Control of key performance indicators of manufacturing production systems through pair-copula modeling and stochastic optimization

Abstract Key performance indicators (KPIs) modeling and control is important for efficient design and operation of complex manufacturing production systems. This paper proposes to implement the KPI control based on KPI modeling and stochastic optimization. The KPI relationship is first approximated using ordered block model and pair-copula construction (OBM-PCC) model, which is a non-parametric model that facilitates a flexible surrogate of the KPI relationship. Then, the KPI control is framed into a stochastic optimization problem, where the randomness in the cost function depends on the decision variables. To solve this stochastic optimization problem, the standard uniform distribution is employed to link the OBM-PCC model and the cost function to transform the problem into an ordinary stochastic optimization problem. The proposed method is efficient in KPI control and the performance is robust to the cost function. Extensive numerical studies and comparisons, together with a case study, are presented to demonstrate the effectiveness of the proposed KPI control framework.

[1]  Ming Liu,et al.  Stochastic Kriging for Efficient Nested Simulation of Expected Shortfall , 2010 .

[2]  John Yen,et al.  Introduction , 2004, CACM.

[3]  Xi Chen,et al.  Steady-state quantile parameter estimation: An empirical comparison of stochastic kriging and quantile regression , 2014, Proceedings of the Winter Simulation Conference 2014.

[4]  Alan Scheller-Wolf,et al.  The Impact of Dependence on Queueing Systems , 2009 .

[5]  Leon F. McGinnis,et al.  Interpolation approximations for queues in series , 2013 .

[6]  Vikas Manjrekar,et al.  Integrated yet distributed operations planning approach: A next generation manufacturing planning system , 2020 .

[7]  Marcel F. Neuts,et al.  Matrix-analytic methods in queuing theory☆ , 1984 .

[8]  Valerio Cozzani,et al.  Inherently Safer Choices in Early Design of Offshore Oil and Gas Installations: A Multi-Target KPI Approach , 2018, Volume 3: Structures, Safety, and Reliability.

[9]  Zeynep Akşin,et al.  The Modern Call Center: A Multi‐Disciplinary Perspective on Operations Management Research , 2007 .

[10]  John A. Nelder,et al.  A Simplex Method for Function Minimization , 1965, Comput. J..

[11]  Ying-Chyi Chou,et al.  Analytic approximations for multiserver batch-service workstations with multiple process recipes in semiconductor wafer fabrication , 2001 .

[12]  N. Zheng,et al.  Global Optimization of Stochastic Black-Box Systems via Sequential Kriging Meta-Models , 2006, J. Glob. Optim..

[13]  Chao Wang,et al.  Approximate multivariate distribution of key performance indicators through ordered block model and pair-copula construction , 2019, IISE Trans..

[14]  B. Morgan Elements of Simulation , 1984 .

[15]  J. Spall Implementation of the simultaneous perturbation algorithm for stochastic optimization , 1998 .

[16]  Fabio Echsler Minguillon,et al.  Selecting key performance indicators for production with a linear programming approach , 2017, Int. J. Prod. Res..

[17]  Nidhal Rezg,et al.  Unreliable manufacturing supply chain optimisation based on an infinitesimal perturbation analysis , 2018 .

[18]  Hong Kam Lo,et al.  Properties of Dynamic Traffic Assignment with Physical Queues , 2005 .

[19]  Barry L. Nelson,et al.  Stochastic kriging for simulation metamodeling , 2008, 2008 Winter Simulation Conference.

[20]  Thomas Mikosch,et al.  Copulas: Tales and facts , 2006 .

[21]  Hyunsoo Lee,et al.  Development of real-time sketch-based on-the-spot process modeling and analysis system , 2020 .

[22]  Rajan Suri,et al.  Infinitesimal perturbation analysis for general discrete event systems , 1987, JACM.

[23]  Y. C. Ho,et al.  A New Approach to Determine Parameter Sensitivities of Transfer Lines , 1983 .

[24]  Barry L. Nelson,et al.  Estimating Cycle Time Percentile Curves for Manufacturing Systems via Simulation , 2008, INFORMS J. Comput..

[25]  Michael C. Fu,et al.  Queueing theory in manufacturing: A survey , 1999 .

[26]  Paul Damien,et al.  Decision dependent stochastic processes , 2014, Eur. J. Oper. Res..

[27]  Alexander Shapiro,et al.  Stochastic Approximation approach to Stochastic Programming , 2013 .

[28]  I. Grossmann,et al.  A Multistage Stochastic Programming Approach for the Planning of Offshore Oil or Gas Field Infrastructure Under Decision Dependent Uncertainty , 2008 .

[29]  Giovanni Giambene Queuing theory and telecommunications , 2014 .

[30]  H. Akaike A new look at the statistical model identification , 1974 .

[31]  J. Spall Multivariate stochastic approximation using a simultaneous perturbation gradient approximation , 1992 .

[32]  Shiyu Zhou,et al.  Estimation and monitoring of key performance indicators of manufacturing systems using the multi-output Gaussian process , 2017, Int. J. Prod. Res..

[33]  J. Michael Harrison,et al.  Design and Control of a Large Call Center: Asymptotic Analysis of an LP-Based Method , 2006, Oper. Res..

[34]  Shaler Stidham,et al.  Monotonic and Insensitive Optimal Policies for Control of Queues with Undiscounted Costs , 1989, Oper. Res..

[35]  Huashuai Qu,et al.  Simulation optimization: A tutorial overview and recent developments in gradient-based methods , 2014, Proceedings of the Winter Simulation Conference 2014.

[36]  Barry L. Nelson,et al.  Fitting Time-Series Input Processes for Simulation , 2005, Oper. Res..

[37]  H. Joe Families of $m$-variate distributions with given margins and $m(m-1)/2$ bivariate dependence parameters , 1996 .

[38]  Philip Heidelberger,et al.  Quantile Estimation in Dependent Sequences , 1984, Oper. Res..

[39]  E. Vicens-Salort,et al.  A statistical system management method to tackle data uncertainty when using key performance indicators of the balanced scorecard , 2018, Journal of Manufacturing Systems.

[40]  Xi Chen,et al.  Enhancing Stochastic Kriging Metamodels with Gradient Estimators , 2013, Oper. Res..

[41]  Chao Wang,et al.  Bayesian learning of structures of ordered block graphical models with an application on multistage manufacturing processes , 2020, IISE Trans..

[42]  Victor Picheny,et al.  Comparison of Kriging-based algorithms for simulation optimization with heterogeneous noise , 2017, Eur. J. Oper. Res..

[43]  P. Sadegh Constrained optimization via stochastic approximation with a simultaneous perturbation gradient approximation , 1997, Autom..

[44]  Nan Chen,et al.  Simulation-based estimation of cycle time using quantile regression , 2010 .

[45]  Mohammad Modarres,et al.  A queueing approach to production-inventory planning for supply chain with uncertain demands: Case study of PAKSHOO Chemicals Company , 2010 .

[46]  J. Spall STOCHASTIC OPTIMIZATION , 2002 .

[47]  Pierre Pinson,et al.  Generation Expansion Planning With Large Amounts of Wind Power via Decision-Dependent Stochastic Programming , 2017, IEEE Transactions on Power Systems.

[48]  M. Sklar Fonctions de repartition a n dimensions et leurs marges , 1959 .

[49]  Christos G. Cassandras,et al.  Perturbation analysis for production control and optimization of manufacturing systems , 2004, Autom..

[50]  A. Frigessi,et al.  Pair-copula constructions of multiple dependence , 2009 .

[51]  Shengwei Ding,et al.  Queueing Theory for Semiconductor Manufacturing Systems: A Survey and Open Problems , 2007, IEEE Transactions on Automation Science and Engineering.

[52]  O. Brun,et al.  Analytical solution of finite capacity M/D/1 queues , 2000, Journal of Applied Probability.

[53]  F. Massey The Kolmogorov-Smirnov Test for Goodness of Fit , 1951 .

[54]  Dimitris Mourtzis,et al.  Lean rules extraction methodology for lean PSS design via key performance indicators monitoring , 2017 .

[55]  Torsten Jeinsch,et al.  Data-driven design of KPI-related fault-tolerant control system for wind turbines , 2013, 2013 American Control Conference.