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The increasing demand for customized products and the highly competitive market have driven a shift from conventional manufacturing to flexible modular manufacturing. Although the flexibility in operations and process routes of modular manufacturing systems (MMS) helps address the complexities of mass-customized production, this high flexibility also increases the complexity of production operations, causing frequent production dynamics. To mitigate the adverse effects of these dynamics on production plans in MMS, a multi-level dynamic response-based resilient production control concept was proposed for digital twin-enabled MMS. The architecture of digital twin-enabled MMS was designed to simulate production schemes and predict performance indicators, and its digital space layer consisted of three-level digital twin models corresponding to workstation, process route, and manufacturing system levels. To effectively manage production dynamics across these levels, a resilient production control mechanism was proposed within the digital twin-enabled MMS. A completion delay prediction-based dynamic production scheduling approach and three levels of dynamic response strategies for reconfiguring process service routes was then developed, respectively. The feasibility and effectiveness of the proposed method were validated through theory-based comprehensive simulations, demonstrating a general way to achieving resilient production control in highly dynamic manufacturing environments by digital twin technology and flexible manufacturing resource reconfigurations.
Liu et al. (Mon,) studied this question.