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IIE Transactions

ISSN: 0740-817X (Print) 1545-8830 (Online) Journal homepage: http://www.tandfonline.com/loi/uiie20

Intelligent Scheduling with Machine Learning


Capabilities: The Induction of Scheduling
Knowledge

M. J. SHAW , S. PARK & N. RAMAN

To cite this article: M. J. SHAW , S. PARK & N. RAMAN (1992) Intelligent Scheduling with
Machine Learning Capabilities: The Induction of Scheduling Knowledge, IIE Transactions, 24:2,
156-168, DOI: 10.1080/07408179208964213

To link to this article: http://dx.doi.org/10.1080/07408179208964213

Published online: 30 May 2007.

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Intelligent Scheduling with
Machine Learning Capabilities:
The Induction of Scheduling Knowledge
M. J. SHAW
Beckman Institute for Advanced Science and Technology
University of D1inois at Urbana-Champaign
Urbana, IL 61801

S. PARK
School of Business
University of Wisconsin at Madison
Madison, WI 53706
Downloaded by [University of Sussex Library] at 08:08 30 May 2016

N.RAMAN
Department of Business Administration
University of D1inois at Urbana-Champaign
Champaign, IL 61820

Abstract: Dynamic scheduling of manufacturing systems has primarily involved the use of dispatching rules. In
the context of conventional job shops, the relative performance of these rules has been found to depend upon the
system attributes, and no single rule is dominant across all possible scenarios. This indicates the need for devel-
oping a scheduling approach which adopts a state-dependent dispatching rule selection policy. The importance
of adapting the dispatching rule employed to the current state of the system is even more critical in a flexible man-
ufacturing system because of alternative machine routing possibilities and the need for increased coordination among
various machines.
This study develops a framework for incorporating machine learning capabilities in intelligent scheduling. A
pattern-directed method, with a built-in inductive learning module, is developed for heuristic acquisition and re-
finement. This method enables the scheduler to classify distinct manufacturing patterns and to generate a decision
tree consisting of heuristic policies for dynamically selecting the dispatching rule appropriate for a given set of
system attributes.
Computational experience indicates that the learning-augmented approach leads to improved system perform-
ance. In addition, the process of generating the decision tree shows the efficacy of inductive learning in extracting
and ranking the various system attributes relevant for deciding upon the appropriate dispatching rule to employ.

• Scheduling forms a part of the operational control proc- Scheduling of production systems is a problem of well
ess in a manufacturing system. The need for schedulingarises known complexity. Nevertheless, it is routinely encountered
whenever a common set of resources in the manufacturing by firms, and there are significant financial incentives for
system must be shared to make a variety of different products them to constantly improve their scheduling practices. The
during the same period of time. The objective of manufac- need for generating efficient manufacturing schedules has
turing scheduling is the efficient allocation of machines and further increased with the introduction of flexible manufac-
other resources to jobs, or operations within jobs, and the turing systems (FMSs). The various machines in these highly
subsequent time-phasing of these jobs on individual ma- automated systems are closely linked to each other, and they
chines. operate under the supervisory control of a central computer.
Because of the tightly-controlledenvironment in which they
Received March 1990; revised September 1990. Handled by the Depart- operate, FMSs present schedulers with several operating
ment of Computer- and Knowledge-Based Engineering. problems that were not encountered earlier in conventional

156 0740-817X/92/$3.00x.OO © 1992 "lIE" Volume 24, Number 2, lIE Transactions, May 1992
manufacturing systems. Consequently, there is a growing the relative importance of the various manufacturing attrib-
need to investigate new approaches to manufacturing sched- utes for a given system. Experimental studies show that this
uling that are capable of addressing these sophisticated sys- learning-augmented approach results in schedules superior
tems. to those obtained by the conventional approach of using a
The maturation of artificial intelligence (AI) indicates that single scheduling rule.
it can provide one such approach (Rodammer and White This paper is organized as follows. First, we discusse how
[30); Stokey [46)). The several capabilities of AI that make machine learning can be applied in solving scheduling prob-
this technology particularly suitable for scheduling include lems and the advantages of doing so. We describe the in-
(1) the ability to provide rich and structured knowledge rep- ductive learning process which is then illustrated in the
resentation schemes that are capable of fully incorporating context of machine scheduling. We also describe the gen-
manufacturing knowledge, constraints, state information, eration of decision trees for selecting the appropriate sched-
and heuristics; (2) reasoning ability that enables schedulers uling rules in an FMS environment. We present an experi-
to do both reactive and predictive scheduling; (3) ease of mental study for evaluating the relative merit of this method
integrating ttte AI-based scheduler with other manufactur- over the single scheduling rule approach adopted in most
ing decision support systems such as diagnostic systems, of the previous research on dynamic scheduling. We con-
process controllers, sensor monitors, and process planning clude with a summary discussion of the major results.
systems; and (4) ability to incorporate descriptive, organi-
zation-specific scheduling knowledge that is usually avail- Intelligent Scheduling and Machine Learning
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able only with human expert schedulers. The adoption of


AI for factory automation is a growing trend in the indus- In the recent past, several researchers have applied arti-
try; for example, a recent survey shows that in the near fu- ficial intelligence (AI) based methods for solving scheduling
ture many manufacturing process controllers will be rule- problems. This body of research can best be reviewed by
based (Booker (5)). However, the development of AI sys- highlighting the focus of the AI techniques used as done be-
tems for intelligent scheduling is now at a critical juncture. low.
It is very much in need of new advancements for resolving Scheduling as Search: Scheduling can be viewed as a proc-
a number of common difficulties encountered in applying ess searching through the state space of all possible partial
this technology. and complete schedules. Search is ubiquitous in AI problems,
The objective of this research is to develop a methodol- but it is more significant an issue in scheduling problems.
ogy which uses machine learning for intelligent scheduling. Several methods have been suggested in the literature to al-
In so doing, we address a number of issues which have hin- leviate the computational complexity incurred by the search
dered the application of AI-based scheduling approaches in process. The ISIS system (Fox and Smith [12), Fox (11»
the past. The questions that we consider in this paper are uses several types of constraints to reduce the state space;
(l)'how to automate the acquisition of scheduling knowl- constraint satisfaction is used as an index to direct the search.
edge in a given manufacturing environment? (2) How to per- Shaw [31], [34], Shaw and Whinston [43) use the combi-
form dynamic, adaptive scheduling? (3) What would be the nation of A· procedure and scheduling heuristics to facili-
most relevant information for making such scheduling de- tate the search for the final schedule. The OPIS system (Ow
cisions? (4) How to improve the robustness of the AI-based and Smith [20)) employs an opportunistic approach to im-
scheduling process? (5) How best to integrate the simula- prove upon ISIS. It selects the most appropriate strategy
tion and scheduling systems for reactive scheduling? for scheduling opportunistically; the resulting flexibility
Machine scheduling in most manufacturing systems is done achieved in problem solving results in better performance.
through the use of heuristic decision rules. Previous research Ow [19] describes the beam search method for scheduling
indicates that the relative effectiveness of a given scheduling problems.
rule is dependent upon the system attributes. In a dynamic Scheduling as Planning/Replanning: One of the goals of
manufacturing system, these attributes change over time. intelligent scheduling is to be able to generate schedules more
It appears conceptually appealing, therefore, to adopt an ap- flexibly whenever alternative machine routing is possible
proach which employs appropriate and possibly different while simultaneously taking the dynamically changing sys-
scheduling rules at various points in time. In order to do tem state information into account. Thus, the scheduler has
so, however, we need a mechanism which can distinguish . to incorporate the machine selection considerations into the
different combinations of these system attributes, and select scheduling decision. Bullers et al. [7) describe an AI ap-
the scheduling rule appropriate for a given combination. proach to manufacturing planning based on predicate cal-
An important first step in the proposed methodology is culus and the resolution refutation procedure. Shaw [31],
the use of inductive learning to provide such a mechanism [34) uses a nonlinear planning method for deciding machine
(Shaw [37)). By integrating inductive learning with pattern- assignments and the temporal relationships among various
directed scheduling, the suggested procedure provides the operations. This method integrates scheduling with process
scheduler with the capability of selecting scheduling rules planning by utilizing a two-phase procedure. In the first
opportunistically, and adapting dynamically to the changing phase, the machine and resource assignments needed for
environment. Equally importantly, it also helps determine achieving the required manufacturing goals are selected. Sub-

May 1992, IIE Transactions 157


sequently, the second phase works to resolve conflicts while The incorporation of machine learning capabilities into
maintaining progressive performance improvement. This ap- intelligent scheduling systems has the potential of signifi-
proach originated with the robot planning method (Fikes cantly improving system performance, Some of the factors
and Nilsson [10]; Georgeff and Lansky [13]), and it is espe- that contribute to this improvement are: I) Acceleration of
cially suitable for dynamic scheduling which is treated as the search process by accumulating heuristics (Shaw [37]),
the problem of replanning with a changed goal. 2) use of learning schemata to facilitate the planning/re-
Scheduling as Rule-Based Inference: This method attempts planning process (Shaw, Menon and Park [40)), 3) enhance-
to incorporate scheduling knowledge into an IF-THEN rule .ment of rule-based inference obtained by automating the ac-
form which is implemented by an expert system. Wysk et quisition and the refinement of rules (Shaw [33]), and 4)
al. [49] use a multipass expert system to decide the appro- cooperative problem solving through improved coordination
priate scheduling rules based on information such as the cur- among the multiple scheduling agents (Shaw and Whinston
rent system status, scheduling objective and management [44]).
goals. Other examples in this line of work include Raghavan
[27], Kusiak and Chen [16] and Kusiak [15]. Bruno et al. Inductive Learning
[6] use an expert system for knowledge representation and
heuristic problem solving in the scheduling domain. In their Inductive learning can be defined as the process of infer-
study, the expert system is coupled with an activity-scanning ring the description (i. e., the concept) of a class from the
scheduler adapted from discrete event simulation and a closed description of individual objects of the class (Shaw [33]).
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queueing network based algorithm for schedule analysis and A concept is a symbolic description which is true if it de-
performance evaluation. Another example is the ISA (Intel- scribes the class correctly when applied to a data case, and
ligent Scheduling Assistant) system developed at Digital false otherwise. The concept to be learned in scheduling,
Equipment Corporation (Kanet and Adelsberger [14]) in for example, can be the identification of the most appropri-
which approximately 300 rules were used to construct the ate dispatching rule (a class) for a given set of manufactur-
evolving schedules. ing attributes.
Scheduling as Cooperative Problem Solving: Scheduling A set of training examples is provided as input for learn-
in manufacturing environment is typically performed by a ing the concept representing each class. A training example
group of scheduling agents. As computer integrated man- consists of a vector of attribute values and the correspond-
ufacturing makes scheduling progressively more complex ing class. A learned concept can be described by a rule which
because of the large number of resources, information re- is determined by the inductive learning process. If a new
quirements and decisions as well as a larger variety of jobs data case satisfies the conditions of this rule, then it belongs
involved, the scheduling of manufacturing processes will to the corresponding class. For example, a rule defining a
increasingly require team effort. In such an environment, concept can be the following:
the scheduling agents can be flexible cells, machine centers,
or human schedulers (parunak [23], Ow et al. [21]). Shaw
and Whinston [42), [44] and Shaw [32), [35], [36] apply
distributed artificial intelligence to the scheduling of man- THEN T.
ufacturing celJs. Using cooperative problem solving, the
scheduling problem is decomposed into several subproblems where al) represents the i-th level of j-th attribute, hI) and
to be solved by individual agents through task sharing and CIJ define the range for aI), and T denotes the class.
parallel processing. This approach fits naturally into the dis- Shaw [37] and Park et al. [22) employ inductive learning
tributed manufacturing environment in which various sub- to derive heuristics for selecting the appropriate dispatching
systems are interconnected through communication net- rules in a flexible manufacturing system. In this instance,
works. the IF-THEN rule is treated as a selection heuristic which
Machine Learning is a rapidly growing research area for is a conjunction of attribute conditions collectively defining
studying methods for developing artificial intelligence sys- the pattern, and T represents the best scheduling rule for
tems that are capable of learning (Michalski [17]). The abil- that pattern.
ity to learn and improve is essential for an intelligent system; An instance that satisfies the defmition of a given concept
however, little work has been done in applying machine is called a positive example of that concept; an instance which
learning to intelligent scheduling. Shaw [37] and Park et does not do so is a negative example. In the dynamic sched-
al. [22] apply machine learning to identify the combination uling problem, because there are several scheduling rules
of system attributes which would lead to the use of a given which can potentially be selected, multiple concepts need
scheduling rule. This knowledge can then be exploited by to be learned. In this situation, the training examples sup-
a pattern-directed scheduler in an adaptive fashion. In ad- porting the use of a given scheduling rule are treated as the
dition to heuristic learning, machine learning results in the positive examples of that rule; training examples support-
identification of manufacturing attributes critical to the sched- ing any other rule are treated as negative examples.
uling decision, and it generates an adaptive mechanism for Generalization and specialization are essential steps for
applying the scheduling rules. the inductive learning process. A generalization of an ex-

158 lIE Transactions, May 1992


ample is a concept definition which describes a set contain- are better able to handle noisy data. For these reasons, we
ing that example. In other words, if a concept description use ID3 in this research. The learning process in ID3 fol-
Q is more general that the concept description P, then the lows a sequence of specialization steps guided by an infor-
transformation from P to Q is called generalization; a trans- mation entropy function for evaluating class membership.
formation from Q to P is specialization. For a set of train- The concept description generated by a learning process can
ing examples, the generalization process identifies the be represented by a decision tree, which is a special case
common features of these examples and formulates a con- of disjunctive normal form expressions.
cept defmition describing these features; the specialization
process, on the other band, helps restrict the coverage of Heuristic Scheduling and Inductive Learning
features for a concept description. Thus, inductive learning
can be viewed as the process of making successive iterations Heuristic Scheduling
of generalizations and specializationson concept descriptions One of the major applicationsof machine learning to sched-
as observed from examples. This process continues until uling is in dynamic job shops and FMSs in which jobs ar-
an inductive concept description which is consistent with rive randomly over time and the system behaves like a net-
all the training examples is found. Thus the generalization! work of queues. Because of the exponential complexity of
specialization relations between concept descriptions pro- the underlying optimization problem, scheduling decisions
vide the basic structure to guide the search within the in- in such systems are usually specified in terms of dispatch-
ductive learning process. For a given problem, applying the ing rules; whenever a machine becomes idle, the scheduler
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inductivelearning process can contribute to one's understand- must decide whichjob should next be processed on the ma-
ing of the decision process on the following three dimen- chine. This selection is based on assigning priority indices
sions (Shaw and Gentry [38]): to various jobs competing for the given machine; the job
• Predictive validity: the ability to predict the decision with the highest priority is selected next. Dispatching rules
outcome for a given data base. differ in how they assign these priority indices.
• Structural validity: the ability to capture the underlying Because it is difficult to evaluate most of these dispatch-
structure of the decision process. ing rules analytically, computer simulation methods are used
• Identifying validity: the ability to infer the most critical generally to study their behavior and compare their relative
attributes in the decision process. performance. Prior research in this area (see, for example,
These features of inductive learning make it useful in deal- Conway et al. [9], and Baker [1], [2] for a survey of this
ing with the scheduling problem. If we can make an induc- research) deals primarily with conventional job shops. The
tive learning system observe the effects of various scheduling conclusions reached by the various studies regarding the rel-
decisions on the manufacturing processes and the resulting ative performance of various dispatching rules are, however,
scheduling performance, then it can 1) predict the outcome at variance with one another.
of any schedule for a given manufacturing process in a spec- Baker [2] suggests that the fundamental reason underly-
ified set of manufacturing conditions (predictive validity), ing these conflicting results is the fact that they address dif-
2) capture the underlying decision structure of the sched- ferent systems, and the relative performance of a given
uling process (structural validity), and 3) identify the crit- dispatching rule depends upon the system and job charac-
ical manufacturing attributes for the scheduling decision teristics. In the context of a job shop, Baker studies the im-
process (identifying validity). pact of one such attribute, namely, the tightness of job due
The input to an inductive learning algorithm consists of dates on mean job tardiness. He shows that, depending upon
three steps: 1) A set of positive and negative examples, 2) due date tightness, there are crossovers among dispatching
a set of generalization and other transformation rules, and rules. In particular, at the extremes, the Earliest Due Date
3) criteria for successful inference. Each training example (EDD) rule is superior when due dates are set loosely, and
consists of two components-a data case consisting of a set the Shortest ProcessingTime (SPT) rule performs well when
of attributes, each with an assigned value; and the classifi- they are tightly set. The Modified Operation Due Date
cation decision made by a domain expert according to the (MOD) rule performs the best in the intermediate range
given data case. The output generated by this inductive learn- (which is, nevertheless, quite wide in his study).
ing algorithm is a set of decision rules consisting of induc- Raman et at. [23] extend Baker's investigation to also
tive concept definition for each of the classes. Learning understand the impact of imbalance of machine workloads
programs falling into this category include AQ15 (Michal- (which leads to one or more bottlenecks in the system) as
ski [17]), PLS (Rendell [29) and ID3 (Quinlan [25]). These well as variability in due date assignment on the perform-
programs are referred to cis similarity-based learning meth- ance of dispatching rule. Their study shows that while MOD
ods. retains its effectiveness under balanced workloads, there are
Shaw, Gentry and Piramuthu [39) compare the above three crossovers between MOD and the Modified Job Due Date
inductive learning programs in terms of their algorithmic (MDD) rule when significant imbalance in machine work-
designs and classification accuracy. They find that, in gen- loads exists. They also study the benefits of using an adap-
eral, ID3 and PLS produce more accurate classifications than tive scheduling procedure in which the selection of the
AQI5. They are also more efficient computationally and dispatching rule is machine workload dependent. In partie-

May 1992, lIE Transactions 159


ular, the shop performance improves significantly if the dis- training examples
patching rule used at the bottleneck machine(s) is MOD, Inductive
Simulation
and MOD is used at other machines. selected attributes
Learning
Unit
Unit
Induction of Heuristic Knowledge characteristics t:xisting lea rned
The aforementioned studies on heuristic scheduling raise of sysltm & job heuristics heur istics
two important questions: 1) What are the system attributes
that affect the relative performance of a given dispatching scheduling rules &<
rule, and 2) how should the scheduler take these into ac- jobs Pattern heuristics Knowledge
count while making scheduling decisions dynamically? In- Directed
Base
ductive learning can help resolve these issues by first Scheduler
identifying the relevant system and job attributes and sub-:
sequently developing scheduling systems capable of select- manufacturing
schedule
ing the dispatching rule most appropriate for a given state
of the manufacturing system as characterized by the com-
bination of these attributes (i. e., the manufacturing panems). Figure 1. Integration of inductive learning and pattem-directed
Because the selection of dispatching rules is determined by scheduling
the dynamically changing manufacturing patterns, we refer
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to this scheduling approach as Pattern-Dlrected Scheduling Figure 2 also shows an additional stage, that of rule re-
(PDS). flnement. This stage collects the performance results of the
The suggested approach consists of two basic stages: 1) pattern-directed stage, and uses a critic program to evaluate
The learning stage, and 2) the scheduling stage. The learn- the performance of a given rule. If the heuristic rule is found
Ing stage extracts relevant manufacturing patterns, which to yield unfavorable results, then the rule-refinement mod-
are conjunctions of attribute-value pairs, from simulation ule generates additional training examples with a view to
experiments. The output of this stage is a set of heuristic revise the rule (possibly through attribute conjunction). Thus,
rules which describe the relationships among manufacturing
patterns and the appropriate dispatching rule in the form

pattern (iJ) - dispatching rule i. SIMULATION


ENGINE
An example of such a heuristic is

IF: (TBF < 14) AND (5 ~ 63) AND (NSDRL ~ 16)


~
THEN: MOD rule. RULE TRAINING
L-....,
REFINEMENT EXAMPLES
This rule states that when the Total buffer size is less than
14, the system utilization is greater than or equal to 0.63,
and the normalized standard deviation of relative machine
loading is greater than or equal to 1.6, then the dispatching
~
INDUCTIVE
rule to be applied is the Modified Job Due Date rule. Index
LEARNING
j is used in the above expression to denote the various pat-
PROGRAM
terns for which rule i would be applicable.
The pattern-directed scheduling stage applies the dis-
patching rules selected in the learning stage adaptively for
performing dynamic scheduling based on the manufacturing
~
pattern manifested by the system. HEURISTIC
CRITIC
The learning stage starts with conducting a series of sim- RULES
ulation experiments to generate training examples to study
the performance of various dispatching rules under a vari-
ety of manufacturing environments which are modeled in
the simulation program. These training examples are input
!
PATTERN-
into the inductive learning process, which generates the heu- PERFORMANCE
DIRECTED
ristic rules describing the dependence between manufactur- RESULTS ~
SCHEDULING
ing patterns and the dispatching rules. This integration of
inductive learning and pattern directed scheduling is depicted
in Figure 1. Figure 2. The inductive learning process

160 na Transactions. May 1992


the rule-refinement program iterates through the steps of in an FMS. Consequently, the ability ofPDS to discern these
obtaining performance results of various rules, analyzing patterns and to apply the appropriate dispatching rules be-
rules which are not satisfactory, and appropriately modify- comes even more appealing in an FMS environment.
ing these rules. (Bundy and Silver [8], Politakis and Weiss In addition to due date tightness and relative workload
[24], and Wilkins [48] describe some methods for refining imbalance, which have been discussed in the previous sec-
rules.) Meta-rules are used to suggest further experimenta- tion, the attributes which are likely to be significant for se-
tion involving training examples. The 'IF' part of the meta- lecting the appropriate dispatching rule in an FMS include:
rule contains a conjunction of predicate clauses that look 1) The scope for alternative job routing, and 2) the limita-
for certain features of the unsatisfactory rules as well as the tion on local buffers available at individual machines. It is
training examples which generated these rules. The 'THEN' possible in an FMS to configure the machines in such a way
part of the meta-rule suggests further experiments with mod- that a given operation can be done on one or more machines.
ified attributes for generating additional training examples Elementary queueing theory suggests that the routing flex-
and refining the rules. ibility provided by such parallel servers can lead to signif-
The proposed pattern-directed scheduling approach can icant reductions in the job flow time, which in tum, should
be viewed as an AI planning process (Georgeff and Lansky reduce job tardiness. However, it is not clear how this flex-
[13]), in which a sequence of operators, i.e., the dispatch- ibility will impact the relative effectiveness of various dis-
ing rules, are selected on the basis of the current manufac- patching rules. The system performance is also affected by
turing state. In terms of the problem solving strategy, the the constraints on the available buffer space. When this con-
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selection of rules in pattern directed scheduling is driven straint is binding, various machines in the system are likely
by the changes in manufacturing pattern, rather than the goal. to go through phases of blocking and starving which ad-
Moreover, rule selection is opportunistic based on t,he dy- versely affect the system performance. The overall perform-
namics of the manufacturing process. It is not preplanned ance of a scheduling rule is, therefore, likely to also depend
as is the case for most planning problems. upon its ability to minimize such instances.
We are now in a position to formally state the difference
in the approach taken by this paper relative to the previous Implementation of PDS
work on dynamic scheduling which has primarily adopted We now discuss the application of PDS in an FMS which
the use of a single dispatching rule. permits random, job shop like material flows. The sched-
uling objective considered is minimizing mean tardiness.
DefmitioD 1. The single rule scheduling problem is rep- As mentioned in the section on inductive learning, a variety
resented by (J, So, H, D) where J denotes the scheduling of dispatching rules have been found to be effective for this
objective. So is the initial state ofthe manufacturing system, objective under different situations. This not only provides
H represents the set of candidate dispatching rules, and D with a larger set H of effective dispatching rules, but more
denotes the decision that selects a dispatching rule from H importantly. we have a strong benchmark for testing the
based on 'So. This rule is used until J is achieved. relative effectiveness of the PDS approach. The set of dis-
patching rules which have been found to be dominant in pre-
nefmition 2. The pattern directed scheduling problem is vious research includes EDD (Baker and Bertrand [3]), SPT
represented by (J, M. H, R. E) where J and H are defined (Baker and Bertrand [3]; Conway [9]), MDD (Baker and
as above. M is the set of manufacturing states. and R is Kanet [4]; Raman et al. [28]) and MOD (Baker [2]; Raman
the set of heuristics for selecting dispatching rules. Each et al. [28]). Consequently, these four dispatching rules were
rule r in R is of the form p - n, P E M. h E H. E is selected in this study.
a list ofevents. e,l, e'l,... , e...... , which trigger the appli- The control attributes selected for capturing the relevant
cation of selection heuristics at time ,., '1 ....At time t •• manufacturing patterns were:
dispatching rule h selected by R is activated, and the man-
ufacturing system transits from state m.; to state m ..... , i. e.• 1. Number of machines in the system (NMAC).
h(m,J = m''''I.
2. Total buffer size (TBF).
FMS Scheduling
3. Maximum relative machine workload (BOTTLE) which
Problem Characteristics checks whether anyone of the machines in the system
FMS scheduling differs from conventional job shop sched- is a bottleneck at a given point in time. It is expressed
uling in that FMSs offer many more alternatives to the sched- as the ratio W.. .)7W, where W..... is the maximum work-
uler. For example, an operation could be processed at any load, measured in terms of remaining processing time,
one of several machines. In addition, the various machines in front of any machine in the system currently, and 1W
in the system are linked more tightly because of limited avail- is the sum of current machine workloads.
able buffer space and the use of common material transport-
ers. This results in a more difficult scheduling problem as 4. Variability in machine workload (NSDRL). This is ex-
it leads to more manufacturing patterns that can be manifest pressed as the ratio of the standard deviation of individ-

May 1992, fiE Transactions 161


ual machine utilizations to the average machine utiliza- switching between dispatching rules was affected immedi-
tion. ately upon a pattern change. In order to mitigate overreac-
tion to patterns which are only transitory, we developed a
5. Contention factor (CFACT) which indicates the average smoothing approach in which the scheduling mechanism re-
number of alternative machines available for processing tains a cumulative score of the number of occasions a given
a given operation. dispatching rule is favored. Whenever a scheduling decision
is to be made, the dispatching rule with the maximum. cu-
6. Contention factor ratio (CFRA TIO) which is the ratio mulative score is selected provided it is above a prespeci-
of CFACT to NMAC. fied threshold. Suppose that the dispatching rule being used
currently is i with a cumulative score of 51' Whenever a
7. Flow allowance factor (F) which measures due date tight- scheduling decision is required, this scheme will select rule
ness. Following Baker [2], we used the Total Work Con- i. if it exists, where
tent (TWK) rule for assigning job due dates. Under TWK,
the due date dJ of job j is determined as follows:

and 8 is a measure of the required threshold; otherwise it


will continue using rule i. (J is, therefore, a smoothing co-
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where aJ is the arrival time and PJ is the total processing efficient; higher (J values lead to increased damping of sys-
time of job j. tem responsiveness. Experimentation with various 8 values
revealed that varying degrees of smoothing are required to
8. Overall system utilization (5). respond to different manufacturing patterns. This resulted
in a scheme in which 8 was allowed to take one of three
NMAC is a measure of system size. BOTILE and NSDRL values-o.O, 0.7 and 1.0, and the rule induction process was
together describe the relative machine workloads. CFACT applied once again to yield another decision tree; the cor-
and CFRA TIO measure the routing flexibility provided by responding set of heuristic selection roles is shown in Fig-
the FMS. S is a measure of the traffic intensity, and in con- ure 4. (8 = 0 corresponds to maximum responsiveness; each
junction with F, is indicative of job due date tightness. pattern change results in a rule switch. 8 = I, on the other
In the learning stage, we generated 130 training examples hand, permits a rule switch only when the cumulative score
through stochastic simulation. These examples covered a of the rule favored by the current pattern is at least as high
range of different values for the eight attributes discussed =
as that of the incumbent rule. 8 0.7 was selected to rep-
above in various combinations. (Details of this experiment resent a system with intermediate responsiveness.)
can be found in Shaw, Park and Raman [41].) For each ex- The overall PDS module, therefore, consists of two func-
ample, steady state statistics pertaining to the mean tardi- tional components: the heuristic selection module (HSM)
ness values under each of the four dispatching rules were and the pattern smoothing module (PSM). These two mod-
recorded. Those instances in which a given rule performed ules and their interactions are depicted in Figure 5. When-
the best were selected as positive examples pertaining to ever a scheduling decision is required, PSM selects the ()
that rule. The ID3 algorithm was used for rule induction value based upon the current manufacturing pattern observed
based on these positive examples. The resulting decision and the induction tree for (). This value of 8 determines the
tree was translated into a set of pattern directed heuristics required smoothing threshold. HSM uses the rule induction
which is depicted in Figure 3. tree to update the scores for all dispatching rules, and in
Note that an important contribution of this decision tree conjunction with the specified threshold, selects the appro-
is in its ability to highlight the relative importance of the priate dispatching rule to use.
control attributes in influencing the selection of dispatching We now discuss the experiments conducted to evaluate
rules. Thus, from Figure 3, these attributes can be ranked . the relative merit of the POS approach.
in the following order of decreasing importance: TBF, (S,
BOTILE), (F, NSDRL), CFACT , and CFRATIO. Experimental Study
When the complexity of the trees generated by inductive
learning is a concern, a tree-pruning procedure can be used This section describes an experimental study conducted
to make the trees simpler and more understandable. The to understand the performance characteristics of PDS. A pri-
procedure consists of three phases: 1) Creating an initial, ori, we expect the PDS approach to be superior to the con-
large tree from the set of examples, 2) pruning this tree to ventional single dispatching rule approach for two reasons.
remove branches with little statistical validity, and 3) proc- First, as depicted in Figure 3, POS identifies the best dis-
essing the pruned tree to improve its understandability (Quin- patching rule for a given manufacturing scenario. Because
lan [26], Mingers [18]). of this selecting ability, PDS should perform at least as well
Preliminary studies with PDS indicated the need to cur- as the best from among the candidate dispatching rules con-
tail excessive nervousness of the scheduling system. We ob- sidered in H. Second, POS is able to adapt its selection of
served that PDS performs poorly in many instances if the best dispatching rule dynamically to the changing pat-

162 llE Transactions, May 1992


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Figure 3. Decision tree for selecting dispatching rules

terns. Such an adapting ability should result in a schedule an extension to this work, we are currently conducting an-
quality which is even superior to that of the best dispatching other study which focuses on the adapting behavior of PDS
rule. Simulation studies were designed specifically to verify in response to such disturbances as machine breakdowns
these two expectations. and sudden changes of job loading patterns.)
As noted earlier, the PDS module consists of the HSM The simulation experiments addressed an FMS at which
and PSM components. This experimental study focused on jobs arrived following a Poisson process. Upon its arrival,
the performance of HSM in selecting the best dispatching each job was assigned the number of required operations
rule through inductive learning. Thus, the selection function randomly from a uniform distribution which ranged between
performed by PSM is emulated by employing the value of 1 and the total number of machines in the system. Opera-
8 which is the best of three predetermined values-O.O, 0.7 tion processing times were sampled from an exponential dis-
and 1.0, so that the impact of HSM can be isolated and bet- tribution with a mean of 400. A range of due date tightness
ter understood. (The smoothing effect of PSM is, however, was achieved by allowing the flow allowance factor to vary
indispensable for achieving the adapting ability of PDS. As between 2 and 15.

May 1992. lIE Transactions 163


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Figure 4. Decision tree for selecting 8

164 lIE Transactions, May 1992


~ ::::
Scheduling
Heuristics (rom
InductiveLearning
.....

Manufactuting Pattern Heuristic DispatcbiIJ1g


Pattern.m Smoothing Selection Rule. h
Module (PSM) m.e Module (HSM)
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Figure 5. PDS module execution through its functional components

Three different system sizes comprising 4, 6 and 8 ma- Table 1. Impact of System Size
chines were considered. The relative machine workload was
No. of Cases in which PDS is
allowed to vary between 0.6 and 1.2. Machine homogene-
ity was allowed to vary between 0 and 0.4. (A value of 0 No. of Machines Better Same Worse
implies that the same number of operations are assigned to 4 18 2 4
all machines.) The contention factor ranged between 2 and 6 10 8 3
4. Job interarrival times were varied to yield overall system 8 5 16 3
utilizations between 50 % and 95 %.
The experiments addressed 69 different combinations of depending upon the appropriate value of 8, a change may
these parameters. In each case, the method of batching was not be affected in practice. Therefore, the number of actual
used to determine the steady state mean tardiness values re- dispatching rule switches would be smaller than the number
sulting from employing SPT. EDD, MOD and MDD dis- of pattern changes. (Also note that the number of pattern
patching rules individually, as well as the values obtained changes is dependent upon the PDS tree generated. If this
by using PDS which incorporated the selection heuristics tree is different, possibly because of the use of a different
depicted in Figures 3 and 4. In each problem instance, PDS rule induction algorithm, the number of pattern changes for
was compared with the dispatching rule that yielded the best the same experiment is also likely to be different.)
result (BEST). A summary of these results is given below; In order to understand these results, it is important to first
the details can be found in Shaw, Park and Raman [41]. note that the relative performance ofPDS will depend, among
Overall, PDS resulted in an improvement of 11.5% over
BEST. It produced lower mean tardiness values in 33 cases
3.5
and the same values in 26 cases. It was worse in the re- 0
'':>
maining 10 cases; however, the tardiness values obtained 0- 3
in 8 of these cases were quite low (less than 19) under both i:
III
E 2.5
BEST and PDS. ~
These experiments indicate that the performance of PDS 2
Q. 2
depends upon two factors. First is the impact of the number .E
of machines in the system. Table I gives a breakdown of
the number of instances in which PDS was better, the same
ic: 1.5
+

and worse for the three system sizes studied. PDS is distinctly ~
superior for 4-machine systems. However, as the system s
41
0.5
size increases, the number of instances in which PDS and ::i
a
BEST are equally effective increases as well. 12 66 160 248 344
No. of Pattern Changes
Second, as depicted in Figure 6, the relative improve-
ment achieved by PDS depends upon the frequency of pat-
EMean Tardiness - - Improvement Ra~~. ]
tern changes realized in the system. Recall that a pauern
change signals a potential switch in the 'applicable dispatch-
ing rule as determined by the PDS decision tree. However, Figure 6. Impact of the number of pattern changes

May 1992, lIE Transactions 165


other factors, upon i) the difference in the performance of ized when the number of pattern changes is medium to rea-
individual dispatching rules under a given pattern, and ii) sonably high, and no pattern is clearly dominant. This range
whether the system characteristics result in a dominant pat- also corresponds to tardiness values ranging from low to
tern. If the system attributes are such that they yield a se- moderately high-a range which would be applicable to most
quence of patterns in which the dispatching rules yield similar viable manufacturing systems.
results, PDS is not likely to be significantly superior to Finally, we note three possible reasons why PDS results
BEST. This argument partially explains the apparent depend- in higher tardiness values compared to BEST in some in-
ence of PDS upon system size. An increase in the number stances. First, because the set of training examples used for
of machines, in general, leads to an increase in contention generating PDS is a subset of the universe of the possible
factor as well. As reported in Wayson's [47] and Stecke scheduling environments, thelearned heuristics are likely
and Raman's [45] studies, the difference in mean flow times to be overgeneralized to an extent leading to some predic-
and mean tardiness values obtained under different dispatch- tion errors. Specifically, PDS may not perform well in a
ing rules decreases with an increase in the number of alter- situation which is not explicitly addressed by the training
native machines available for processing any operation. examples. Second, the performance of PDS is limited by
Consequently, higher contention factors lead to smaller dif- the number and the range of system attributes considered
ferences between PDS and BEST. Therefore, conceptually, for designing the training examples. (This partially explains
we would expect POS and BEST to behave identically in why the SPT rule is never selected in the decision tree shown
the limit. in Figure 3.) For a given system, it is possible that the se-
Downloaded by [University of Sussex Library] at 08:08 30 May 2016

However, in most real FMSs, providing high contention lection of-appropriate dispatching rules is affected signifi-
factors, which amounts to creating more redundancies in cantly by some other attributes. Third, because the training
the system, may not be economically viable because it leads examples are driven by simulation experiments, the appro-
to a reduction in the number of parts which can be man- priateness of a dispatching rule for a given pattern is deter-
ufactured concurrently and/or a reduction in system utili- mined by its steady state average performance over the length
zation. In most practical situations, contention factor is likely of the simulation run. Its implementation during real time
to be low to moderately high, a range in which PDS is sig- scheduling is, however, based on the pattern which is ob-
nificantly superior to BEST. served at the instant a scheduling decision is to be made.
We observed from our experiments that the relative dif- While a dispatching rule may perform well in the long run
ference between various dispatching rules decreases also for a given set of attributes, it need not necessarily be ef-
when mean tardiness values are small. (This result is reported fective when it is applied on a rolling basis on transient pat-
in earlier simulation studies of job shops as well; see, for terns.
example, Baker [2].) In such cases, the benefit in using PDS The adverse impact of overgeneraJization can be mitigated
is small even ifthere are large number ofrule switches. (As in practice by employing a feedback mechanism to monitor
shown in Figure 6, the experiments do show that small tar- scenarios in which PDS does not perform well, and to up-
diness values are accompanied by a large number of pattern date the set of training examples accordingly. The suggested
changes. This would indicate the existence of several cross- rule induction process can then be used to appropriately re-
overs among the dispatching rules when tardiness is small fine the selection heuristics. In a similar vein, if empirical
even though they differ only marginally from each other.) evidence suggests that one or more system attributes, which
This argument partially explains why, in Figure 6, we find were not previously considered for generating training ex-
that the improvement ratio decreases with a decrease in mean amples, have significant impact on the selection of dispatch-
tardiness and an increase in the number of pattern changes. ing rules, then they can be included in new training examples
At the other extreme, fewer pattern changes imply that (and, if necessary, selection heuristics can be modified). In
there is a small number of dominant patterns that charac- a real system, therefore, the relative performance of PDS
terize the system. In such cases, PDS would frequently se- should continuously improve with the incorporation of a feed-
lect the dispatching rule(s) most appropriate for the dominant back mechanism.
pattern(s); as a result, the difference between POS and BEST However, the use of steady state average values for de-
would be marginal. As shown in Figure 6, we observed that termining the appropriateness of any dispatching rule is in-
dominant patterns are accompanied by high tardiness val- trinsic to the overall POS approach in the context of dynamic
ues. This would happen, for example, if system utilization scheduling. The adverse impact, if any, of doing so is par-
levels are high and buffer sizes are small. In such instances, tially mitigated by the use of 8 which helps in smoothing
MDD would be the most appropriate dispatching rule across out the transient patterns. Nonetheless, it must be understood
a wide range of other system attributes. Consequently, the that PDS may not perform very well if the pattern changes
manufacturing pattern which favors MOD will be dominant are extremely frequent. This is another factor which con-
resulting in a small difference between POS and MOD tributes to a reduction in improvement ratio as the number
(which would be the BEST rule). Of course, it is unlikely of pattern changes increases, although the experimental re-
that most real systems would operate at high tardiness val- sults suggest that in most such instances there is only a mi-
ues on a sustained basis. nor degradation in the quality of the POS schedule. However,
In summary, the maximum effectiveness of PDS is real- in this regard, we do note that a promising area for future

166 liE Transactions, May 1992


inquiry is the design of a look-ahead window that allows Scheduling, Morgan Kaufmann, Los Altos, CA (1987).
POS to look into future while making real time decisions. [12J Fox, M.S., and Smith. S. F.• "ISIS: A Knowledge-Based System
for Factory Scheduling," Expen Systems. Vol. I, No. 1.25-49 (1984).
[I3J Gcorgeff, M. P., and Lansky, A. L.. Reasoning about A.ctions and
Conclusion
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in the presence of a feedback mechanism, is its ability to
don, U. K. (1987).
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weU. Consequently, in a real system, the relative perform- (1984). .
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[26J Quinlan, J. R .• "Simplifying Decision Trees," buernasional Journal
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May 1992. IlE Transactions 167


[35] Shaw, M. 1., "Dynamic Scheduling in Cellular Manufacturing Sys- (47] Wayson, R. D., "The Effects of Alternate Machines on Two Pri-
tems: A Fnunework for Networked Decision Making," Journal of ority Dispatching Disciplines in General Job Shops," Master's the-
Manufacturing Sysr~m.r, Vol. 7, No.2, 83·94 (1988). sis, Cornell University. Ithaca. NY (1965).
[36] Shaw, M. 1., "FMS Scheduling as Coopemtive Problem Solving," (48] Wilkins, D. C., "Knowledge-base Refinement as Improving an In-
Annals of Operations Research, Vol. 17, 323-346 (1988). correct and Incomplete Domain Theory," Report #UIUCDCS·R·~
[37] Shaw, M.l., "A Pattern-Directed Inference Approach 10 FMS Sched- 1585, Dept. of Computer Science, University of Illinois at Urbana-
uling," Inr~matiollDlJ oumal ofFluibk Manu.ftu:nu'ing Sysrems, Vol. Champaign, Urbana. IT. (1990).
2, No.2, 121-144 (1989). [49] Wysk, R. A., Wu, S. D .• and Yang, N.• "A Multi-pass Expert Con-
[38) Shaw, M. J., and Gentry, 1., "Inductive Learning for Risk Analy- trol System for Manufacturing SyStelll5," in PTOC~~dingS ofthe Sym-
sis," IEEE Expens, Vol. 5, No. I, 47-53 (1990). posium on Real-rune Optimization in Aulomaud Manufacruring
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Systems for Decision Support: A Comparative Study," CompUUT Sci-
ence in Economics and MtJtIQgemenr, forthcoming (1990). Michael J. Shaw is an Associate Professor of Business Administration and
[40] Shaw, M. J., Menon, U., and P11rk, S. C., "Machine Learning Meth- a research faculty member of the Beckman Institute for Advanced Science
ods for CompulCr-llidcd Process Planning," in &pm Sysums and and Technology, both at the University of Illinois, Urbana-ehampaign.
ManufoauringDesigns, edited by A. Kusiak, Society of Manufactur- He earned his B.S. in Industrial Engineering from Tsing Hwa University,
ing Engineers Press, Dearborn, MI (1988). R.O.C., and Ph.D. in Information Systems from Purdue University. His
[41) Shaw, M. 1., Park, S. C., and Raman, N., "Intelligent Scheduling current research interests are concerned with the applications of artificial
with Machine Learning Capabilities: The Induction of Scheduling Intelligence to designing decision BUPPOn and manufaetllring information
Knowledge," Working Paper #90-1639, Bureau of Economic and systems. He has published in the areas of knowledge-based scheduling,
Business Research. University ofnJinois at Urbana-Champaign, Cham- information systems, machine learning, distributed artificial intelligence,
Downloaded by [University of Sussex Library] at 08:08 30 May 2016

paign, IT. (1990). and intelligent manufacturing. In 1990, Professor Shaw spent his sabbat-
[42] Shaw, M. J., and Whinston, A., "Task Bidding, Distributed Plan- ical leave at the Robotics Institute in the School of Computer Science of
ning, and Flexible Manufacturing, " in Proceedings ofrheIEEE Con- Carnegie MeDon University.
feTenc~ on ATlificialInrellig~nce Applications, Miami, FL (1985).
(43] Shaw, M. J., and Whinslon, A., "An Artificiallntelligen~Approach Sangchan Park is Assistant Professor at the University of Wisconsin, Madi·
to Scheduling in Flexible Manufacturing Systems." lIE Transactions, son. Professor Park's primary research interests focus on using machine
Vol. 21, No.2, 170-183 (1989). learningand other artificial intelligence based approaches to problems arising
[44) Shaw, M. J., and Whinston, A., "Learning and Adaptation in a Dis- in areas of decision support systems and intelligent manufacturing.
tributed Artificial Intelligence System," in Distributed Artificial In-
tellig~fIC~. Vol. U, edited by M. Huhns, Morgan Kaufmann, Los Altos, Namyan Raman is Assistant Professor of Business Administration at the
CA (1989). University of Illinois, Urbana-Champaign. He holds a B.Tech. in Mechan-
[45) Stecke, K. E., and Raman, N., "Pre-Production Planning Decisions ical Engineering from Indian Institute of Technology, a PGDM from In-
in Flexible Manufacturing Systems with Random Material Flows," dianInstitute of Management and a Ph.D. in Operations Management from
Worlcing Paper #90-1646, Bureau of Economic and Business Research. the University of Michigan. His current research interests are in the areas
University of Illinois at Urbana-Champaign, Champaign, IT. (1990). of production planning, machine scheduling and computer integrated man-
[46] Stokey, R. J., "AI Factory Scheduling: Multiple Problem Formula- ufacturing.
tions," SIGART Newsletter, No. 110, 27-30 (1989).

168 nE Transactions. May 1992

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