A Machine-Learning-Assisted Simulation Approach for Incorporating Predictive Maintenance in Dynamic Flow-Shop Scheduling

In this paper, a machine-learning-assisted simulation approach for dynamic flow-shop production scheduling is proposed. This is achieved by introducing a novel framework to include predictive maintenance constraints in the scheduling process while a discrete event simulation tool is used to generate the dynamic schedule. A case study for a pharmaceutical company by the name of Factory X is investigated to validate the proposed framework while taking into consideration the change in forecast demand. The proposed approach uses Microsoft Azure to calculate the predictive maintenance slots and include it in the scheduling process to simplify the process of applying machine-learning techniques with no need for hard coding. Several machine-learning algorithms are tested and compared to see which one provides the highest accuracy. To gather the required dataset, multiple sensors were designed and deployed across machines to collect their vitals that allow the prediction of whether and when they require maintenance. The proposed framework with discrete event simulation generates optimized schedule with minimum makespan while taking into consideration predictive maintenance parameters. Boosted Decision Tree and Neural Network algorithms showed the best results in estimating the predictive maintenance slots. Furthermore, the Earliest Due Date (EDD) model produced the minimum makespan with 76.82 h while scheduling 25 products using 18 machines.