Industrial Systems Comparison
Industrial Systems Comparison
By
CLASS : TI-D
RAISAL RASYID ZIDHANE ERLANGGA / 122240122
SUBJECT : ENGLISH
LECTURER : BERTY DWI RAHMAWATI, S.T., M.Sc.
Abstrac The purpose of this paper, which aims to compare the focus of the
system on PLCs and the system that is based on multi-agent
systems, is to determine which system performs better. The
comparison will focus on metrics that show how effectively a
system meets the production needs which are required by the
market. Because the market is changing, especially in terms of
layout and programming, this comparison becomes essential.
Therefore, it is necessary that both the old and the new solution
are compared so that we can see which system adapts better to
modern requirements.
Introduction The paper compares systems that focus on programmable logic
controllers (PLCs) and systems which are based on multi-agent
systems (MAS), with an emphasis on comparing metrics that can
identify better-performing systems so that they can address the
needs of the manufacturing industry, which is currently
undergoing a transformation driven by the increasing demand for
customized products. Since traditional mass production methods,
which focus on producing a variety of products on a large scale,
no longer meet the dynamic and diverse needs of modern
consumers, it has become essential to adopt more flexible and
adaptable systems.
Methodology The methodology involved a study comparing two system
approaches, namely programmable logic controllers (PLCs) and
systems that are based on multiagent systems (MAS), focused on
several parameters that were measured: variation time, production
maintenance when adding or removing stations, memory used by
the program, and skills required to operate or change the system.
The simulation implementation for the second approach was
conducted using a graphical interface, while the PLC-based
system was implemented using IsaGraf 3.3 software, and the
MAS-based system was developed with the JADE platform. The
method used in the journal is quantitative. This is due to the use
of data-based measurements that focus on performance
comparisons between two systems (PLC and MAS) using certain
metrics, such as production time variation, memory usage, and
number of lines of programming code.
Results Based on the comparison results of two system methods, namely
the systems that are programmable logic controller (PLS) and
multiagent system (MAS) based management systems, it is
known that the PLC-based system has a more stable production
time when additional stations are added, while the MAS-based
system shows an increase in production time with the addition of
stations. Both systems can continue operating even if several
stations are replaced, as long as the remaining stations possess
similar abilities to absorb tasks. To add a new station, that PLC
system requires lighting and reprogramming, while in MAS, it is
enough to instantiate a new station without having to stop the
system. The MAS system uses more memory when the number of
stations increases compared to PLC. MAS requires basic
knowledge of the system to operate and change configurations,
while PLC requires higher programming skills for changes. MAS
shows better efficiency in programming, because it only requires
one program regardless of the number of stations added, while
PLC requires additional code for each station added.
Discussion The paper presents a detailed comparison between Multi-Agent
Systems (MAS) and Programmable Logic Controllers (PLC) for
managing industrial manufacturing systems, which are critical for
ensuring smooth and efficient operations. The findings offer
critical insights into the strengths and limitations of both systems,
particularly when considering modern manufacturing needs, such
as flexibility, adaptability, and autonomy. PLC, which has been
used for many years, excels in automating industrial processes
because of its stability, efficiency, and effectiveness in repetitive
tasks. However, as discussed in this paper, the inherent rigidity of
PLC systems becomes a disadvantage when manufacturers need
to adapt quickly to changes in production demand, such as
product type variations, reconfigurations, or operational
upgrades. On the other hand, MAS, with its decentralized
structure, offers more flexibility and scalability. The results of this
study emphasize that there is no universal solution to managing
manufacturing systems. This study advocates a hybrid approach,
in which the strengths of both systems can be utilized based on
manufacturing needs with a balance between flexibility and
performance.
Future Research There are several things that could be explored further for the
future, including the implementation of MAS in a manufacturing
environment, which requires careful consideration. It is crucial
that performance be assessed and empirical data be obtained from
the current industrial environment so that more real insights can
be gained into the strengths and weaknesses of this system.
Moreover, there is a need for research that focuses on the hybrid
approach between MAS and PLC, which aims to combine the
flexibility of MAS with the stability of PLC so that it becomes an
ideal solution in various industrial contexts. By utilizing the
advantages of each, this approach could offer the best of both
worlds.
SWOT Analysis
STRENGHTS WEAKNESSES
• The topics discussed, which are highly • In writing the journal, which is often
relevant to the needs of the modern overlooked is not given enough
manufacturing industry, require high special points, so it becomes quite
infrastructure and adaptability. confusing for readers who are
• This journal provides an in-depth looking for a clear methodology
analysis of the comparison between • This study used only simulations,
MAS and PLC, while covering without real-world trials in a physical
various important aspects such as manufacturing environment, which
flexibility, scalability, and limits the applicability of the findings
performance.
OPPORTUNITIES THREATS
• There is a great opportunity to test and • The technical complexity of MAS
develop MAS in real-world may hinder adoption in industries
environments, which can provide that do not have sufficient resources
further validation of its benefits. or expertise to manage it.
• The combination of MAS and PLC • There are advantages and
can pave the way for more efficient disadvantages to both methods, and a
and flexible solutions, taking method that combines the advantages
advantage of the strengths of each and disadvantages of both methods.
system.
NB : Adjective Clause, Adverbial Clause, Noun Clause, Connector of Clause,
Coordinate Conjunction, countable noun, uncountable noun, agreement.
Proceedings of the 19th World Congress
The International Federation of Automatic Control
Cape Town, South Africa. August 24-29, 2014
* Institute SENAI of Inovation Integrated Solutions for Metalmechanics, Brazil (e-mail: joao.peixoto@senairs.org.br)
** Institute SENAI of Inovation Integrated Solutions for Metalmechanics, Brazil (e-mail:bernardo.reis@senairs.org.br)
*** Institute SENAI of Inovation Integrated Solutions for Metalmechanics, Brazil (e-mail: jose.souza@senairs.org.br)
**** Department of Electrical Engineering of Federal University of Rio Grande do Sul – UFRGS, Brazil (e-mail:
cpereira@ece.ufrgs.br)
Abstract: The requirements of industrial manufacturing indicate a need for reconfiguration and
reprogramming process flow, in order to meet changes in the product with the changing market
requirements. These changes imply changes in the manufacturing process, which in many cases means
changing the layout, reprogramming the systems, etc. The sizes of production lots are getting smaller and
the variety of products on the same line has increased. This makes the preparation time of manufacturing
devices an important factor in the formation of the final cost. Devices with more autonomy, able to
manage themselves and allow a rapid exchange of features are still to be desired in a manufacturing
environment, where conventional systems with centralized scheduling, with defined sequence in the
central controller and array of features still fall short. But new solutions must be compared in
performance with traditional solutions as there are features that traditional systems are performing well,
and that are still on the market. Comparing a solution using multi-agent systems and using a solution
centric management on a Programmable Logic Controller can clearly define which metric systems have
better performance.
Keywords: MAS, Multiagents Systems, Industrials Manufacturing, PLC, Automation.
1. INTRODUCTION
The manufacturing industry has been facing a market need 2. CONCEPTS OF MANUFACTURING SYSTEMS
which refers to the consumption of products highly
customized. For several years the concept of mass 2.1. Centralized control of processes
production, characterized by production of the few products
on a large scale has been widely implemented, but nowadays
Traditionally the control in an automation system is
it is unable to deal with the variations of the type of goods performed in a centralized and hierarchical (Colombo, A. et
and no longer able to respond to the challenges of modernity
al. 2008). A component capable of processing information is
and dynamism. Large production batches, production lines
responsible for receiving data from input devices (sensors,
with identical machines and processes and standardization of
switches, keypads, etc.), and trigger output devices (actuators
products no longer exist. The high-volume production
and solenoid valves, motors, solenoids, etc.), according to a
continues to be processed, however, there is a tendency to logical relation and previously defined in an automation
mass production of highly customized goods.
program.
The business environment in the future would be
One of the most used components in control automation
characterized by constant changes in market demand and systems is the Programmable Logic Controller (PLC). A PLC
global competitiveness would press the entry of new products is a component that meets all points of input and output
(James, F. and Smit, H.,2005).
signals, which controls the flow of the process and manages
Centralized management on a Programmable Logic the manufacturing process. The PLC inspects the signs of all
Controller (PLC), integrated manufacturing, flexible inputs (Georgini, M., 2000), performs the logical process
manufacturing systems, manufacturing systems evolvable predefined, and sets the logic state of the outputs, as the logic
stand as proposed in order to attend to this market need. But of the process. This is repeated in cycles. (Fig. 1) shows the
there are management systems with better performance than structure of the centric management system by PLC, where
other. the signals from all system components are connected to
central controller.
Specifically, this paper compares management systems
focused on PLC and management system based on mult-
agent systems, with focus on comparing metrics that can
define the system with better results compared to the
production requirements that the market demands.
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3. INDUSTRIAL MANUFACTURING MANAGED BY is initiated by search piece in the yellow pages to identify the
MULTI-AGENT SYSTEMS agents, who have the capacity to provide the service
requested, then makes contact with them to schedule and run
Industrial manufacturing managed by mult-agent systems is a the service.
proposal to have reprogrammable systems, self-managed and
autonomous, which share information and negotiate the tasks
to be performed.
This approach to manufacturing systems adds functionality
reprogramming of process. Each step is negotiated between
manufacturing subsystems (agents), so that the order in which
the manufacturing is performed is defined through
negotiation and availability of each agent of the system. The
proposal combines features of this point pluggability, the
capacity of each subsystem (agent) to connect or disconnect
the manufacturing system, having no need to be
reprogrammed or stop the process.
The implementation of manufacturing systems using MAS Fig. 3. System emulator mult-agent system applied in
begins of a vision of decentralized processes. Can be industrial manufacturing
performed in 5 steps:
• Identify the components that have the ability to work
autonomously; 4. INDUSTRIAL MANUFACTURING MANAGED BY
• Checking if the elements of transport must be mapped as PROGRAMMABLE LOGIC CONTROLLERS
carriers (TUA); The simulation of the assembly system with management
centered on a PLC is implemented through the IsaGraf3.3
• Consider each product or set of products as agent of product software, developed by CJ International, which provides a
(PA); graphical interface that links all the element flags accessible
• Promote the implementation of devices such as agents, each by the programming language that meets the IEC61131
agent implementing a module interconnection with the (Georgini, M., 2000) and (Silveira, P. and Santos, W., 1999).
hardware, a logic module that manages the device and a With The five languages on this standard, we chose the
communication module that enables the exchange of sequencing function graph (Sequential Function Chart-SFC).
messages with other agents; By the product requirements it was concluded that the system
assembly stations allocated around a circular track, with a
• Connecting agents on a platform of communication between continuous drive, it would be more feasible the
agents. implementation of the manufacturing management centered
with the PLC. (Fig. 4) presents the simulation environment
The programming of the agent can be performed on JAVA proposed for management centered on a programmable logic
[18], which brings the functionality of using the JADE controller.
platform for interconnection of agents and protocols FIPA
Request and FIPA Contract Net, that provide safe and
consistent communication almost agents (Bellifemine, F. et
al., 2004).
To simulate the functionalities of the transport system, the
assembly stations and pallets in a mounting system using
mult-agent systems, was developed a graphical interface in
the Java language, which contains classes and methods that
simulate the physical devices. This interface is called the
agent display and runs on a computer connected to the JADE
platform, as well as every computer that instantiates the
resource agents, forming the assembly stations. This virtual
system is shown in (Fig. 3), the simulation environment of
the monitor agent, which will hold the animation of the
simulation of resource agents, product and conveyor. Each
assembly station is modeled in a process agent, coded in java,
JADE platform connected to it and communicating with the Fig. 4. Didactic plan virtual of assembly system centered
other agents through the protocol FIPA Request and FIPA PLC
Contract Net. When instantiated, the agent puts its services in This implementation consists of an interface that has the
the yellow pages of the JADE platform. The communication hardware components. For each component there is one
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Cape Town, South Africa. August 24-29, 2014
object that simulates the behavior of the component, by Tabel 2. Analysis of the metrics observed
inserting a variable linked with an image. The request for
Analysis of Metrics Best
production is carried out by defining the type of installation
and the command button insert. In PLC the additional stations are not significant for the
production time, unlike MAS, where the addition of stations PLC
affects the production time.
The withdrawal of stations in both systems does not affect the
5. CHOOSE THE METRICS continuity of production, provided that other stations have Equal
similar abilities to those that came out of the station.
The definition of metrics or characteristics qualifies a system In the PLC to insert a new station was necessary to disconnect
requirement, allowing for comparative analysis. When it is and reprogram again. MAS is sufficed instantiate the new MAS
said that they measure the metrics are quantitative (Sato, D., season.
In the PLC with the addition of some stations interferes with the
2007). Qualified when it is said that the metrics are amount of memory used (4% from 1 to 6 stations). Already
qualitative, no possible measure them. The metrics can be MAS
MAS there is a more significant difference (82% from 1 to 6
measured directly (cost, effort, lines of code, execution stations).
speed, memory, number of errors, etc.) or indirectly In MAS, the operation of the system requires a basic knowledge
of the operating system, even for insertion and removal of MAS
(functionality, quality, complexity, efficiency, reliability, stations. In the PLC is required to make changes to the system.
maintainability, modularity, and others) (Pereira, C. and In MAS, because its instances, the programming effort is
Carro, L., 2007). unique, regardless of the station number. Already in each PLC
MAS
insertion station becomes necessary to add codes, higher cost
The purpose of this work is points to more qualitative programming effort.
aspects, which refer to the system performance (performance
tends to be qualitative), which implies that the metrics are of This is not define which one system is the best, but to
a qualitative nature. Some metrics are listed and defined as indicate which system responds best to a given metric. The
not relevant to the proposed analysis, as suggested: cost application is that if one set of metric requirements are more
(more focused to the hardware than the software on a important than others.
production system), number of errors (longer about systems
that are already in production), reliability (very subjective for With all news technology that provides automation systems,
this proposal), among others. there is still systems requirements of manufacturing in the
classical view has better performance. And this is why this
The metrics defined as appropriate and relevant to the vision still occupies a good space in the implementation of
analysis are presented in Table 1, along with their technical manufacturing systems.
justification, how to obtain and evaluation criteria.
Comparing manufacturing systems is not trivial, because
each system has concepts and management devices
Tabel 1. List of metrics used in the experimental validation. implemented in different technologies. It would be difficult to
Metrics Technical justification
compare the memory space occupied on a managed system
for a computer and a managed system in a PLC, because the
Time variation of the
production increase
The increased production stations should not result would indicate the ability of the technology and not the
cause an increase in production time. manufacturing system. But, to compare the extra memory
with the seasons.
Maintenance of the In case of failure in one season, the mounting with the addition of subsystems (agents) gives more meaning
production with the system should continue the process, leaving in terms of effort system to absorb another subsystem.
removal of stations. the other station absorb the task missing.
Maintenance of the In case of bottleneck formation, the system The definition of specific metrics allows a significant
production to the should allow that more stations are inserted in
insertion station. aid of the mounting system. correlation between the systems and become feasible and
Amount of memory meaningful the comparison. And this is the point that
The amount of memory occupied defines the
occupied by the
need for computing capacity of the system to deserves special attention in order to compare characteristics
program by adding that represent meaning for the production desired. And here it
deployment.
the entire system.
Skills required to is clear that depending on the desired characteristics, a
Increased complexity in the implementation of system would be more appropriate either another.
operate and
changes refers to the need for specific
implement changes
knowledge of the operator / system
in the assembly 7. CONCLUSION
programmer.
system.
Lines of The number of lines of program code denoting
programming code. the programming effort.
In the scenario of industrial manufacturing, the need for
highly customized goods refers to the search of new
paradigms for management of automation of production. But
it does not mean the previous paradigms disuse , since these
6. RESULTS are still found in implementations with its features and
Analyzing the results of each metric was observed that can be functionalities.
attributed advantages and disadvantages to each of the In this context, multi-agent systems applied to industrial
concepts, using the comparison. Table 2 describes the manufacturing intended to be an alternative management
analysis and shows which concept had the best perform. automation production device, offering features more
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