Development of a hybrid simulator for manufacturing processes

Advanced manufacturing processes are normally characterised by large numbers of controlled machinery and processes (e.g., lathes, milling machines, conveyors, robots, etc.), whose synchronisation and precision is paramount to the quality of the ultimate product. Coordination and control of such environments is normally a long term planning project. To accommodate effective planning and automation of many manufacturing processes, real-time discrete-event simulation methods have been developed to simulate and test the conditions likely to be encountered in manufacturing. Continuous simulation packages have also been used (independently of discrete simulators) to increase product reliability and production flexibility. Since for most processes the utilisation and control of resources and equipment is a continuous-time event, a purely discrete-time simulation would only produce approximate results. On the other hand, an entirely continuous simulation system would be insufficient to provide process optimisation only possible through logistic control. The work described here aims to bridge this gap through a simulation package which combines both discrete-event and continuous-time simulation.