Adaptive Real-Time Speed Control for Automated Smart Manufacturing Systems: A Disturbance-Resilient Solution for Productivity

Manufacturing is going through a significant shift propelled by Industry 4.0 and smart manufacturing infrastructures, requiring sophisticated production control techniques that can adaptively adjust to fluctuating operational situations. This paper presents a novel five-step hybrid simulation framework for adaptive real-time production speed control in smart manufacturing lines, integrating conceptual modelling, hybrid simulation, algorithm redefinition, design of experiments, optimisation, and real-system implementation. The framework transforms the speed management systems into online digital twins capable of optimising system performance and mitigating unforeseen fluctuations, faults, and congestion. A comprehensive case study from the beverage manufacturing sector demonstrates the framework’s effectiveness, utilising a universal simulation platform to model both continuous fluid flow and discrete event processes. The proposed stepwise, multi-threshold algorithm employs multiple distinct logical thresholds evaluated sequentially to optimise both upstream and downstream station speeds, with decision thresholds independently adjustable for each production line segment. The experimental results show significant improvements, including around an 18% increase in overall throughput and a 95.7% reduction in work-in-process inventory. A comprehensive resiliency analysis and statistical tests under various disruption scenarios further validated the approach, demonstrating its superiority. Beyond the studied case, the framework provides a transferable pathway for real-time adaptive control across a wide range of smart manufacturing environments, enabling enhancements to operational efficiency without requiring additional capital investment in new equipment or infrastructure.