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Production events graphical deduction model enabled real-time production

control system for smart job shop

Article  in  ARCHIVE Proceedings of the Institution of Mechanical Engineers Part C Journal of Mechanical Engineering Science 1989-1996 (vols 203-210) · September 2017
DOI: 10.1177/0954406217728531

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Original Article

Proc IMechE Part C:

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Production events graphical deduction 0(0) 1–18
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control system for smart job shop DOI: 10.1177/0954406217728531

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Chuang Wang, Pingyu Jiang and Tiantian Lu

Abstract
Under industry 4.0, the production control system of smart job shop should be able to real-time respond to various
production events and effectively coordinate different kinds of manufacturing resources in good order according to their
material flows. Production events enabled real-time production control system is good at responsibility and flexibility.
Internet of things (IoT) can provide enormous real-time production events, which represent the change of material
flows. However, some of production events seriously interfere with production control procedures. They sharply
restrict the real-time capability of production control system. Thus, it is imperative that an efficient realization
method of production control system, which is enabled by useful production events. Additionally, the control system
should satisfy production control procedures visibility. For solving the problems, a production events graphical deduction
model enabled real-time production control system for smart job shop is proposed in this article. Firstly, the manu-
facturing resources are divided into work in process related, operator-related, cutting tool-related, fixture tool-related,
and measuring tool-related. And the material flows of different manufacturing resources in IoT-enabled smart job shop
are described in detail. Secondly, the graphical deduction model of production event is put forward. Based on the model,
the material flows of manufacturing resources in a process are segmented into several stages according to different
production events. And then, the cooperation model of manufacturing resources is established by using the time and
logical relationships between production events. Thirdly, the control model in a process is drawn from the cooperation
model. Next, the entire control procedure of work in process production in IoT-enabled smart job shop is proposed.
Finally, a small-scale IoT-enabled manufacturing system is used to verify the feasibility of the proposed model and
methods.

Keywords
Production events, graphical deduction model, real-time production control system, smart job shop, IoT/RFID

Date received: 9 October 2016; accepted: 31 July 2017

However, process level alone is not sufficient to main-

Introduction
Rapid market changes, increased product variety, and
short product life cycles have become the most
important features of manufacturing.1 Those changes
of production demand that the future manufacturing
system should be more responsive and flexible.2
Under industry 4.0, the production control system
(PCS) of the smart job shop should real-time coord-
inate the manufacturing resources according to
machining process of work in process (WIP).3
PCS is to ensure that the enterprise products can be
always under control in accordance with the provi-
sions of the methods and orders in the manufacturing
process. And it aims at preventing and stopping the
possible occurring or occurred plan departure from
the production process. Hence, the common PCS
can only achieve the control at process level.
tain smooth production flow at the operational level.1
The production system operates in a dynamic
environment where the unpredictable disturbances
emerge at any time. Therefore, an effective PCS
should respond rapidly to the different production
events (PEs). The PCS of smart job shop is a closed-
loop system by using real-time production informa-
tion from production planning, planning execution,
production monitoring to planning updating.
State Key Laboratory for Manufacturing Systems Engineering, Xi’an
Jiaotong University, Xi’an, PR China
Corresponding author:
Pingyu Jiang, State Key Laboratory for Manufacturing Systems
Engineering, Xian Jiaotong University, No. 28, Xianning West Road,
Xi’an, Shaanxi 710049, PR China.
Email: pjiang@mail.xjtu.edu.cn
2 Proc IMechE Part C: J Mechanical Engineering Science 0(0)
PE is an indispensable part of PCS for smart job
shop. To realize operational level control, the PCS
needs more PEs which can represent the changes
of material flows of manufacturing resources in a
process. But it is impossible in traditional job shops
because the PCS cannot get the real-time production
information.4
With the advent of Internet of things (IoT), espe-
cially RFID, the material flows of manufacturing
resources can be captured by RFID devices that are
deployed in job shop. The IoT-enabled job shop, also
called smart job shop in industry 4.0, is beneficial to
production tracking and control. RFID applied in
material flow tracking has been studied in greater
detail.5 Wang et al.6 used RFID to develop a tracking
system for tracking the object movement and further
predict object positions in the assembly lines. Huang
et al.7 used RFID and wireless information networks
for the collection and synchronization of the real-time
data about material and manpower flows from man-
ufacturing workshops. Vogel et al.8 used RFID-based
asset tracking and more precisely tool tracking to
monitor tool real-time location and condition.
Qu et al.9 discussed a real-life case of applying
RFID for managing material distribution in a com-
plex assembly shop floor, where the entrance/exit
of RFID-tagged objects were monitored by RFID-
Gateways. In the authors’ early research, an RFID-
driven graphical formalized deduction model was
proposed for monitoring the time-sensitive state
changes of material flow in a job shop.10–12
IoT provides enormous real-time PEs. But most of
them are useless for PCS. They should be quickly
distinguished by the PCS in order to reduce their
adverse effects.3 Brusey and McFarlane13 separated
valid events from other events by some time period
for correctly identifying, tracking, and dealing with
aggregated objects in customized production with
the use of RFID. Wang et al.14 proposed the declara-
tive RFID rules language to detect RFID event.
Moon et al.15 presented an XML-based language for
describing RFID event and then processed the RFID
event as contextual event. In fact, many more meth-
ods to detect valid PEs can be found from the litera-
ture, but most of them are mainly suitable for RFID
events. And they are not appropriate for other IoT
events (e.g. sensor event).15
Although IoT and RFID have long been used to
track the material flows of manufacturing resources,
they as integral part of the PCS are not to be fully
exploited.13,16 Huang et al.17 proposed a wireless
manufacturing framework where RFID devices are
deployed to workstations, critical tools, key compo-
nents, and containers of WIP. RFID tracked the
manufacturing resources and fed back shop floor
disturbance to decision makers on a real-time basis.
The authors proposed a rescheduling decision
mechanism, which used RFID to detect the recessive
disturbances in actual manufacturing processes, and
real-time rescheduled the original production schedule
according to the impact of recessive disturbances.4
Liu and Miao18 applied RFID in PCS in a discrete
manufacturing system. They built a RFID activity
monitor system to satisfy real-time production pro-
cess control requirement. From the existing literature,
it can be found that the IoT/RFID-based PCS is at
process level. And they can real-time control job shop
production to reduce the differences between produc-
tion planning and actual production procedures.19
But the PCS in industry 4.0 needs lower level.
It should real-time coordinate all manufacturing
resources in the process.
Some researchers have started using IoT/RFID to
realize lower real-time control system in manufactur-
ing domain. By virtue of RFID, Qiu20 achieved
process automation of semiconductor equipment to
ensure the completion of each machining process.
Liu et al.2 proposed a distributed control system for
mass customization production, in which RFID made
the control system more dynamic and flexible in tack-
ling instant changes in the manufacturing systems.
The authors introduced IoT and RFID into machin-
ing process to realize a decentralized control system in
which the WIP can communicate with other manufac-
turing resources. From the discussion above, it can be
seen that IoT/RFID is conducive to the improvement
of process automation as well as collaboration among
manufacturing resources. But the existing literature does
not combine the PCS with the production planning.
In addition, real-time PCS should satisfy produc-
tion control procedures visibility. Visibility system is
utilized in the manufacturing processes to detect the
status of the production activity, analyze its perform-
ance, and help making intelligent decisions. It is an
essential element of real-time PCS and can improve
production control efficiency by giving operator
prompting message.21,22 Additionally, network man-
ufacturing forces companies to improve production
visibility by implementing effective production moni-
toring.23 It has been illustrated by numerous indus-
trial applications that RFID can enhance production
visibility and transparency. But there are few studies
focused on the visibility of production control proced-
ures using IoT and RFID in a process.
For solving above problems of IoT/RFID applica-
tion, this article proposes a production events enabled
real-time production control system. Firstly, this
article defines the manufacturing resources which
should be controlled in production procedures, such
as WIP-related, operator-related, cutting tool-related,
fixture tool-related, and measuring tool-related. Then,
it describes the material flows of different manufactur-
ing resources in IoT-enabled smart job shop in detail.
Next, it segments each material flow in a process into
several stages with the help of PEs, which are
obtained by IoT/RFID. According to the time and
logical relationships between PEs, the cooperation
model of manufacturing resources for a process is
Wang et al.
established, which can identify the valid PEs in time.
Based on the authors’ previous work, this article
presents a production events graphical deduction
model (PEGDM). And relying on PEGDM, the visu-
alization of production control procedures would be
easy to realize not only at operational level but also at
process level.
This article combines the efforts of the following
three aspects: (1) the real-time PCS can achieve the
refined control not only at process level but also at
operational level, it can ensure that different kinds of
manufacturing resources work in the desired order;
(2) the identification of PE is valid for RFID events
as well as other IoT events, and the real-time PCS can
reduce the occurrence of improper response and
improve the responsibility; (3) the real-time produc-
tion control procedures are visible for job shop
managers.
The remainder of this article is organized as fol-
lows: the upcoming section describes the material
flow of manufacturing resources in IoT-enabled
smart job shop. Next, the material flow model of man-
ufacturing resources based on production events
graphical deduction model is depicted. Production
events based real-time PCS is discussed later.
Subsequently, a small-scale IoT-enabled manufactur-
ing system is taken as an example to illustrate the
utility of the proposed models and methods. Finally,
discussion and conclusion are presented.
The material flow of manufacturing
resources in IoT-enabled smart job shop
The PCS of job shop controls the material flow of
manufacturing resources according to production
schedule. The manufacturing resources involved in
WIP manufacturing procedures mainly include
WIP, operators, cutting tools, fixture tools, and
measuring tools. Correspondingly, the material flow
of manufacturing resources can be divided into WIP-
related, operator-related, cutting tool-related, fixture
tool-related, and measuring tool-related, as described
in Figure 1.
The material flow of WIP
The material flow of WIP can be depicted by the red
arrow lines as shown in Figure 1. Firstly, the raw
material of WIP is from the raw material warehouse.
Secondly, it is delivered sequentially to the worksta-
tions according to its processing routine in the smart
job shop by logistics operator. Finally, the WIP is
transported to the finished products warehouse.
Obviously, the WIP may be directly transported
to the scraped products warehouse at each process
endpoint if the machining result is not qualified.
The material flow of WIP in a workstation can be
further subdivided to lower-level stages, as the work-
station n shown in Figure 1. (1) Transportation.
3
The logistics operator uses delivering vehicle to trans-
port the WIP. (2) In-buffer hoisting. When the WIP
arrives at the entrance of the workstation, the porter
hoists it from the delivering vehicle by using crane. (3)
In-buffer. The porter puts the WIP into the in-buffer
of the workstation waiting for machining. (4)
Loading. If the WIP would be machined, the porter
hoists it from the in-buffer onto the machine tool. (5)
Fastening. The WIP is fastened onto the machine tool
by fixtures. (6) Machining. The WIP is in machining
until all requiring machining tasks of the process are
completed. (7) Unloading. If the machining tasks
finish, the porter unloads the WIP from the machine
tool. (8) Out-buffer. The WIP is put into out-buffer
waiting for machining quality inspection. (9)
Inspection hoisting. If the measurer and measuring
tools are ready, the porter hoists the WIP from the
out-buffer onto the measuring table. (10) Quality
inspection. The measurer inspects the machining
results according to the quality requirements of the
process. (11) Transportation hoisting. The porter hoists
the WIP from the measuring table onto the delivering
vehicle for transportation to next workstation.
The material flow of fixture tools
The use of fixture tools is closely related to the
machining tasks of the process. The material flow of
fixture tools in a process can be depicted as the green
arrow lines shown in Figure 1. It can be divided to
several stages according to the machining procedure.
(1) Transportation. When the WIP is in in-buffer, the
machine operator applies for the fixture tools used
in current process. And then, the fixture tools are
transported from the fixture tools warehouse to the
workstation. (2) In-buffer. The fixture tools arrive at
the workstation, and are put into the in-buffer waiting
for mounting on the machine tool. (3) Mounting.
If the WIP would be machined, the fixture tools are
mounted onto the machine tool waiting for the WIP
loading. (4) Dismounting. If the machining tasks com-
pleted and the WIP is unloaded, the fixture tools are
dismounted from the machine tool. (5) Out-buffer.
The fixture tools are put into the out-buffer waiting
for returning the fixture tools warehouse. (6) Returning.
The fixture tools are returned into the fixture tools
warehouse.
The material flow of cutting tools
The material flow of cutting tools is similar to the
fixture tools depicted by purple arrow lines in
Figure 1. (1) Transportation. When the WIP is
loaded on the machine tools from the in-buffer, the
machine operator applies for the cutting tools used in
current process. And the cutting tools are transported
from the cutting tools warehouse to the workstation.
(2) In-buffer. The cutting tools arrive at the worksta-
tion, and are put into the in-buffer waiting for
4 Proc IMechE Part C: J Mechanical Engineering Science 0(0)

Figure 1. The material flow of manufacturing resources in IoT-enabled smart job shop.

mounting on the machine tool. (3) Mounting. If the and the machining results are qualified, the cutting
WIP has been loaded on the machine tool, the cutting tools are dismounted from the machine tool. (5)
tools are mounted onto the machine tool. (4) Out-buffer. The cutting tools are put into the out-
Dismounting. If the machining tasks are completed buffer waiting for returning the cutting tools
Wang et al.
warehouse. (6) Returning. The cutting tools are
returned into the cutting tools warehouse.
The material flow of measuring tools
The material flow of measuring tools can also be
divided to six stages according to its using procedure,
as shown by the blue arrow lines in Figure 1. (1)
Transportation. When the WIP is loaded on the
machine tools from the in-buffer, the machine
operator applies for the measuring tools used in
the current process. And the measuring tools are
transported from the measuring tools warehouse to
the workstation. (2) In-buffer. The measuring
tools arrive at the workstation, and are put into the
in-buffer. (3) Inspection. If the machining tasks are
completed, the machine operator could use the
measuring tools to confirm the machining results.
Note that this inspection is the self-inspection, which
is different from the quality inspection checked by the
measurer. (4) Out-buffer. If the machining results are
qualified, the measuring tools are put into the
out-buffer waiting for returning the measuring tools
warehouse. (5) Returning. The measuring tools are
returned into the measuring tools warehouse.
From what has been discussed above, it can be
found that all material flows of manufacturing
resources intersect with each other at a workstation.
Hence, the real-time PCS should achieve the coordin-
ation of different manufacturing resources at process
level.
The material flow model of
manufacturing resources based
on production events graphical
deduction model
Under industry 4.0, IoT plays an important role in
real-time PCS. In IoT-enabled smart job shop, All
WIPs and manufacturing resources should be labeled
with RFID tags. And other RFID devices are
deployed everywhere in the job shop.24 Smart job
shop can use the real-time production data from
IoT to achieve real-time production control and man-
agement.3,4,25 The typical IoT configuration of a
workstation is the same as follows, as shown in
Figure 1. The workstation is configured with one
RFID reader, which has six RFID antennas. The
RFID antenna 1 is deployed at the entrance of
the workstation which captures the ID information
of the passed WIPs and manufacturing resources.
The RFID antenna 2 is deployed at the in-buffer of
the workstation, which monitors the WIPs and man-
ufacturing resources in in-stock. The RFID antenna 3
is deployed at the machine tool of the workstation,
which monitors the WIPs and manufacturing
resources on the machine tool. The RFID antenna 4
is deployed at the out-buffer of the workstation which
5
monitors the WIPs and manufacturing resources in
out-stock. The RFID antenna 5 is deployed at the
quality inspection table. And the RFID antenna 6 is
deployed at the exit of the workstation.
Through configuring RFID devices, the PCS can
detect the time-sensitive state and position changes of
WIPs and manufacturing resources in a workstation.
Additionally, IoT in smart job shop also includes
intelligent sensors, which can send the running
status of machine tool to the PCS. For example, the
energy sensor can capture the start time and end time
of the machining tasks.
The real-time production data captured by IoT can
be viewed as the representation of production events
which reflect the changes about time, space, and status
of the WIPs and manufacturing resources.
Production events graphical deduction model
For explanatory purposes, some definitions should be
firstly defined as follows:
Definition 1.
A production event is defined as the production
action that happens on a process at a specific time-
stamp, e.g. machining task start event, machining task
finish event, WIP pass-through event.
Definition 2.
A production state is defined as the temporarily
continuous situation of a production stage, e.g. WIP
in in-buffer, WIP in machining, WIP in out-buffer, etc.
A production event would trigger the process from
one production state to another production state.
This means that at the time of the production event
occurrence, the manufacturing resources used in
next production state should be ready to complete
corresponding machining action. Hence, the graphical
deduction model of production event and production
state can be described as in Figure 2.
If the production event and the subsequent
machining action are taken into consideration as a
whole, the production event can be formalized by
the following equation
n o
PEki,j ::¼ tki,j , TRki,j , Aki,j , Tki,j , Cki,j , Pki,j ð1Þ
where PEki,j is the jth production event in process i for
WIP k. tki,j and TRki,j represent the triggering time and
trigger source of PEki,j , respectively. Aki,j is the operator
of subsequent machining action. Tki,j is the tools used
in subsequent machining action. Cki,j stands for the
subsequent machining action. Pki,j is the position of
production event occurrence.
From Figure 2, it can be found that a production
event is the only reason that changes the production
state. In other words, the triggering time tki,j of the
production event is the ending time of the previous
6 Proc IMechE Part C: J Mechanical Engineering Science 0(0)

Figure 2. The graphical deduction model of production event.

inspection transportation
transportation in-buffer fastening unloading hoisting hoisting

in-buffer quality
hoisting loading machining out-buffer inspection

time

Figure 3. The material flow graphical deduction model of WIP in a workstation.

production state PSki,j1 , and it is also the starting time
of the subsequent production state PSki,j .
The material flow graphical deduction
model of WIP
Using the PEGDM, the previous material flow of
WIP in a workstation can be modeled as in Figure 3.
From Figure 3, it can be found that there are 13
PEs driving this process. Note that for describing the
relationship between the material flow of WIP and
other manufacturing resources material flows in
detail, the ‘‘Loading’’ stage is divided into two states
as ‘‘loading’’ and ‘‘fastening’’. The definitions of those
PEs and corresponding detecting sensor are listed as
in Table 1.
The material flow graphical deduction models of
fixture tools, cutting tools, and measuring tools
Similarly, the material flows of fixture tools, cutting
tools, and measuring tools can be easily depicted by
Wang et al. 7

Table 1. The production events of the work in process (WIP) material flow in a workstation.

Notation Definition Detecting sensor

PEki,1 the WIP reaches the entrance RFID antenna 1

PEki,2 the WIP is moved in in-buffer RFID antenna 2
PEki,3 the fixture tools has been mounted onto the machine tool RFID antenna 3
PEki,4 the WIP is moved on the machine tool RFID antenna 3
PEki,5 the WIP is fastened on the machine tool using fixture tools smart Kanban
PEki,6 the cutting tools has been mounted onto the machine tool RFID antenna 3
PEki,7 the machining tasks finish energy sensor
PEki,8 the machine operator completes the self-inspection digital measuring tools
PEki,9 the WIP is unloaded from the machine tool RFID antenna 3
PEki,10 the WIP is moved in out-buffer RFID antenna 4
PEki,11 the WIP is moved on quality inspection table RFID antenna 5
PEki,12 the quality inspection finish digital measuring tools
PEki,13 the WIP reaches the exit RFID antenna 6

using the PEGDM (see Figure 4(a), (b), and (c)). Additionally, from the material flow graphical deduc-
From Figure 4, it can be found that the material tion models of manufacturing resources, it can be seen
flows of three types of tools do not have hoisting that most PEs occur in a sequence for a manufacturing
states, which are different from the material flows of resource. Hence, another time relationship between the
WIP. It is because that the common fixture tools, production events is sequence, it can be described as
cutting tools, and measuring tools are not heavy,
Y   Y   Y  
e.g. combination fixture and combination cutter, PEk
5 PE k
5 PEk
ð3Þ
tk i,l tk i,m tk i,n
and they can be directly taken by the machine tool i,l i,m i,n

operator from warehouse to the workstation.

Correspondingly, the transportation state can be The graphical deduction model of the sequential
changed to in-buffer by using the data of RFID time relationship is as depicted in Figure 5(b).
antenna 2 and ignoring the data of RFID antenna 1
(see Tables 2, 3, and 4).
The definitions of PEs in Figure 4(a), (b), and (c)
The logical relationships between production events
and corresponding detecting sensor are listed in There are three kinds of logical relationships between
Table 2, Table 3, and Table 4: the PEs, i.e. AND, OR, NOT. The AND relationship
means that PEki,n can occur only when PEki,l and PEki,m
have happened. For example, before the WIP is
Production events based real-time moved on the machine tool, the WIP must be in in-
production control system buffer and the fixture tools have been mounted onto
the machine tool, i.e. PEki,2 and PEki,17 have happened.
The time relationships between production events Otherwise, the WIP would not be moved on the
From Tables 1 to 4, it can be found that the definition machine tool, i.e. PEki,4 would not occur. The AND
and detecting sensor of some PEs are the same, e.g. relationship can be depicted as Figure 6(a), and its
PEki,4 , PEki,21 , PEki,28 . It means that the triggering time formulation can be described as
and trigger source of the PEs are same. For example,
when the WIP is moved on the machine tool, PEki,4 , PEki,n ¼ PEki,l ^ PEki,m ð4Þ
PEki,21 , and PEki,28 would trigger WIP fastening,
cutting tools transportation, and measuring tools The OR relationship means that PEki,n can occur
transportation, respectively. Hence, one of the time only when PEki,l or PEki,m has happened. For example,
relationships between the PEs is synchronization, the WIP would be transported to scrapped products
which can be described as warehouse if the machining results could not meet the
    corresponding quality requirements at any process.
Y Y
PEki,l ¼ PE k The OR relationship is as depicted in Figure 6(b),
tki,l , TRki,l k k
ti,m , TRi,m i,m
  ð2Þ and its formulation can be described as
Y
k
¼ k
t , TR k PE i,n
i,n i,n
PEki,n ¼ PEki,l _ PEki,m ð5Þ

The graphical deduction model of the synchronized The NOT relationship means that PEki,n occur only
time relationship is as depicted in Figure 5(a). when PEki,m does not occur. For example, the
8 Proc IMechE Part C: J Mechanical Engineering Science 0(0)

(a)
transportation mounting out-buffer

in-buffer dismounting returning

time

(b)
transportation mounting out-buffer

in-buffer dismounting returning

time

(c)
transportation inspection returning

in-buffer out-buffer

time

Figure 4. The material flow graphical deduction model of other tools in a workstation: (a) the material flow graphical deduction
model of fixture tools in a workstation; (b) the material flow graphical deduction model of cutting tools in a workstation; (c) the
material flow graphical deduction model of measuring tools in a workstation.

Table 2. The production events of the fixture tools material flow in a workstation.

Notation Definition Detecting sensor

PEki,14 the WIP is moved in in-buffer RFID antenna 2

PEki,15 the fixture tools are put into in-buffer RFID antenna 2
PEki,16 the fixture tools are moved onto the machine tool RFID antenna 2
PEki,17 the fixture tools have been mounted onto the machine tool RFID antenna 3
PEki,18 the WIP is unloaded from the machine tool RFID antenna 3
PEki,19 the fixture tools are dismounted from the machine tool RFID antenna 3
PEki,20 the fixture tools are put into out-buffer RFID antenna 4
WIP: work in process.

machining results of current process are qualified only
when any failed machining result does not occur.
The NOT relationship is as depicted in Figure 6(c),
and its formulation can be described as
PEki,n ¼ : PEki,m
Material flow graphical deduction model based
cooperation model of manufacturing resources
In a machining process, the manufacturing resources
must cooperate with each other to complete the
ð6Þ machining tasks of the WIP smoothly. Based on
Wang et al. 9

Table 3. The production events of the cutting tools material flow in a workstation.

Notation Definition Detecting sensor

PEki,21 the WIP is moved on the machine tool RFID antenna 3

PEki,22 the cutting tools are put into in-buffer RFID antenna 2
PEki,23 the WIP is fastened on the machine tool using fixture tools smart Kanban
PEki,24 the cutting tools have been mounted onto the machine tool RFID antenna 3
PEki,25 the machine operator completes the self-inspection digital measuring tools
PEki,26 the cutting tools are dismounted from the machine tool RFID antenna 3
PEki,27 the cutting tools are put into out-buffer RFID antenna 4
WIP: work in process.

Table 4. The production events of the measuring tools material flow in a workstation.

Notation Definition Detecting sensor

PEki,28 the WIP is moved on the machine tool RFID antenna 3

PEki,29 the measuring tools are put into in-buffer RFID antenna 2
PEki,30 the machining tasks finish energy sensor
PEki,31 the machine operator completes the self-inspection digital measuring tools
PEki,32 the measuring tools are put into out-buffer RFID antenna 4

(a) (b)

time time

Figure 5. The time relationships between production events: (a) synchronization; (b) sequence.

(a) (b) (c)

Figure 6. The logical relationships between production events: (a) AND; (b) OR; (c) NOT.

the previous material flow graphical deduction model,
the cooperation model of WIP, cutting tools, fixture
tools, and measuring tools is as described in Figure 7.
According to the definitions of PEs in Tables 1, 2,
3, and 4, it can be found that there are four sets of
synchronized production events. Their implications
are explained as follows.
1. When the WIP is moved in in-buffer, there should
be two production activities that must be performed
concurrently, i.e. applying for the fixture tools
(PEki,14 ), and keeping the WIP in in-buffer until
the fixture tools have been mounted onto the
machine tool (PEki,2 ), as the red line 1 in Figure 7.
2. When the WIP is moved on the machine tool, there
are three production activities that could be per-
formed concurrently, i.e. applying for the cutting
tools (PEki,21 ), applying for the measuring tools
(PEki,28 ), and keeping the WIP on the machine
tool (PEki,4 ), as the red line 2 in Figure 7.
10 Proc IMechE Part C: J Mechanical Engineering Science 0(0)

time

time

6 7 8 time

2 4
1
5

time

Figure 7. The cooperation model of manufacturing resources in a process.

3. When the machine operator completes the self- Production events based production
inspection by using digital measuring tools, there
control in a process
are three production activities that could be
performed concurrently, i.e. putting the measuring According to Figure 7, the control procedures of
tools into out-buffer (PEki,8 ), dismounting the manufacturing resources in a process can be described
cutting tools from the machine tool (PEki,25 ), and as in Figure 8. Based on Figure 8, the real-time PCS in
unloading the WIP from the machine tool (PEki,31 ), a process can be designed as follows.
as the red line 3 in Figure 7.
4. When the WIP is unloaded from the machine tool, 1. The generation of real-time control instruction.
there are two production activities that could When a PE occurs, the real-time control system
be performed concurrently, i.e. dismounting the would judge its validity. From Figure 8, it can
fixture tools from the machine tool (PEki,9 ) and be easily found that the validity of the PE can be
keeping the WIP in the out-buffer (PEki,18 ), as the judged according to the time and logical relation-
red line 4 in Figure 7. ships between related PEs. According to the
graphical deduction model of the relationships
Additionally, there are four sets PEs that trigger (see Figures 5 and 6), a valid PE indicates that
the state change of another manufacturing resource. all the former PEs, which are connected to the
Their implications are explained as follows. PE using directed line, have occurred in sequence.
For example, the validity of PEki,3 can be described
1. The WIP can be moved on the machine tool only as follows
when the fixture tools have been mounted onto the
machine tool, as the red line 5 in Figure 7.
2. The cutting tools can be mounted onto the 8
machine tool only when the WIP has been fas- > PEki,3 ¼ PEki,2 ^ PEki,16
>
> Q   Q   Q  k 
>
>
tened on the machine tool using fixture tools, as < tki,14 PEki,14 5 tki,15 PEki,15 5 tki,16 PEi,16
the red line 6 in Figure 7. Q  k  Q  k 
>
> tki,1 PEi,1 5 tk PEi,2
3. The machine operator starts the machining >
>   i,2 Q  
>
:Q k
tasks only when the cutting tools have been k
t , TRk PEi,2 ¼ tk , TRk PEki,14
i,2 i,2 i,14 i,14
mounted onto the machine tool, as the red line 7
in Figure 7. ð7Þ
4. The machine operator starts to inspect the
machining results only when the machining tasks If the PE is valid, the real-time PCS would generate
finished, as the red line 8 in Figure 7. the real-time control instruction according to the
Wang et al.
measuring
tools
cutting
tools
fixture tools
WIP
t time
Figure 8. The control procedures of manufacturing resources in a process.
graphical deduction model of the PE. The real-time
control instruction can be formalized as follows
Y  
CIki,j ¼ Aki,j , Tki,j , Cki,j , Pk
PEk
i,m
i,j
where CIki,j is the real-time control instruction for the
jth PE in process i for WIP k.
2. The monitoring of the real-time control instruc-
tion execution. The real-time PCS would send
the real-time control instruction to corresponding
operator Aki,j as soon as possible when the PE
occurs. The operator would comply with the
real-time control instruction to complete the
machining task Cki,j using tools Tki,j at position
Pki,j . The real-time PCS monitors the appearance
of subsequent PE ceaselessly which represents the
end of the real-time control instruction.
3. The update of real-time control instruction. If the
real-time PCS finds the valid subsequent PE, it
means that current machining action is achieved,
and the control instruction should be quitted
timely. Next, the new real-time control instruction
would be generated by the real-time PCS accord-
ing to equation (8).
From the control procedures in a process above, it
can be found that the validity of the PE can be
promptly identified, and the corresponding control
instruction can be generated in real time. Therefore,
the PCS is more conducive to the improvement of
manufacturing system responsibility. Here, the
responsibility coefficient, which is the ratio of the
actual processing time to the planned processing
time in a process, is used to measure the performance
of the PCS as follows
rcki ¼ ATki =PTki
where rcki is the responsibility coefficient of WIP k in
process i, ATki represents the actual processing time of
11
the process, and PTki stands for the planned process-
ing time of the process.
ð8Þ Production control in IoT-enabled smart job shop
Figure 8 shows the control procedures in a process
for the machining task of one WIP. According to
Figure 1, the entire production control procedures
of the WIP in IoT-enabled smart job shop can be
depicted as in Figure 9.
From Figure 9, it can be seen that the WIP is
moved out from the raw material warehouse to the
finished products warehouse or the scrapped products
warehouse through several workstations to achieve
the machining tasks. The WIP would be directly
transported to the scraped products warehouse when
it becomes scrapped at any workstation. Otherwise,
the WIP is delivered sequentially to next workstation.
In Figure 9, PE rk represents PE where the raw
material of the WIP leaves the raw material ware-
house, which is captured by the RFID gateway. The
PE triggers the logistics operator moving the material
to workstation 1. PE fk stands for PE that the quali-
fied WIP arrives at the entrance of the finished prod-
ucts warehouse. The PE triggers the warehouse keeper
moving the WIP to the finished products warehouse.
PE sk represents PE that the unqualified WIP arrives
at the entrance of the scrapped products warehouse.
The PE triggers the warehouse keeper moving the
WIP to the scrapped products warehouse.
Case study
The introduction of experiment environment
To verify the proposed approach, a small-scale IoT-
enabled manufacturing system in our lab is taken as
an example. It consists of seven parts: raw material
ð9Þ warehouse, scrapped products warehouse, finished
products warehouse, measuring tools warehouse, cut-
ting tools warehouse, fixture tools warehouse, and a
flexible automated production line, as shown in
12 Proc IMechE Part C: J Mechanical Engineering Science 0(0)

Workstation 1 Workstation i Workstation n

Raw Finished
material ... ... ... products
warehouse warehouse

Scrapped
products
warehouse

time

Figure 9. The WIP production control procedures in IoT-enabled smart job shop.

RFID RFID RFID RFID smart digital tools warehouse

antenna 2 antenna 3 antenna 4 antenna 5 Kanban measuring tools (measuring,
fixture, cutting)

Workstation 1
Workstation 3 Workstation 2

energy sensor sorting cylinder

conveyer RFID RFID to scrapped to finished

KUKA PLC products warehouse
belts antenna 1/6 reader products warehouse

Figure 10. The RFID-enable manufacturing system in our lab.

Figure 10. The flexible automated production line has

three machine tools (i.e. micro lathe, milling machine,
milling center), and all machine tools are connected
together by conveyer belts which are controlled by
PLC (SIEMENS CPU315-2 DP). At the end of the
conveyer belts, there is a cylinder that is used to sort
the unqualified WIP to the scrapped products ware-
house. Every workstation is equipped with one RFID
reader, six RFID antennas, an operator, and a smart
Kanban. Note that antenna 1 and antenna 6 are the
same one because the workstation has only one
entrance/exit. The energy consumption of every
machining tool is monitored by energy sensor
(Janitza UMG 604/103). Additionally, there is a
public quality inspection table in this case.
The production control in a process
Here, workstation 3 is used as an example to illus-
trate the production control procedures in a process.
From the introduction of the manufacturing system,
it can be found that PLC and conveyer belts corres-
pond to the logistics operator and delivering vehicle
in Figure 1, and the porter is the same as the oper-
ator of machine tool. The material flows of all man-
ufacturing resources in the process are the same as
those shown in Figures 3 and 4. Therefore, the con-
trol procedures of the manufacturing resources can
be achieved according to Figure 8. The control pro-
cedures of manufacturing resources for a WIP
are shown in Figure 11. The processing routine of
Wang et al. 13

Figure 11. The control procedures of the manufacturing resources for a WIP in workstation 3.

the WIP includes three parts that correspond to and corresponding control instructions are listed
workstation 1, workstation 2, and workstation 3, as in Table 5.
respectively. And the hole and keyway are machined From Table 5, it can be seen that the control pro-
on workstation 3. The detailed information of PEs cedures involve operator-related manufacturing
 14
Table 5. The detailed information of control procedures for a work in process (WIP) in workstation 3.
Production events Control instructions

No. implications operator tool machining action

1 the WIP reaches the entrance KUKA no take the WIP from conveyer belts
2 the WIP reaches the in-buffer operator 3 no put the WIP into in-buffer
3 the vise has been mounted onto the milling center operator 3 no move the WIP onto the table of milling center
4 the WIP reaches the table of the milling center operator 3 the vise fasten the WIP into the vise
5 the WIP is fastened on the milling center no no no
6 drills and milling cutter are installed operator 3 the milling center carry out the machining tasks
in the tool magazine of the milling center
7 the machining tasks finish no no no
8 operator 3 completes the self-inspection operator 3 no unload the WIP from the milling center
9 the WIP is unloaded from the milling center operator 3 no put the WIP into out-buffer
10 the WIP reaches the out-buffer operator 3 no put the WIP onto the quality inspection table
11 the WIP is put on quality inspection table measurer digital caliper inspect the results of machining tasks
12 the quality inspection finish operator 3 no put the WIP onto conveyer belts
13 the WIP reaches the exit PLC conveyer belts transport the WIP to products warehouse
14 the WIP reaches the in-buffer fixture tools warehouse keeper no send the vise to workstation 3
15 the vise reaches the entrance operator 3 no put the vise into in-buffer
16 the vise reaches the in-buffer operator 3 no mount the vise onto the milling center
17 the vise has been mounted onto the milling center no no no
18 the WIP is unloaded from the milling center operator 3 no dismount the vise from the milling center
19 the vise has been dismounted from the milling center operator 3 no put the vise into out-buffer
20 the vise reaches the out-buffer fixture tools warehouse keeper no take back the vise
21 the WIP reaches the table of the milling center cutting tools warehouse keeper no send the drills and milling cutter to workstation 3
22 the drills and milling cutter reach the entrance operator 3 no put the drills and milling cutter into in-buffer
23 the WIP is fastened on the milling center operator 3 no install the drills and milling cutter in the tool
magazine of the milling center
24 the drills and milling cutter are installed in no no no
the tool magazine of the milling center
25 operator 3 completes the self-inspection operator 3 no uninstall the drills and milling cutter from
the tool magazine of the milling center
26 the drills and milling cutter are uninstalled operator 3 no put the drills and milling cutter into out-buffer
from the tool magazine of the milling center
27 the drills and milling cutter reach the out-buffer cutting tools warehouse keeper no take back the drills and milling cutter
28 the WIP reaches the table of the milling center measuring tools warehouse keeper no send the digital caliper to workstation 3
29 the digital caliper reaches the entrance operator 3 no put the digital caliper into in-buffer
30 the machining tasks finish operator 3 digital caliper inspect the results of machining tasks
31 operator 3 completes the self-inspection operator 3 no put the digital caliper into out-buffer
Proc IMechE Part C: J Mechanical Engineering Science 0(0)

32 the digital caliper reach the out-buffer measuring tools warehouse keeper no take back the digital caliper
Wang et al. 15

resources (i.e. KUKA, the operator of milling center, resources (i.e. the drills and milling cutter), fixture
measurer, PLC, fixture tools warehouse keeper, cutting tool-related manufacturing resources (i.e. the vise),
tools warehouse keeper, and measuring tools ware- and measuring tool-related manufacturing resources
house keeper), cutting tool-related manufacturing (i.e. the digital caliper). It is important to note that

(a)
WIP information
ID
Name bogan
Type others
Routine completed
Designer Xi’an
completed
Jiaotong University
Drawing download
3D model download
Date

production procedures

workstation 1 workstation 2 workstation 3

raw checkout enter qualified? enter qualified? enter qualified? checkin finished
material ... ... ... products
warehouse warehouse

checkin scrapped
products
warehouse

Return

(b)
WIP information
ID 16
Name bogan
Type others
Routine completed
Designer Xi’an
completed
Jiaotong University
Drawing download
3D model download
Date

production procedures

workstation 1 workstation 2 workstation 3

raw checkout enter qualified? enter qualified? enter qualified? checkin finished
material ... ... ... products
warehouse warehouse

checkin scrapped
products
warehouse

Return

Figure 12. The control procedures of the manufacturing resources for a WIP in workstation 3: (a) the control procedures of
qualified product; (b) the control procedures of unqualified product.
16 Proc IMechE Part C: J Mechanical Engineering Science 0(0)

industrial robot (KUKA) and computer (PLC) are
viewed as an especial operator which can instead
people to complete some machining action.
The production control procedures in the
manufacturing system
The production control procedures of two WIPs in the
manufacturing system are shown in Figure 12. From
Figure 12(a), it can be found that the raw material of
WIP ‘‘a’’ leaves the raw material warehouse, and suc-
cessfully passes through three workstations. And at the
end of the production, it becomes a qualified product to
be put into the finished products warehouse. Compared
with WIP ‘‘a’’, WIP ‘‘b’’ becomes an unqualified prod-
uct at workstation 2 (see Figure 12(b)). When WIP ‘‘b’’
leaves workstation 2, it is directly transported to the
sorting station. And the cylinder puts WIP ‘‘b’’ into
the scrapped products warehouse.
The measurement of the PCS performance
Here, the production procedures of 20 WIPs of the
same type are used to illustrate the performance in the
experiment manufacturing system, which selects from
the PEGDM-enabled PCS and conventional produc-
tion mode, respectively. The processing routine of
selected WIPs includes three processes, and the cor-
responding planned processing times are 80 min, 70
min, and 45 min, respectively. The test results of
the actual processing time of 20 WIPs are shown
in Table 6.
The statistical analysis of the test results is shown
in Table 7. A few conclusions can be seen from the
statistical analysis:
1. The average processing time of PEGDM-enabled
PCS in every process is much less than the con-
ventional production mode. This is because that
PEGDM-enabled PCS can trigger fixture tools,
cutting tools, and measuring tools transportation
in time.
2. Compared with the conventional production
mode, the fluctuation of processing time in
PEGDM-enabled PCS for a process is relatively
small (see the standard deviation in Table 7).
This is because that PEGDM-enabled PCS can
reduce human influence by using different produc-
tion events.
3. PEGDM-enabled PCS dramatically shortens the
actual processing time, as the average responsibil-
ity coefficient shown in Table 7. This means that
the planned processing time can be reduced, and
the job shop manager can arrange more WIPs.

Table 6. The test results of actual processing time.

PEGDM-enabled PCS Conventional production mode

Process 1 Process 2 Process 3 Process 1 Process 2 Process 3

WIP no. (min) (min) (min) WIP no. (min) (min) (min)

1 44.3 43.1 30.2 11 75.1 71.2 46.2

2 47.6 40.6 28.9 12 76.3 68.5 44.3
3 42.9 39.8 32.1 13 81.2 69.3 45.8
4 48.1 41.2 30.6 14 73.9 70.5 44.1
5 49.2 42.5 29.7 15 77.4 72.1 41.9
6 44.7 41.9 31.5 16 75.3 65.8 45.7
7 43.8 38.5 30.4 17 80.5 66.7 43.8
8 45.9 41.5 29.8 18 82.1 71.3 42.9
9 42.2 42.4 27.4 19 72.9 67.6 40.7
10 45.1 43.7 32.6 20 78.6 70.2 52.3
PEGDM: production events graphical deduction model; PCS: production control system.

Table 7. The statistical analysis of the test results.

PEGDM-enabled PCS Conventional production mode

Process 1 Process 2 Process 3 Process 1 Process 2 Process 3

Average processing time (min) 45.38 41.52 30.32 77.33 69.32 44.77
Standard deviation 2.30 1.57 1.53 3.18 2.11 3.17
Average responsibility coefficient (%) 56.73 59.31 67.38 96.66 99.03 99.49
PEGDM: production events graphical deduction model; PCS: production control system.
Wang et al.
Discussion
From the case study, it can be found that the pro-
posed model and methods are suitable for the real-
time PCS of smart job shop. However, there are still
the following issues that need to be discussed:
1. PEGDM can depict the material flows of manu-
facturing resources. By virtue of the PEGDM, the
cooperation model of manufacturing resources
can be established. Using the PEs, the control pro-
cedures of manufacturing resources can be
achieved according to the cooperation model.
This article only shows the PEGDM applied in
the real-time PCS of smart job shop. Not limited
to manufacturing domain, it can also adapt to
other real-time control system.
2. PEGDM is used to describe specific material flows
of manufacturing resources. Therefore, for differ-
ent IoT environments and controlled objects, the
model and control procedures are different.
3. PEGDM can segment the material flows of man-
ufacturing resources finely and finely according to
the control requirement. Hence, the real-time PCS
can achieve the refined control of production.
4. And the real-time PCS not only effectively coord-
inate different kinds of manufacturing resources,
but also link-up the operations of different oper-
ators such as people, industrial robot, PLC in
good order.
5. Additionally, the real-time PCS can filter the
disruptive PEs rapidly according to the control
procedures model of manufacturing resources.
It can greatly reduce the occurrence of impro-
per response to different disruptive production
events.
Conclusion
This article proposes a PEGDM-enabled real-time
PCS for smart job shop. Firstly, the material flows
of manufacturing resources, which include WIP, cut-
ting tools, fixture tools, and measuring tools, in IoT-
enabled smart job shop are described. Secondly, the
PEGDM is introduced to segment the material flows
of manufacturing resources in a process. Thirdly, the
time and logical relationships between production
events are put forward. Based on that, the cooper-
ation model of WIP, cutting tools, fixture tools, and
measuring tools in a process is described in detail.
Then, the PEs-enabled control procedures model of
manufacturing resources in a process is drawn from
the cooperation model. Next, the whole control pro-
cedures of WIP production in IoT-enabled smart job
shop are proposed. Finally, a small-scale IoT-enabled
manufacturing system as a case is discussed to illus-
trate the application of proposed model and methods.
PEGDM is an explicit way to segment the control
17
procedures. It is very conducive to form the real-
time events enabled control system.
Future work in this area includes two aspects: (1)
the seamless update of PCS should be taken into
account under rescheduling production planning; (2)
the proposed model should be applied in diverse fields
where the control system must be real-time and
refined.
Declaration of Conflicting Interests
The author(s) declared no potential conflicts of interest with
respect to the research, authorship, and/or publication of
this article.
Funding
The author(s) disclosed receipt of the following financial sup-
port for the research, authorship, and/or publication of this
article: This study was supported by the National Natural
Science Foundation of China (Grant No. 51275396).
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