工总时长,单位为min
Q j 机台j更换原料次数

Fig.4

algorithm flow chart"

Fig.5

Chromosome coding and decoding diagram"

Tab.2

Comparison of different scale scheduling results"

调度规模 th/min tM/min tN/min nh nM nN
20×100 5 753.2±445.8 5 012.4±256.9 3 076.2±167.8 257±79.2 208±52.5 165±31.6
20×200 6 672.4±678.9 5 978.4±424.6 3 453.2±221.5 454±98.3 394±78.3 257±42.4
50×200 6 034.2±899.6 5 987.7±789.7 2 799.3±245.9 607±108.0 413±88.7 206±45.9
50×500 9 023.4±1 478.5 8 876.9±975.9 4 067.2±387.7 1 478±364.7 1 012±339.3 389±78.7
100×500 7 033.2±1 522.3 6 577.9±1 008.2 3 044.5±543.9 1 378±448.9 978±398.9 549±114.5
100×1 000 15 323.2±2 311.6 13 878.7±1 657.6 6 277.9±876.9 2 978±569.8 2 019±421.0 949±289.7
200×1 000 11 562.7±2 981.7 8 089.1±1 879.9 4 907.2±931.2 2 768±643.7 1 867±522.7 879±453.6
200×2 000 19 218.3±3 467.0 12 378.9±2 178.1 8 987±997.2 6 357±1 556.3 5 697±865.8 2 231±525.7
500×2 000 14 232.1±4 436.3 10 238.8±2 679.1 5 789±1 067.7 6 123±1 623.8 5 588±1 548.9 2 312±667.9
500×4 000 23 431.3±5 789.9 17 897.6±3 398.2 10 896±1 564.5 11 272±3 178.1 9 245±1 780.1 4 123±891.0

Tab.3

Different scale scheduling optimization rate %"

调度规模 R1 R2 R3 R4
20×100 47.0 33.9 55.7 26.1
20×200 63.2 45.1 76.6 53.1
50×200 77.6 60.8 105.3 67.5
50×500 107.9 89.2 158.8 98.4
100×500 131.0 116.1 178.5 112.7
100×1 000 164.3 121.1 236.1 167.5
200×1 000 175.8 155.8 267.4 189.4
200×2 000 196.6 179.3 356.9 243.8
500×2 000 221.4 205.2 389.3 267.1
500×4 000 289.1 268.0 466.1 289.2

Fig.6

Minimize maximum completion time optimal fitness variation"

Fig.7

Minimize optimal fitness change of number of raw material changes between orders"

Fig.8

Pareto frontier diagram"

Fig.9

Main function modules of APS system"

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