A radio frequency identification based optimal material delivery method for digital plant production

Abstract

Currently, Just-in-Time (JIT) is becoming one of the increasingly important manufacturing modes applied by enterprises for surviving in drastic market competition. As a key function of JIT manufacturing, the material delivery characterised by real time, accuracy and optimisation can make sure of JIT's implementation in enterprises effectively and efficiently. In the study, we present a new kind of real-time optimal material delivery method for plant production by utilising radio frequency identification (RFID) technology. In the method, the precise and visual layouts for the whole physical plant and all kinds of its inner manufacturing resources such as machines, RFID devices, forklifts and inventories are realised. Later, the mathematical model for dynamically obtaining the optimal routes for forklifts is established by taking the minimal travel distance as the objective. Particularly, to solve the problem, a real-time optimum route planning method based on the ant colony optimisation (ACO) algorithm is developed. In order to monitor and navigate the forklifts in real time during material distribution in the plant for material delivery planners and operators, a position locating scheme for forklifts and materials is proposed. Finally, a case study is carried out to demonstrate the feasibility of the presented method, which establishes the base for implementing JIT manufacturing in plant production.

Keywords:

• material delivery
• RFID
• plant production
• route planning
• monitoring
• navigation

Acknowledgement

This paper has been presented in DET2009 conference held at the University of Hong Kong during 14–16 December 2009 and included in the conference proceeding published by Springer. Gratitude is extended to the National Natural Science Foundation of China (Grant Nos. 50605050, 50805116) and Ministry of Education for New Century Excellent Talent Support Program of 2007 (NCET-07-0681) for the financial supports. Special thanks also to Hongzhou Zhang for the programming efforts in implementing and demonstrating the presented optimal material delivery method.