This document presents two models for visualizing and understanding production in complex process facilities: the production flow network (PFN) and the production flow map (PFM). The PFN models the physical flow of materials through units like reactors, tanks, and pipelines. The PFM complements the PFN by explicitly mapping the connections between input and output ports throughout the production chain, making it easier to follow individual stock flows. Both views represent units, operations, and stocks as the basic elements of any production system and can help planners, operators and managers better understand and optimize complex multimodal production operations.
1. The document discusses the design, development, and implementation of an Integrated Warehouse Management System based on Demand Flow Technology (DFT) to optimize material handling in a manufacturing plant.
2. DFT is a pull system that pulls raw materials and products through the process according to customer demand using Kanban techniques to trigger manufacturing.
3. The finished goods warehouse holds minimal stock and is replenished based on customer demand, enabling a Just-In-Time system and Total Quality Management.
Advanced Production Accounting (APA) uses statistical data reconciliation and regression to clean past production data when processes are assumed to be at steady-state. It defines a simultaneous mass and volume problem with density. This is depicted in an oil refinery flowsheet using the unit-operation-port-state superstructure (UOPSS). Key differences from prior work are that UOPSS uses "ports" to represent flows, requiring fewer quality measurements. Industrial Modeling Framework (IMF) implements the mathematical formulations using IMPRESS modeling language and solvers like SECQPE and SORVE for data reconciliation problems. IMFs provide pre-configured models for industrial projects.
See how the Center for the Advancement of Jewish Education built instructional leadership capacity, embedded instructional coaches in the schools, built a leadership team within each school, and documented student improvement using strategic conversations to build the relationships that have sustained the work beyond its initial two years.
SPICE is a general-purpose circuit simulation program used to simulate nonlinear DC, nonlinear transient, and linear AC analyses. It was developed in the 1970s at the University of California, Berkeley to save money by simulating circuits instead of physically building them. SPICE allows users to place circuit components graphically, change simulation parameters easily, and run simulations to obtain output, helping engineers learn circuit behavior without physical construction.
This document outlines the classification and guidelines for 15 and 18 rated films in the UK. Films rated 15 may contain drug use, horror, swearing and nudity within restraints. Sexual activity can be shown without detail. Strong violence is allowed without dwelling on pain or sexual violence. Films rated 18 cannot be shown to those under 18 and contain more explicit sexual images and violence. Both ratings have guidelines around discrimination, harm, and illegally promoting drugs.
The document discusses irregular verbs, which do not follow the regular rule of adding "-ed" to form the past tense and instead have different past tense spellings that must be memorized. It provides examples of irregular verb conjugations in the present and past tense, as well as with helping verbs. Worksheets and activities are suggested for practicing identifying and using irregular verbs in speaking and writing.
Este documento presenta una lista de productos y herramientas para el sector agrícola, incluyendo sistemas de conducción, postes, alambres, mallas, herramientas de poda y cosecha, y accesorios. Se proporcionan detalles técnicos de cada producto como diámetros, longitudes, materiales, usos y especificaciones. El documento también incluye tablas comparativas de las características de diferentes tipos de postes, alambres y herramientas.
You can take it with you: Rollover planningJayme Lacour
The document discusses options for what to do with retirement savings when changing jobs. It notes that Americans on average change jobs 11 times by age 42. The main options presented are to leave savings in the previous employer's plan, withdraw as cash and pay taxes/penalties, roll over to a new employer's plan, or roll over to an IRA. Rolling over avoids taxes and allows continued growth, while withdrawing cash has significant tax consequences and should generally be avoided to meet retirement savings goals.
1. The document discusses the design, development, and implementation of an Integrated Warehouse Management System based on Demand Flow Technology (DFT) to optimize material handling in a manufacturing plant.
2. DFT is a pull system that pulls raw materials and products through the process according to customer demand using Kanban techniques to trigger manufacturing.
3. The finished goods warehouse holds minimal stock and is replenished based on customer demand, enabling a Just-In-Time system and Total Quality Management.
Advanced Production Accounting (APA) uses statistical data reconciliation and regression to clean past production data when processes are assumed to be at steady-state. It defines a simultaneous mass and volume problem with density. This is depicted in an oil refinery flowsheet using the unit-operation-port-state superstructure (UOPSS). Key differences from prior work are that UOPSS uses "ports" to represent flows, requiring fewer quality measurements. Industrial Modeling Framework (IMF) implements the mathematical formulations using IMPRESS modeling language and solvers like SECQPE and SORVE for data reconciliation problems. IMFs provide pre-configured models for industrial projects.
See how the Center for the Advancement of Jewish Education built instructional leadership capacity, embedded instructional coaches in the schools, built a leadership team within each school, and documented student improvement using strategic conversations to build the relationships that have sustained the work beyond its initial two years.
SPICE is a general-purpose circuit simulation program used to simulate nonlinear DC, nonlinear transient, and linear AC analyses. It was developed in the 1970s at the University of California, Berkeley to save money by simulating circuits instead of physically building them. SPICE allows users to place circuit components graphically, change simulation parameters easily, and run simulations to obtain output, helping engineers learn circuit behavior without physical construction.
This document outlines the classification and guidelines for 15 and 18 rated films in the UK. Films rated 15 may contain drug use, horror, swearing and nudity within restraints. Sexual activity can be shown without detail. Strong violence is allowed without dwelling on pain or sexual violence. Films rated 18 cannot be shown to those under 18 and contain more explicit sexual images and violence. Both ratings have guidelines around discrimination, harm, and illegally promoting drugs.
The document discusses irregular verbs, which do not follow the regular rule of adding "-ed" to form the past tense and instead have different past tense spellings that must be memorized. It provides examples of irregular verb conjugations in the present and past tense, as well as with helping verbs. Worksheets and activities are suggested for practicing identifying and using irregular verbs in speaking and writing.
Este documento presenta una lista de productos y herramientas para el sector agrícola, incluyendo sistemas de conducción, postes, alambres, mallas, herramientas de poda y cosecha, y accesorios. Se proporcionan detalles técnicos de cada producto como diámetros, longitudes, materiales, usos y especificaciones. El documento también incluye tablas comparativas de las características de diferentes tipos de postes, alambres y herramientas.
You can take it with you: Rollover planningJayme Lacour
The document discusses options for what to do with retirement savings when changing jobs. It notes that Americans on average change jobs 11 times by age 42. The main options presented are to leave savings in the previous employer's plan, withdraw as cash and pay taxes/penalties, roll over to a new employer's plan, or roll over to an IRA. Rolling over avoids taxes and allows continued growth, while withdrawing cash has significant tax consequences and should generally be avoided to meet retirement savings goals.
The Science Society had another successful year in 2011. Several activities were carried out including trips to the Science Centre, a cement factory, and UPM. Film shows on NASA and Asian scientists were also well-attended. Talks on technology, engineering, and electronics drew encouraging support. The monthly subscription was increased to RM3 to fund future activities. The secretary thanked the former and new advisers for their guidance in making the society more active.
The document discusses the benefits of using iPads in education, noting that they are lightweight, thin, and easy to use. It highlights features like long battery life, wireless printing, cameras and video capabilities, and iCloud which allows sharing from students' iPads to teachers' desks instantly. In conclusion, the iPad is a portable and efficient device that can streamline classroom resources and benefit both students and teachers.
La dimensione di genere nell'Agenda DigitaleMargot Bezzi
Presentazione per la sessione "#PianoD: come liberare le risorse delle donne", in occasione di Forum PA 2013. In collaborazione con WISTER - Women for Intelligent and Smart Territories.
KIx is Karolinska Institutet's partnership with edX, an online learning platform created by Harvard and MIT to provide high-quality education through massive open online courses (MOOCs). The goals of KIx are to expand access to education for everyone, enhance teaching and learning both on campus and online, and advance teaching through research. KIx will offer a variety of MOOCs covering various subjects like science, engineering, and healthcare.
Presented in this short document is a description of what we call "Advanced" Property Tracking or Tracing (APT). APT is the term given to the technique of predicting, simulating, calculating or estimating the properties (i.e., densities, compositions, conditions, qualities, etc.) in a network or superstructure with significant inventory using statistical data reconciliation and regression (DRR)
Pakistan's planning process aims to reduce poverty through economic growth but has struggled with fiscal deficits and declining long-term growth. Strategic environmental assessment is not legally required but is being informally used to incorporate environmental concerns into economic policies and plans. The planning process involves formulation of long, medium, and short-term national plans by working groups consisting of government stakeholders. Projects are then developed and subjected to lengthy approval processes before implementation, but civil society engagement is limited. While regulations for environmental protection have been made, implementation and enforcement have been lax.
James E Cook Jr. was born on August 31, 1973 and passed away on March 18, 2007 at the age of 33. The brief document provides the name and dates of birth and death for an individual named James E Cook Jr.
El niño empezó a dibujar libremente cuando la maestra dijo que harían dibujos, pero ella quería que esperaran. En la arcilla, él hizo varias formas de platos hasta que la maestra les enseñó a hacer uno solo. Pronto aprendió a copiar a la maestra. En la nueva escuela, cuando dijo que dibujaran, dejó que el niño eligiera su propia flor roja con tallo verde.
This document provides information on available homes for sale in the River Valley Highlands community in Lancaster, Ohio. It describes two inventory homes that are currently available, including a 3 bedroom, 2.5 bathroom home priced at $196,898 located on Zachariah Ave. It also lists available home sites, including some with walkout basements, and notes that 5 sites remain across from the new school. Financing is available through Pulte Mortgage with $3,000 in contributions.
- The document outlines a process for turning an essay prompt into a paper, beginning with turning the prompt into a question, then freewriting and narrowing the focus into a preliminary thesis and outline.
- An example prompt is given about the diversity of Standard American English, which is narrowed into a question about how African American Vernacular English and European American Vernacular English differ from SAE.
- A preliminary thesis and outline are then developed from the narrowed question before conducting further research.
A Regularization Approach to the Reconciliation of Constrained Data SetsAlkis Vazacopoulos
This document proposes a new regularization approach to reconcile constrained data sets. The approach assumes unmeasured variables have a finite but equal uncertainty to derive an iterative solution that does not require explicitly computing a projection matrix at each step. This avoids issues when the projection matrix is non-invertible. The method arrives at a minimized solution by reformulating the problem to include an added regularization term for the unmeasured variables. It also provides an alternative way to classify variables without using the projection matrix.
The document discusses some of the challenges Singapore faces in preserving historical buildings and places of heritage as the country develops economically and its land space becomes more scarce. As Singapore grows, more modern buildings need to be constructed, which can require demolishing older structures. Additionally, preserving many old buildings long-term requires substantial resources. While some buildings are historically significant, Singapore may not always be able to support preserving them due to lack of sufficient land for other development.
Este documento presenta las primeras lecciones de un curso sobre la seguridad de la salvación. Explica que las personas se condenan porque aman sus pecados en lugar de creer en Jesús, y que quienes no creen en él morirán con su pecado sin perdón. También enseña que Jesús es el único que puede quitar los pecados, y que creer en él significa recibirlo como Señor y Salvador para tener vida eterna en lugar de la ira de Dios.
The document encourages children to eat Lucky Charms cereal every day to grow big and strong, describing it as yummy and healthy, and suggests asking your mom to buy Lucky Charms cereal.
Advanced Process Monitoring for Startups, Shutdowns & Switchovers Industrial ...Alkis Vazacopoulos
Presented in this short document is a description of what is called “Advanced” Process Monitoring as described by Hedengren (2013) but related to Startups, Shutdowns and Switchovers-to-Others (APM-SUSDSO). APM is the term given to the technique of estimating or fitting unmeasured but observable variables or "states" using statistical data reconciliation and regression (DRR) in an off-line or real-time environment. It is also referred to as Moving Horizon Estimation (MHE) (Robertson et. al., 1996) in Advanced Process Control (APC) which goes beyond simply updating a bias to implement some form of measurement or parameter feedback (Kelly and Zyngier, 2008b). Essentially, the model and data define a simultaneous nonlinear and dynamic DRR problem where the model is either engineering-based (first-principles, fundamental, mechanistic, causal, rigorous) or empirical-based (correlation, statistical data-based, observational, regressed) or some combination of both (hybrid) (Pantelides and Renfro, 2012).
This document discusses different types of process flows and classifications for production processes. It describes three main types of process flows: line flow, intermittent/batch flow, and project flow. Line flow involves a linear sequence of standardized operations, like an assembly line. Intermittent flow involves production in batches using flexible, general-purpose equipment. Project flow is for unique, one-off products like works of art. The document also discusses how process selection decisions impact costs, quality, flexibility and other operational factors.
The Science Society had another successful year in 2011. Several activities were carried out including trips to the Science Centre, a cement factory, and UPM. Film shows on NASA and Asian scientists were also well-attended. Talks on technology, engineering, and electronics drew encouraging support. The monthly subscription was increased to RM3 to fund future activities. The secretary thanked the former and new advisers for their guidance in making the society more active.
The document discusses the benefits of using iPads in education, noting that they are lightweight, thin, and easy to use. It highlights features like long battery life, wireless printing, cameras and video capabilities, and iCloud which allows sharing from students' iPads to teachers' desks instantly. In conclusion, the iPad is a portable and efficient device that can streamline classroom resources and benefit both students and teachers.
La dimensione di genere nell'Agenda DigitaleMargot Bezzi
Presentazione per la sessione "#PianoD: come liberare le risorse delle donne", in occasione di Forum PA 2013. In collaborazione con WISTER - Women for Intelligent and Smart Territories.
KIx is Karolinska Institutet's partnership with edX, an online learning platform created by Harvard and MIT to provide high-quality education through massive open online courses (MOOCs). The goals of KIx are to expand access to education for everyone, enhance teaching and learning both on campus and online, and advance teaching through research. KIx will offer a variety of MOOCs covering various subjects like science, engineering, and healthcare.
Presented in this short document is a description of what we call "Advanced" Property Tracking or Tracing (APT). APT is the term given to the technique of predicting, simulating, calculating or estimating the properties (i.e., densities, compositions, conditions, qualities, etc.) in a network or superstructure with significant inventory using statistical data reconciliation and regression (DRR)
Pakistan's planning process aims to reduce poverty through economic growth but has struggled with fiscal deficits and declining long-term growth. Strategic environmental assessment is not legally required but is being informally used to incorporate environmental concerns into economic policies and plans. The planning process involves formulation of long, medium, and short-term national plans by working groups consisting of government stakeholders. Projects are then developed and subjected to lengthy approval processes before implementation, but civil society engagement is limited. While regulations for environmental protection have been made, implementation and enforcement have been lax.
James E Cook Jr. was born on August 31, 1973 and passed away on March 18, 2007 at the age of 33. The brief document provides the name and dates of birth and death for an individual named James E Cook Jr.
El niño empezó a dibujar libremente cuando la maestra dijo que harían dibujos, pero ella quería que esperaran. En la arcilla, él hizo varias formas de platos hasta que la maestra les enseñó a hacer uno solo. Pronto aprendió a copiar a la maestra. En la nueva escuela, cuando dijo que dibujaran, dejó que el niño eligiera su propia flor roja con tallo verde.
This document provides information on available homes for sale in the River Valley Highlands community in Lancaster, Ohio. It describes two inventory homes that are currently available, including a 3 bedroom, 2.5 bathroom home priced at $196,898 located on Zachariah Ave. It also lists available home sites, including some with walkout basements, and notes that 5 sites remain across from the new school. Financing is available through Pulte Mortgage with $3,000 in contributions.
- The document outlines a process for turning an essay prompt into a paper, beginning with turning the prompt into a question, then freewriting and narrowing the focus into a preliminary thesis and outline.
- An example prompt is given about the diversity of Standard American English, which is narrowed into a question about how African American Vernacular English and European American Vernacular English differ from SAE.
- A preliminary thesis and outline are then developed from the narrowed question before conducting further research.
A Regularization Approach to the Reconciliation of Constrained Data SetsAlkis Vazacopoulos
This document proposes a new regularization approach to reconcile constrained data sets. The approach assumes unmeasured variables have a finite but equal uncertainty to derive an iterative solution that does not require explicitly computing a projection matrix at each step. This avoids issues when the projection matrix is non-invertible. The method arrives at a minimized solution by reformulating the problem to include an added regularization term for the unmeasured variables. It also provides an alternative way to classify variables without using the projection matrix.
The document discusses some of the challenges Singapore faces in preserving historical buildings and places of heritage as the country develops economically and its land space becomes more scarce. As Singapore grows, more modern buildings need to be constructed, which can require demolishing older structures. Additionally, preserving many old buildings long-term requires substantial resources. While some buildings are historically significant, Singapore may not always be able to support preserving them due to lack of sufficient land for other development.
Este documento presenta las primeras lecciones de un curso sobre la seguridad de la salvación. Explica que las personas se condenan porque aman sus pecados en lugar de creer en Jesús, y que quienes no creen en él morirán con su pecado sin perdón. También enseña que Jesús es el único que puede quitar los pecados, y que creer en él significa recibirlo como Señor y Salvador para tener vida eterna en lugar de la ira de Dios.
The document encourages children to eat Lucky Charms cereal every day to grow big and strong, describing it as yummy and healthy, and suggests asking your mom to buy Lucky Charms cereal.
Advanced Process Monitoring for Startups, Shutdowns & Switchovers Industrial ...Alkis Vazacopoulos
Presented in this short document is a description of what is called “Advanced” Process Monitoring as described by Hedengren (2013) but related to Startups, Shutdowns and Switchovers-to-Others (APM-SUSDSO). APM is the term given to the technique of estimating or fitting unmeasured but observable variables or "states" using statistical data reconciliation and regression (DRR) in an off-line or real-time environment. It is also referred to as Moving Horizon Estimation (MHE) (Robertson et. al., 1996) in Advanced Process Control (APC) which goes beyond simply updating a bias to implement some form of measurement or parameter feedback (Kelly and Zyngier, 2008b). Essentially, the model and data define a simultaneous nonlinear and dynamic DRR problem where the model is either engineering-based (first-principles, fundamental, mechanistic, causal, rigorous) or empirical-based (correlation, statistical data-based, observational, regressed) or some combination of both (hybrid) (Pantelides and Renfro, 2012).
This document discusses different types of process flows and classifications for production processes. It describes three main types of process flows: line flow, intermittent/batch flow, and project flow. Line flow involves a linear sequence of standardized operations, like an assembly line. Intermittent flow involves production in batches using flexible, general-purpose equipment. Project flow is for unique, one-off products like works of art. The document also discusses how process selection decisions impact costs, quality, flexibility and other operational factors.
Kelly zyngier oil&gasbookchapter_july2013Jeffrey Kelly
This document discusses modeling unit operations for production flowsheets in process industries. It describes six basic unit operation models - blenders, splitters, separators, reactors, fractionators, and black boxes. Blenders are modeled using recipes that specify the fraction of each inlet stream in the outlet stream. Splitters are modeled using split ratios that specify the fraction of the inlet stream in each outlet stream. The models allow representing both continuous and batch processes at steady-state.
Unit-Operation Nonlinear Modeling for Planning and Scheduling ApplicationsAlkis Vazacopoulos
The focus of this chapter is to detail the quantity and quality modeling aspects of production flowsheets found in all process industries. Production flowsheets are typically at a higher-level than process flowsheets given that in many cases more direct business or economic related decisions are being made such as maximizing profit and performance for the overall plant and/or for several integrated plants together with shared resources. These decisions are usually planning and scheduling related, often referred to as production control, which require a larger spatial and temporal scope compared to more myopic process flowsheets which detail the steady or unsteady-state material, energy and momentum balances of a particular process unit-operation over a relatively short time horizon. This implies that simpler but still representative mathematical models of the individual processes are necessary in order to solve the multi time-period nonlinear system using nonlinear optimizers such as successive linear programming (SLP) and sequential quadratic programming (SQP). In this chapter we describe six types of unit-operation models which can be used as fundamental building blocks or objects to formulate large production flowsheets. In addition, we articulate the differences between continuous and batch processes while also discussing several other important implementation issues regarding the use of these unit-operation models within a decision-making system. It is useful to also note that the quantity and quality modeling system described in this chapter complements the quantity and logic modeling used to describe production and inventory systems outlined in Zyngier and Kelly (2009).
Logistics: The Missing Link in Blend Scheduling OptimizationAlkis Vazacopoulos
This document discusses logistics scheduling optimization for blending liquids. It begins by introducing blending and describing logistics scheduling as the "coarse-tune" that determines quantity and logic details, while quality scheduling performs the "fine-tune." It then provides examples of key logistics constraints like minimum/maximum run lengths. The document emphasizes that ignoring logistics leads to suboptimal schedules. It proposes various metrics to quantify non-compliance with logistics constraints. Finally, it presents a framework to trade off quantity and quality using "logistics isotherms" and argues explicit logistics scheduling can improve this trade-off relationship.
1) The document discusses allocation of equipment in a multi-stage manufacturing process where multiple equipment are used at each stage to minimize wait times between stages.
2) It presents a linear model to estimate the effects of main equipment and interactions between adjacent stages on final product quality. Fractional factorial designs are used to analyze the model with multiple factors of mixed levels.
3) As an example, a six-stage process with two two-level and three three-level factors is examined. A resolution III fractional factorial design is constructed by taking the product of two-level and three-level fractional designs to estimate all main and two-way interaction effects between adjacent stages.
Stock Decomposition Heuristic for Scheduling: A Priority Dispatch Rule ApproachAlkis Vazacopoulos
Highlighted in this article is a closed-shop scheduling heuristic which makes use of the traditional priority dispatch rule approach found in open-shop scheduling such as job-shop scheduling. Instead of prioritizing and scheduling one job or project (or stock-order) at a time, we schedule one stock or stock-group at a time where a stock-group is a collection of individual stocks and their one or more stock-orders. These stocks can be feed-stocks, intermediate-stocks or product-stocks of which we focus on product-stocks given that most production is demand-driven. A key feature of this heuristic is our ability to compress the production network or superstructure so that only those unit-operations necessary to produce the stocks in question are included in the model thus reducing the size of the problem considerably at each iteration of the heuristic. The stock-specific network compression technique uses what we call a unit-capacity transshipment linear program to successively determine which unit-operations are redundant when making a particular stock. This heuristic is also particularly useful for those process industries that can potentially produce many product-stocks but only a fraction of these are produced within the scheduling horizon whereby the model is significantly reduced at solve time to include only those stocks that are demanded whereby redundant unit-operations are removed. An illustrative example is provided with recycle loops (i.e., stock flow-reversals) and shared units or equipment (i.e., unit flow-reversals) that demonstrates the effectiveness and efficiency of the technique.
CH6 6.1 PROCESS THINKING Process thinking is the point o.docxsleeperharwell
1. The document discusses process thinking and viewing a business as a system of interconnected processes. It defines key terms like system, transformation process, inputs, outputs, and boundaries.
2. Process flowcharting is introduced as a way to visually map out a transformation process by identifying steps, activities, customers, and suppliers. Creating flowcharts can help identify areas for improvement.
3. Little's Law is discussed as relating the average number of items in a system to the average arrival rate and average time spent in the system. It can be applied to manufacturing, services, and other settings.
The document describes value stream mapping techniques that incorporate both lean manufacturing and environmental sustainability principles. Conventional value stream mapping can overlook environmental impacts and wastes. The Green Suppliers Network promotes "lean and clean" value stream mapping to help identify sources of non-value added time, materials, and environmental impacts. It provides guidance on creating current and future state maps to establish baselines and improvement opportunities for reducing waste, costs, and environmental impacts across production processes.
Achieving a "Flow" type of Production is, or at least should be, a prime target for the Manufacturing Industry.
by Carlo Scodanibbio
https://www.scodanibbio.com
Natural gas operations considerations on process transients design and controlISA Interchange
This manuscript highlights tangible benefits deriving from the dynamic simulation and control of operational transients of natural gas processing plants. Relevant improvements in safety, controllability, operability, and flexibility are obtained not only within the traditional applications, i.e. plant start-up and shutdown, but also in certain fields apparently time-independent such as the feasibility studies of gas processing plant layout and the process design of processes. Specifically, this paper enhances the myopic steady-state approach and its main shortcomings with respect to the more detailed studies that take into consideration the non-steady state behaviors. A portion of a gas processing facility is considered as case study. Process transients, design, and control solutions apparently more appealing from a steady-state approach are compared to the corresponding dynamic simulation solutions.
Presented in this short document is a description of what is called a “Pipeline Scheduling Optimization Problem” and was first described in Rejowski and Pinto (2003) where they modeled the first-in-first-out (FIFO) and multi-product nature of the segregated pipeline using both discretized space (multi-batches, packs or pipes) and time (multi-intervals, slots or periods). The same MILP model can also be found in Zyngier and Kelly (2009) along with other related production/process objects.
Improving Supply Chain Activity using Simulationijsrd.com
The discovery through computational modeling and simulation has become the third pillar of science, alongside theory and experimentation. As computational power increases, simulation has gained in importance and has become a major research area, where highly parallel computation is utilized. In this dissertation, we have performed the simulation by selecting a single machine which is involved in manufacturing the highest number of products. Data are collected for all the processes involved in the manufacturing processes and an input modelling analysis is been done for the data collected. After the analysis is completed, a simulation model is constructed using ARENA which involved all the manufacturing process using the simulation tools. With the help of the simulation tools we will be able to identify activities causing the bottlenecks and delays in the entire manufacturing processes. Similarly, this simulation can be carried out for each and every machine of the company so that we can identify the bottlenecks and delays. As a result, the bottlenecks and delays can be reduced and the entire supply chain can be improved. This paper aims at combining supply chain management and simulation - to give an overview of both areas and shows how supply chain management can profit from simulation and also to identify the delays and bottlenecks in the overall manufacturing process. Lastly, a sample of how a supply chain can be optimized, in the simulation development suite ARENA.
This document provides information on flow systems, activity relationships, and space requirements for facilities design. It discusses:
- Activity relationships are key inputs and are defined by flow and organizational relationships.
- Flow includes materials, people, equipment, information, and money moving through a facility via patterns and measurements.
- Space requirements include workstation specifications, department specifications, and other needs.
- The document then provides more details on flow patterns within and between workstations and departments, as well as principles of effective flow and tools for analyzing relationships and requirements like flow diagrams and relationship charts.
Fluid Dynamics Simulation of Two-Phase Flow in a Separator Vessel through CFDtheijes
The poly (ethylene-co-vinyl acetate) - is an EVA polymer produced that has an important role in the National petrochemical industry chain. Understanding the fluid dynamic behavior during processing in pots separators is of fundamental interest for operational continuity. The drag of polymer melt to the top of the vase, is a source of interest to understand the behavior of the flow inside the machine and reduce contamination. The objective of this work is to study the phenomena the fluid dynamic behavior of EVA during processing inside the separator vessel, to propose a modification of the process. We performed numerical simulations of two-phase flow (gas and ethylene polymer melt), using the commercial computational fluid dynamics package CFX 5.5. The turbulence model used was the k-ε for the fluid phase and a model with an Eulerian approach. The modeling used was satisfactory, because during the simulations, we studied the velocity profiles, concentration and trajectory of the biphasic mixture of fluids.
This document discusses a study on the sensitivity of three virtual metering systems to input measurement uncertainties, degradation, and availability. The study found that:
1) Certain instruments have a larger impact on estimated rates, and their degradation over time must be considered.
2) Measurement uncertainties propagate differently through each system's models, impacting the estimated rates.
3) Data availability, affected by instrument failures, also impacts rate quality estimates differently in each system.
The study provided insights into how virtual metering systems respond to real-world challenges and helped identify which instruments were most critical for system functionality.
Plant wide control design based on steady-state combined indexesISA Interchange
This work proposes an alternative methodology for designing multi-loop control structures based on steady-state indexes and multi-objective combinatorial optimization problems. Indeed, the simultaneous selection of the controlled variables, manipulated variables, input-output pairing, and controller size and interaction degree is performed by using a combined index which relies on the sum of square deviations and the net load evaluation assessments in conjunction. This unified approach minimizes both the dynamic simulation burden and the heuristic knowledge requirements for deciding about the final optimal control structure. Further, this methodology allows incorporating structural modifications of the optimization problem context (degrees of freedom). The case study selected is the well-known Tennessee Eastman process and a set of simulations are given to compare this approach with early works.
What are the limitations of using traditional Value Stream Mapping (V.pdframasamyarm
What are the limitations of using traditional Value Stream Mapping (VSM) in mapping a current
state of \"push\" control from a Factory Physics viewpoint? How does VMS+ \"Learning to see
better\" improve this situation?
Solution
Unlike traditional process mapping tools, VSM is a mapping tool that maps not only material
flows but also information flows that signal and control the material flows. This visual
representation facilitates the process of lean implementation by helping to identify the value-
adding steps in a value stream and eliminating the non-value adding steps, or wastes (muda).
Using a VSM process requires development of maps: a Current State Map and a Future State
Map. In the Current State Map, one would normally start by mapping a large-quantity and high-
revenue product family. The material flow will then be mapped using appropriate icons in the
VSM template. The (material) flow path of the product will be traced back from the final
operation in its routing to the storage location for raw material. Relevant data for each operation,
such as the current schedule (push, pull, and order dispatching rules in effect at any process ex.
FIFO) and the amount of inventory in various queues, will be recorded. The information flow is
also incorporated to provide demand information, which is an essential parameter for
determining the “pacemaker” process in the production system. After both material and
information flows have been mapped, a time-line is displayed at the bottom of the map showing
the processing time for each operation and the transfer delays between operations. The time-line
is used to identify the value-adding steps, as well as wastes, in the current system. The
comparison between the processing times and the takt time (calculated as Available
Capacity/Customer Demand) is a preliminary measure of the value and wastes in a stream. This
takt time is mostly used as an ideal production rate for each operation to achieve. Ideally, the
cycle time for each operation should be less than or equal to the takt time.
Based on the analysis of the Current State Map, one then develops a Future State Map by
improving the value-adding steps and eliminating the non-value adding steps (waste). According
to Rother & Shook, there are seven guidelines, adapted and modified based on the concepts of
Lean Thinking, that can be followed when generating the Future State Map for a lean value
stream:
1) Produce to takt time
2) Develop continuous flow
3) Use supermarkets to control production where continuous flow does not extend upstream
4) Schedule based on the pacemaker operation
5) Produce different products at a uniform rate (Level the production mix)
6) Level the production load on the pacemaker process (Level the production volume)
7) Develop the capability to make “every part every (EPE)
Advantages of VSM
> Relates the manufacturing process to supply chains, distribution channels and information
flows.
> Integrates material and information flows.
The document discusses process design. It defines a process as transforming inputs into outputs through a set of activities. Process design determines the workflow, equipment needs, and implementation requirements for a particular process. It typically uses tools like flowcharting and process simulation software. The key aspects of process design discussed are process planning, documentation, design considerations, and serial vs parallel processes. Process planning involves defining requirements, building a team, planning and implementing, auditing, and retiring processes. Documentation includes block flow diagrams, process flow diagrams, piping and instrumentation diagrams, and equipment specifications. Design considerations are objectives like throughput and constraints like costs. Serial processes have activities that occur one after another, while parallel processes can occur simultaneously to reduce flow time or
The document is an operations and maintenance transition plan template to facilitate migrating an application system from development to production. It provides sections and suggestions for including information on the product scope, relationships to other projects, transition strategies and schedule, resource requirements, acceptance criteria, management controls, and reporting procedures. The template also includes a sample work breakdown structure as an appendix.
Similar to Modeling Multimodal Process Operations (20)
This document summarizes a presentation given at the INFORMS Annual Meeting in 2008 about using Xpress-Tuner to automatically fine-tune the heuristics in Xpress-MP to improve solving mixed integer programs (MIPs). Xpress-Tuner allows tuning control parameters to find settings that reduce solve times by 2-10x on benchmark problems. Examples show tuning advertising and retail planning MIPs to meet time/gap targets. The document highlights Xpress-Tuner's new parallel tuning features and its ability to specialize heuristic threads to further optimize solutions.
This document discusses using the Xpress-Mosel modeling environment for solving data mining problems. It provides an overview of key Mosel features like integration of modeling and solving. It then discusses how Mosel can be used to model various common data mining problems like classification, regression, and clustering as optimization problems. These include formulations as linear programs, mixed integer programs, and stochastic programs.
We tested ODH|CPLEX 4.24 on Miplib Open-v7 Models, a public collection of 286 models to which and optimal solution has not been proven. 257 of these are known to have a feasible solution.
ODH|CPLEX proved optimality on 6 models and found better solutions in 2 hours, to 40% of the models with 12 threads and 35% with 8 threads. ODH|CPLEX matched on 21% of the models.
This document discusses optimizing fantasy football teams to maximize points scored over a 17-week season. It develops a nonlinear programming model using an evolutionary solver with 200 binary variables representing each player. The model aims to select players with the highest historical scoring averages who provide consistent weekly points and availability. Future improvements will add constraints to reduce total variance across positions and simulate different draft outcomes based on pick order, as well as calculating optimal bench players for bye-weeks.
This document outlines the scheduling rules for the National Football League (NFL) and presents an optimization of the NFL game schedule to maximize commercial value. The NFL earned $11.09 billion in revenue in 2014. The scheduling of games is crucial to maximize commercial value. The project uses a step-by-step optimization approach that considers attendance ratios to develop a schedule that achieves the greatest commercial value for the NFL.
2017 Business Intelligence & Analytics Corporate Event Stevens Institute of T...Alkis Vazacopoulos
The document summarizes student poster presentations from a Business Intelligence & Analytics program event at Stevens Institute of Technology. It provides background on the BI&A program, which has grown from 4 students to over 220 students. The posters presented research conducted by students on a wide range of topics under faculty guidance. Over 80 company representatives and 150 students/faculty attended the event to view the 76 posters presenting analytics projects and research.
The team participated in Google's Online Marketing Challenge to build an AdWords campaign for the nonprofit True Mentors. They designed campaigns around search and display ads to promote brand awareness, fundraising events, and donations. Their campaign included 23 ad groups and over 200 ads targeting 700 keywords. The campaign finished as a finalist in the Social Impact category and semi-finalist in the Business category, ranking in the top 10, 15, and 5 respectively. The live campaign ran for 3 weeks on the AdWords platform.
- Large optimization models are increasingly challenging to solve optimally due to super-linear growth in solving effort as model size increases. Parallel heuristic methods provide good quality solutions within practical time limits by solving smaller submodels simultaneously on multiple processor threads.
- Testing on scheduling, supply chain, and telecommunications models found parallel heuristics found high quality solutions for most models in hours, while optimal solutions were impossible within days for some larger models. However, using too many threads showed diminishing returns and even degradation in solution quality due to memory bus bandwidth limitations.
- A retailer buys seasonal stock in advance from overseas suppliers and tries to sell it all over a limited season, usually using discounts.
- An optimization model was created to analyze past sales data, model demand as a function of price, and determine optimal pricing and season length to maximize revenue.
- The model found that allowing for small price increases over the season and extending the season length could significantly increase total expected revenue compared to the retailer's current approach.
Optimization Direct: Introduction and recent case studiesAlkis Vazacopoulos
This document provides an overview of Optimization Direct, an IBM business partner that specializes in optimization software and consulting. It discusses Optimization Direct's experience implementing optimization technology for various industries. The document also summarizes Optimization Direct's product offerings, which focus on IBM ILOG CPLEX Optimization Studio. It then highlights several recent case studies where Optimization Direct helped customers solve scheduling, resource allocation, and pricing problems using analytics and optimization modeling approaches like MIP and heuristic algorithms. Finally, it shares an example of how Optimization Direct helped a retail client optimize markdown pricing and promotions to improve sales and margins.
Informs 2016 Solving Planning and Scheduling Problems with CPLEX Alkis Vazacopoulos
This document discusses optimization solutions for planning and scheduling problems using CPLEX. It begins with an introduction to DecisionBrain and examples of applications in manufacturing, supply chain, and maintenance scheduling. Case studies are presented on production planning in electronics manufacturing, container terminal optimization, and field service scheduling. Best practices are discussed around choosing the right optimization technology, emphasizing decision support over pure optimization, understanding business goals, and integrating process improvements with advanced decision support. Project risks around not achieving benefits, performance issues, and user acceptance are also addressed.
EX Optimization Studio* solves large-scale optimization problems and enables better business decisions and resulting financial benefits in areas such as supply chain management, operations, healthcare, retail, transportation, logistics and asset management. It has been applied in sectors as diverse as manufacturing, processing, distribution, retailing, transport, finance and investment. CPLEX Optimization Studio is an analytical decision support toolkit for rapid development and deployment of optimization models using mathematical and constraint programming. It combines an integrated development environment (IDE) with the powerful Optimization Programming Language (OPL) and high-performance ILOG CPLEX optimizer solvers. CPLEX Optimization Studio enables clients to: Optimize business decisions with high-performance optimization engines. Develop and deploy optimization models quickly by using flexible interfaces and prebuilt deployment scenarios. Create real-world applications that can significantly improve business outcomes. Optimization Direct has partnered with and entered into a technology licensing and distribution agreement with IBM. By combining the founders' industry and software experience and IBM’s CPLEX Optimization Studio product with the arsenal of Optimization modeling and solving tools from IBM provides customers the most powerful capabilities in the industry.
Missing-Value Handling in Dynamic Model Estimation using IMPL Alkis Vazacopoulos
Presented in this short document is a description of how IMPL handles missing-values or missing-data when estimating dynamic models which inherently involve time-lagged or time-shifted input and output variables. Missing-values in a data set imply that for some reason the data is not available most likely due to a mal-functioning instrument or even lack of proper accounting. Missing-data handling is relatively well-studied especially for time-series or dynamic data given that it is not as easy as removing, ignoring or deleting bad sections of data when static or steady-state models are calibrated (Honaker and King, 2010; Smits and Baggelaar, 2010; Fisher and Waclawski, 2015). Unfortunately, all of their methods involve what is known as “imputation” i.e., replacing or substituting missing-data with some reasonably assumed value which is at the very least is a biased estimate. When regression techniques such as PLS and PCR are used (Nelson et. al., 2006) then missing-data can be handled without imputation by computing the input-output covariance matrices excluding the contribution from the missing-values given the temporal and structural redundancy in the system. However, it is shown in Dayal (1996) that using PLS and other types of regression techniques such as Canonical Correlation Regression (CCR) and Reduced Rank Regression (RRR) to fit non-parsimonious and non-parametric finite impulse/step response models (FIR/FSR), that this is not as reliable as fitting lower-ordered transfer functions especially considering the robust stability of the resulting model predictive controller if that is its intended use.
Finite Impulse Response Estimation of Gas Furnace Data in IMPL Industrial Mod...Alkis Vazacopoulos
Presented in this short document is a description of how to estimate deterministic and stochastic non-parametric finite impulse response (FIR) models in IMPL applied to industrial gas furnace data identical to that found in TSE-GFD-IMF using parametric transfer-functions. The methodology of time-series analysis or system identification involves essentially three (3) stages (Box and Jenkins, 1976): (1) model structure identification, (2) model parameter estimation and (3) model checking and diagnostics. We do not address (1) which requires stationarity and seasonality assessment/adjustment, auto-, cross- and partial-correlation, etc. to establish the parametric transfer function polynomial degrees especially when we are using non-parametric FIR estimation. Instead we focus only on the parameter estimation and diagnostics. These types of parameter estimation problems involve dynamic and nonlinear relationships shown below and we solve these using IMPL’s Sequential Equality-Constrained QP Engine (SECQPE) and Supplemental Observability, Redundancy and Variability Estimator (SORVE). Other types of non-parametric identification known as Subspace Identification (Qin, 2006) and can used to estimate state-space models.
Our Industrial Modeling Service (IMS) involves several important (but rarely implemented) methods to significantly improve and advance your existing models and data. Since it is well-known that good decision-making requires good models and data, IMS is ideally suited to support this continuous-improvement endeavour. IMS is specifically designed to either co-exist with your existing design, planning, scheduling, etc. applications or these same models and data can be used seamlessly into our Industrial Modeling and Programming Language (IMPL) to create new value-added applications. The following techniques form the basis of our IMS offering.
Dither Signal Design Problem (DSDP) for Closed-Loop Estimation Industrial Mod...Alkis Vazacopoulos
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This short note describes a relatively simple methodology, procedure or approach to increase the performance of already installed industrial models used for optimization, control, simulation and/or monitoring purposes. The method is called Excess or X-Model Regression (XMR) where the concept of “excess modeling” or an X-model is taken from the field of thermodynamics to describe the departure or residual behaviour of real (non-ideal) gases and liquids from their ideal state (Kyle, 1999; Poling et. al., 2001; Smith et. al., 2001). It has also been applied to model the non-ideal or nonlinear behaviour of blending motor gasoline octanes with its synergistic and antagonistic interactional effects (Muller, 1992).
The fundamental idea of XMR is to calibrate, train, fit or estimate, using actual data and multiple linear regression (MLR) or ordinary least squares (OLS), the deviations of the measured responses from the existing model responses. The existing model may be a glass, grey or black-box model (known or unknown, linear or nonlinear, implicit/open or explicit/closed) depending on the use of the model. That is, for optimization and control the model structure and parameters are available given that derivative information is required although for simulation and monitoring, the model may only be observed through the dependent output variables given the necessary independent input variables.
Distillation Curve Optimization Using Monotonic InterpolationAlkis Vazacopoulos
The document discusses optimization of distillation curves for blending multiple distillation streams. It presents a methodology to interconvert temperatures between ASTM D86 and true boiling point (TBP) scales, interpolate the points to generate evaporation curves using monotonic interpolation, and blend the components using an ideal blending law. The methodology allows manipulating cutpoints of one or more streams' distillation curves to shift the front and back-ends and optimize the final blended product properties and flows while satisfying demands and specifications. An example optimization problem is presented to maximize the flow of two distillation streams in a blend subject to property and flow constraints.
Presented in this short document is a description of how to model and solve multi-utility scheduling optimization (MUSO) problems in IMPL. Multi-utility systems (co/tri-generation) are typically found in petroleum refineries and petrochemical plants (multi-commodity systems) especially when fuel-gas (i.e., off-gases of methane and ethane) is a co- or by-product of the production from which multi-pressure heating-, motive- and process-steam are generated on-site. Other utilities include hydrogen, electricity, water, cooling media, air, nitrogen, chemicals, etc. where a multi-utility system is shown in Figure 1 with an intermediate or integrated utility (both produced and consumed) such as fuel-gas, steam or electricity. Itemized benefit areas just for better management of an integrated steam network can be found in Pelham (2013) where his sample multi-pressure steam utility flowsheet is found in Figure 2.
Advanced Parameter Estimation (APE) for Motor Gasoline Blending (MGB) Indust...Alkis Vazacopoulos
Presented in this short document is a description of how to model and solve advanced parameter estimation (APE) problems in IMPL. APE is the term given to the application of estimating, fitting or calibrating parameters in models involving a network, topology, superstructure or flowsheet. When estimating parameters with multiple linear regression (MLR), ordinary least squares (OLS), ridge regression (RR), principal component regression (PCR) and partial least squares (PLS) there is no explicit model but simply an X-block and Y-block of data. Hence, these methods are referred to as “non-parametric” or “data-based” methods as opposed to the “parametric” or “model-based” method used here. To solve these types of problems we use what is commonly referred to as “error-in-variables” (EIV) regression which is conveniently implemented as nonlinear data reconciliation and regression (NDRR) using the technology found in Kelly (1998a; 1998b; 1999) and Kelly and Zyngier (2008a). The primary benefit of using EIV (NDRR) over the other regression methods is that we can easily handle the inclusion of conservation laws and constitutive relations, explicitly, a must for any industrial estimation problem (IEP).
This presentation provides valuable insights into effective cost-saving techniques on AWS. Learn how to optimize your AWS resources by rightsizing, increasing elasticity, picking the right storage class, and choosing the best pricing model. Additionally, discover essential governance mechanisms to ensure continuous cost efficiency. Whether you are new to AWS or an experienced user, this presentation provides clear and practical tips to help you reduce your cloud costs and get the most out of your budget.
HCL Notes und Domino Lizenzkostenreduzierung in der Welt von DLAUpanagenda
Webinar Recording: https://www.panagenda.com/webinars/hcl-notes-und-domino-lizenzkostenreduzierung-in-der-welt-von-dlau/
DLAU und die Lizenzen nach dem CCB- und CCX-Modell sind für viele in der HCL-Community seit letztem Jahr ein heißes Thema. Als Notes- oder Domino-Kunde haben Sie vielleicht mit unerwartet hohen Benutzerzahlen und Lizenzgebühren zu kämpfen. Sie fragen sich vielleicht, wie diese neue Art der Lizenzierung funktioniert und welchen Nutzen sie Ihnen bringt. Vor allem wollen Sie sicherlich Ihr Budget einhalten und Kosten sparen, wo immer möglich. Das verstehen wir und wir möchten Ihnen dabei helfen!
Wir erklären Ihnen, wie Sie häufige Konfigurationsprobleme lösen können, die dazu führen können, dass mehr Benutzer gezählt werden als nötig, und wie Sie überflüssige oder ungenutzte Konten identifizieren und entfernen können, um Geld zu sparen. Es gibt auch einige Ansätze, die zu unnötigen Ausgaben führen können, z. B. wenn ein Personendokument anstelle eines Mail-Ins für geteilte Mailboxen verwendet wird. Wir zeigen Ihnen solche Fälle und deren Lösungen. Und natürlich erklären wir Ihnen das neue Lizenzmodell.
Nehmen Sie an diesem Webinar teil, bei dem HCL-Ambassador Marc Thomas und Gastredner Franz Walder Ihnen diese neue Welt näherbringen. Es vermittelt Ihnen die Tools und das Know-how, um den Überblick zu bewahren. Sie werden in der Lage sein, Ihre Kosten durch eine optimierte Domino-Konfiguration zu reduzieren und auch in Zukunft gering zu halten.
Diese Themen werden behandelt
- Reduzierung der Lizenzkosten durch Auffinden und Beheben von Fehlkonfigurationen und überflüssigen Konten
- Wie funktionieren CCB- und CCX-Lizenzen wirklich?
- Verstehen des DLAU-Tools und wie man es am besten nutzt
- Tipps für häufige Problembereiche, wie z. B. Team-Postfächer, Funktions-/Testbenutzer usw.
- Praxisbeispiele und Best Practices zum sofortigen Umsetzen
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TrustArc Webinar - 2024 Global Privacy SurveyTrustArc
How does your privacy program stack up against your peers? What challenges are privacy teams tackling and prioritizing in 2024?
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https://www.wask.co/ebooks/digital-marketing-trends-in-2024
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Overview
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Key Topics Covered
1. Introduction to Anomaly Detection
- Understand the fundamentals of anomaly detection and its importance in identifying unusual behavior or failures in systems.
2. Understanding Edge (IoT)
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3. What is ArgoCD?
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4. Deployment Using ArgoCD for Edge Devices
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5. Introduction to Apache Kafka and S3
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6. Viewing Kafka Messages in the Data Lake
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7. What is Prometheus?
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8. Monitoring Application Metrics with Prometheus
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9. What is Camel K?
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10. Configuring Camel K Integrations for Data Pipelines
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11. What is a Jupyter Notebook?
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12. Jupyter Notebooks with Code Examples
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System Design Case Study: Building a Scalable E-Commerce Platform - Hiike
Modeling Multimodal Process Operations
1. Production Modeling for Multimodal Operations
Jeffrey Dean Kelly1
1
Industrial Algorithms LLC., 15 St. Andrews Road, Toronto, Ontario, Canada, M1P 4C3
E-mail: jdkelly@industrialgorithms.ca
2. 2
Introduction
Understanding and modeling the production inside complex process industry facilities can be a difficult task at the best of times. In
part I we described the formulation of nonlinear planning models required to optimize production and some of the fine-points on its
mathematical modeling. The focus of part II is to highlight two views of production called the production flow network (PFN) and the
production flow map (PFM) which can help to clarify the complexities surrounding the production of any process industry facility.
There are already several techniques and devices available to aid in this endeavor however relatively little attention has been paid to
modeling the details of production when several operating modes, production activities or processing tasks exist for any given
production or processing-unit across multiple stages of production. As mentioned, the purpose of this article is to present two distinct
and complementary views of the production system in context with both the physical and functional aspects of the production or
manufacturing. These new views engage the spatial framework or the material-flow-path of the production as opposed to its
hierarchical decision-making (i.e., planning, scheduling and control) and its temporal dimensions (i.e., years to months to weeks to
days, etc.).
Any manufacturing or production environment can be modeled using three fundamental objects or constructs and they are units,
operations and stocks. Units represent the physical equipment which support the production and includes such objects as reactors,
fractionators, heat exchangers, tanks, spheres, warehouses, pipelines, cranes, pumps and compressors. Units are considered to be
renewable resources which may also include manpower and tools or even catalysts. Operations are the functional activities, tasks or
instructions performed by the units. Every unit must be assigned to at least one operation over its life-time else it is considered to be
redundant. Stocks are the feedstock, intermediate, work-in-progress and product materials being either mixed, separated and/or
transformed inside the units in a particular operation. Stocks are considered to be non-renewable resources because they are consumed
and produced by the unit-operations. Other examples of stocks include chemicals and utilities such as caustic soda, corrosion
inhibitors, flow improvers, air, water, steam, electrical power and fuel. Effluents and emissions of hazardous materials or by-products
are also considered as stocks but are dealt with in different ways (i.e., incinerated, treated, scrubbed, etc.)
From the perspective of modeling the complete production scenario inside a process industry facility, several tools and methodologies
are available which involve all aspects of the facility’s life-cycle from its conception, design and construction to its planned, scheduled
and controlled operation. These include the well-known practices of critical path methods (CPM), program evaluation and review
techniques (PERT) (Rardin, 1998), process flow diagrams (PFD) (or flow-sheets), piping and instrumentation diagrams (P&ID),
Gantt (or time-line) charts, disjunctive graphs, throughput charts (Pinedo, 1995), schedule-graphs (Sanmarti et. al., 1998), string
diagrams (Newman et. al. 2002), recipe networks (Mauderli and Rippin, 1979 and Wang et. al., 1997), state-task network (STN)
3. 3
(Kondili et. al., 1993), resource-task network (RTN) (Pantelides, 1994) and the state-equipment network (SEN) (Yoemans and
Grossmann, 1999). All of these methods can in some degree be applied to both continuous and semi-continuous (CSC) and batch and
semi-batch (BSB) type processes including processes which have convergent and divergent material-flow-paths. CSC processes are
characterized by continuous (concurrent, simultaneous) and non-accumulating flow of material through their boundaries whereas BSB
processes have batch (consecutive, sequential) flow implying some level of flow accumulation to occur. Convergent or Leontief
processes have many input or feed streams and only one output or product stream (i.e., co-feeds, mono-product) whereas divergent
processes have one feed stream and many product streams (i.e., mono-feed, co, joint and by-products). Obviously hybrid processes
involving both convergent and divergent flows can also be easily accommodated. The next two sections to follow detail the PFN and
PFM which are intended to provide distinct and informative views on the production.
Production Flow Network (PFN)
The first view to describe is the PFN. An example of a small process industry plant is shown in Figure 1. There are several distinctive
unit objects drawn which are the parcel (inverted triangle), pool (triangle), continuous process (vertical rectangle), batch process
(vertical rectangle partially filled), perimeter (diamond) and pipeline-units (horizontal rectangle). The collection of all units,
operations and stocks is known as the plant. The continuous and batch process-units are flow consumers and producers where batch
process-units, parcel-units and pool-units all contain inventory or hold-up and are the flow accumulators of the production. Pipeline-
units are assumed to always be full so flow accumulation is not expected which implies no change in the total amount of transit-stock
although parcel-unit inventory can affect the transit-stock position. The notions of safety and cycle-stock then apply to the batch
process-units and pool-units only. The bolded arrows denote external streams which can only be connected by what are known as inlet
and outlet port-units (circles); these are the flow interfaces to and from other units. The smaller arrows attached to the other units are
referred to as internal streams whereby process yields can be attached for example when modeling the behavior and effects of the
processes on the product stocks. Both external and internal streams carry the flow of stocks.
4. 4
Parcel
Port with
Internal Stream Pool Continuous Process PerimeterBatch Process Pipeline
Multi-Process
Multi-Product
Multi-Plex
External Stream
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
A
B
A
B
C
D
E
A
AA
A
B
Figure 1. Production Flow Network for a Small Plant Example.
5. 5
The PFN is very similar in spirit to the PFD and in the chemical engineering literature this is sometimes referred to as a superstructure
as opposed to a network given the temporal intermittent nature of the unit-operations. However in the PFN, explicit representation of
the operations are shown which is absent in the PFD. We decompose the operations into three functions and they are called modes,
materials and moves. Modes are operations in or on process-units and perimeter-units and can be both productive and non-productive
activities. These modes are used to effectively discretize the operating region of the units as a function of feed and product quantity
and quality and processing conditions such as temperatures and pressures; within any given mode, the yields of products for example
are assumed to be relatively constant or interpolate linearly in a base plus delta fashion. Materials are operations in or on parcel-units,
pool-units, pipeline-units and port-units such as the material-service of a swing tank. Moves are the transfer or movement operations
between an outlet port-unit and an inlet port-unit. Each of the operations also have transitioning details associated such as sequencing,
start-up, stand-by, switch-over and shut-down events. There can also be ramp-down and ramp-up operations just before a unit-
operation is shut-down and just after it has started-up which effectively turns-down the flows in and out of the equipment in order to
lessen the impact or disruption of the production event on downstream units or utility providers.
The dotted-line boxes surrounding selected units indicate that a particular unit is multi-purpose. Multi-purpose means that it can swing
from one operation to another although if the renewable resource is not of the shared-type then it can only perform one operation at a
time (i.e., unary or single-use); an example of a shared resources is a parcel-unit which represents a marine-vessel with multiple holds
or compartments. Process-units which are multi-purpose are called multi-process meaning that they have multiple modes. Pool-units
are said to be multi-product if they can store more than one product but not at the same time. It should be noted that the logic or
operating rule when swinging-over any material-service on a tank for example must ensure that the heel inventory is below a certain
threshold quantity specified for safety and contamination reasons. Outlet ports can be of the multi-plexed type if one or more
concurrent flows can be accommodated at any given time; inlet ports can also be multi-plexers. The objects contained inside the
dotted-line boxes become what are known as unit-operation pairs or tuples. They represent the virtual, logical or implicit views of
either the meta-physical or meta-functional dimension of the production. The prefix “meta” is used to describe the metaphor or image
that the physical objects can co-exit at least notionally with their meta-physical (or meta-functional) counter-parts. It should be pointed
out that if a particular unit-operation is not scheduled or operated, then all of the external stream flows in and out are forced to zero.
In contrast to the recipe and state-task networks which are used quite extensively in the batch processing industries for planning,
scheduling and executing production for specialty chemicals, pharmaceuticals and other relatively low-volume but high-valued
products, the PFN should be considered as a complement in the sense that it views production more along the lines of the equipment
units and material flow and not strictly from the point view of the recipe or process structure. In recipe networks, equipment or units
are not explicitly shown until a final control recipe is derived (ISA, 1995). Instead the sequence of functional operations (sometimes
6. 6
referred to as a process) is charted with specific ingredient amounts or intensities attached where necessary when material flow is
represented. Hence, recipe networks are more functional than physical. On the other hand, the PFN shows the production from the
perspective of the meta-physical or unit-operations also in the context with the flow of stocks. Moreover, in contrast with the job-shop
or flow-shop scheduling found in the discrete-parts manufacturing industries (Pinedo, 1995) which utilize disjunctive graphs, the PFN
as mentioned shows the flow of materials explicitly. Disjunctive graphs on the other hand, albeit are meta-physical in the sense that
they show both the operations (jobs) and units (machines) on one diagram, do not depict the flow of the parts being manufactured or
operated on.
Production Flow Map (PFM)
The second view is the production flow map which is almost identical to the PFN in terms of information yet it can be a little easier to
navigate and modify (or augment) than the PFN especially for large production instances which may also include not just the
production-chain but also the other supply and demand-chain physical and functional objects. Figure 2 provides the PFM for the same
small but representative plant example.
Feed or Inlet-Side
Product or Outlet-Side
1 2
3
4
5
7
6
8 10
11
12
13
14
159
A B A B
A B
A
C D E
A A
EDCA
BA
BA
Figure 2. Production Flow Map for the Small Plant Example.
The same objects are used except that the unit-operation tuples are split into their feed and product-sides. Product-sides have attached
the outlet ports whereas feed-sides have the connected inlet ports. The idea is to present each of the sides on opposite ends of the view
where it is equally valid to have the products on the left and the feeds on the right and visa-versa. Furthermore, the order of the
product-sides and feed-sides in terms of the meta-physical object placement can also be arbitrary (i.e., the order or sequence of unit-
7. 7
operations inside the respective feed or product-sides can be specified). The PFM is useful because there is no retention of a spatial
material-flow-path concept or structure as in the PFN. The PFM’s prime objective is to show the explicit mapping of outlet ports to
inlet ports throughout the entire production-chain setting clearly and succinctly. This is of value when it is necessary to focus on a
particular stock or related set of stocks when in the PFN the stream flows can be very far apart spatially in the network making
graphical navigation cumbersome. Consequently, the PFM should be considered as more of a stock-specific or focused view whereas
the PFN is more of a unit-operation-specific view (thus the complementary relationship between them). To make this more evident
consider an oil-refinery where the production is sometimes demarcated along the lines of clean or white-oil product versus dirty or
dark-oil product, then the PFM could be used as a helpful tool to model and monitor the daily stock flows for both related oils in the
plant separately in different views or in the same view just positioned at different locations in the map. The PFM can also be used to
represent certain distributed products inside a supply or demand-chain whereby the product-side can represent the supply-side
producers or suppliers and the feed-side can represent the demand-side consumers or customers. This would enable the individual
product-lines (or groups of stocks) for a particular market to be shown easily. Without the PFM, a large flow network view can be
constructed with the unavoidable result of many overlapping and crossing flow lines making the picture somewhat difficult to trace
what supplier is delivering what material to what customer. This is mostly avoided in the PFM because there is a single assignment or
association of one supplier flow of stock to one customer where the spatial representation of the material flow context is abstracted.
Summary
Presented in this brief article are some of the fine-points around the production details found in all process industry plants. The focus
of this paper has been to delineate several of the most fundamental concepts underlying production and manufacturing. Two novel
views, the production flow network and the production flow map are shown which can aid any planner, scheduler, process engineer,
operator and manager in more effectively understanding, formulating and stewarding his or her production responsibilities.
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