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A Decision Support System Architecture Based on Simulation Optimization for

Cyber-Physical Systems

Article · January 2018

DOI: 10.1016/j.promfg.2018.07.151

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 Available online at www.sciencedirect.com
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ScienceDirect
ScienceDirect
Procedia Manufacturing
Available 00 (2018) 000–000
Availableonline
onlineatatwww.sciencedirect.com
www.sciencedirect.com
Procedia Manufacturing 00 (2018) 000–000 www.elsevier.com/locate/procedia
www.elsevier.com/locate/procedia
ScienceDirect
ScienceDirect 
Procedia Manufacturing 26 (2018) 1147–1158
Procedia Manufacturing 00 (2017) 000–000
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46th SME North American Manufacturing Research Conference, NAMRC 46, Texas, USA
46th SME North American Manufacturing Research Conference, NAMRC 46, Texas, USA
A Decision Support System Architecture Based on Simulation
A Decision Support System Architecture Based on Simulation
Optimization
Manufacturing Engineering for Cyber-Physical
Society International Systems
Conference 2017, MESIC 2017, 28-30 June
Optimization for Cyber-Physical
2017, Vigo (Pontevedra), Spain
Systems
Shady Salamaaa*, Amr B. Eltawilaa
Shady Salama *, Amr B. Eltawil
Costing Industrialmodels
a
Engineering andfor capacity
Systems optimization
Management, Egypt-Japan in and
University of Science Industry 4.0: Trade-off
Technology, Alexandria 21934, Egypt
Industrial Engineering and Systems Management, Egypt-Japan University of Science and Technology, Alexandria 21934, Egypt
a

between
* Corresponding author. used capacity and operational efficiency
Tel.: +2-010-904-67052.
E-mail address:author.
* Corresponding Tel.: +2-010-904-67052.
shady.salama@ejust.edu.eg
E-mail address: shady.salama@ejust.edu.eg
A. Santana , P. Afonsoa,*, A. Zaninb, R. Wernkeb
a

Abstract a
University of Minho, 4800-058 Guimarães, Portugal
Abstract b
Unochapecó, 89809-000 Chapecó, SC, Brazil
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© 2018 The Authors. Published by Elsevier B.V.
and theoretical perspectives. This paper presents and discusses a mathematical
© 2018for
model The Authors. management
Published by Elsevier B.V.different costing models (ABC and TDABC). A generic model has been
© 2018 Thecapacity
Peer-review Authors.
under Published by
responsibility based
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scientific committeeof oftheNAMRI/SME.
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Keywords:The trade-off
Decision capacity
support maximizationdiscrete
system; meta-modeling; vs operational efficiency
event simulation; design of is highlighted
experiments; and itbased
simulation is shown that internet
optimization; capacityof
optimization
Keywords:
things; might
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cyber-physical hidesystem;
support operational
systems; inefficiency.
meta-modeling;
the fourth industrial discrete event simulation; design of experiments; simulation based optimization; internet of
revolution.
things;
© 2017cyber-physical
The Authors.systems; the fourth
Published industrial
by Elsevier B.V.revolution.
Peer-review under responsibility of the scientific committee of the Manufacturing Engineering Society International Conference
1. Introduction
2017. pricing pressures. Therefore, decision-makers are
1. Introduction pricing to
striving pressures. Therefore,
rapidly adjust decision-makers
their production are
lines to keep
Nowadays,
Keywords: manufacturing
Cost Models; ABC; TDABC; companies face fierce
Capacity Management; striving
Idle Capacity;pace to rapidly adjust
with Efficiency
Operational their production lines
changes in market trends because of to keep
Nowadays,in manufacturing
competition the global market companies
to meet face fierce
customer's pace with demand
increasing changes and
in market trends ofbecause
customization of
products.
competition in the global market to meet
expectations with lower prices, and higher quality duecustomer's increasing demand and customization of products.
Recently, the emerging "industry 4.0" introduced new
to1.globalization,
Introduction
expectations with fluctuating
lower prices,market
and higher quality due
conditions, and Recently, the
paradigms foremerging "industry
manufacturing and4.0" introduced
service new
industries,
to globalization, fluctuating market conditions, and paradigms for manufacturing and service industries,
The cost of idle capacity is a fundamental information for companies and their management of extreme importance
in modern©production
2351-9789 systems.
2018 The Authors. In general,
Published it isB.V.
by Elsevier defined as unused capacity or production potential and can be measured
in several©under
2351-9789
Peer-review ways: tons of production,
2018responsibility
The Authors. Published
of available
by Elsevier
the scientific B.V.hours
committee of manufacturing, etc. The management of the idle capacity
of NAMRI/SME.
Peer-review underTel.:
* Paulo Afonso. responsibility
+351 253 of the761;
510 scientific committee
fax: +351 253 604of741
NAMRI/SME.
E-mail address: psafonso@dps.uminho.pt

2351-9789 © 2017 The Authors. Published by Elsevier B.V.

Peer-review under responsibility of the scientific committee of the Manufacturing Engineering Society International Conference 2017.
2351-9789 © 2018 The Authors. Published by Elsevier B.V.
Peer-review under responsibility of the scientific committee of the 4th International Conference on System-Integrated Intelligence.
10.1016/j.promfg.2018.07.151
1148 Shady Salama et al. / Procedia Manufacturing 26 (2018) 1147–1158
2 Author name / Procedia Manufacturing 00 (2018) 000–000
such as internet of things (IoT), cyber-physical
systems, cloud computing, machine learning, and
wireless systems [1]. Many researchers emphasize that
advances in Information and Communication
Technologies (ICT) will reshape the manufacturing
environment, eliminate existing problems, and reveal
new challenges [2]. The industry 4.0 paradigm consists
of three pillars; smart product, smart machine, and
augmented operator. These pillars can be employed to
achieve less waste, more flexibility, self-configuration,
and facilitate data acquisition and analysis [3].
From the practical perspective, the assembly line is
one of the main divisions of many manufacturing
facilities which can significantly affect the
productivity and its efficiency has a great impact on
reducing production costs. Assembly lines are adopted
globally in many industries including, but not limited
to, automotive, appliances, furniture, semiconductors,
etc. It is very challenging to smoothly distribute the
workload among workstations. Therefore, researchers
have adopted several solution approaches for the sake
of solving the assembly line balancing problem, such
as mathematical modeling, and simulation models [4].
Mathematical modeling entails oversimplified
assumptions and rough approximations to overcome
the complexity of manufacturing systems which widen
the gap from reality. In contrary, simulation modelling
is one of the key tools that have proven its superiority
in delivering satisfactory results to practitioners when
the variability and complexity increase in systems
hindering the use of pure algebraic methods [5].
Discrete Event Simulation (DES) has a long history of
resolving operational and tactical issues that arise in
the manufacturing domain which include; workload
balance, resource allocation, capacity planning, layout
design, inventory level assessment, supply chain
management, and so on [6]. DES can mimic the real
production line with minimal assumptions to analyze
current line, investigate potential improvements, and
evaluate different alternatives.
However, the remarkable advantages of simulation
modelling, it has some limitations, for example, the
large computational time, black-box characteristics,
and not being an optimization tool. Simulation model
helps in evaluating the system response for
predetermined values of input setting, but it doesn't
guarantee the optimality for a specific performance
indicator. Also, it is very challenging to know which
decision variables have a significant impact on the
system response using simulation modelling solely [7].
Thereby increasing the burden on managers to make
informed decisions about future investments.
Kleijnen (2017) [8] pinpointed the pivotal role of
Design of Experiments (DOE) in overcoming the
pitfalls of DES simulation by supporting simulation
practitioners with well-organized designs to plan their
simulation experiments and interpret the obtained
results. DOE is a method of employing statistical
techniques with systematic designs to assess the effect
of inputs factors and their interactions in the system
performance. The literature emphasizes the essential
role of the integration between DES and DOE to get
more insight into the system under-study with minimal
simulation experiments, thus taking less computational
time. Furthermore, DOE can support in formulating
regression metamodels which are mathematical
abstraction of the stochastic simulation models [9].
Metamodeling combines the merits of simulation
modeling and design of experiments by providing
optimal solutions at a limited computational time, and
the ability to model complex and stochastic systems in
an explicit form. The metamodel is an alternative to the
simulation model for transferring design parameters
into output response with some features that outweigh
simulation, such as deterministic output, inexpensive
computational time, and straightforward form.
Typically, metamodels are proposed in order to
understand the system behavior, predict the model
response for some input values that were not
simulated, and find optimal solution of input factors.
Despite the tremendous number of scientific articles
already existing in literature about Decision Support
Systems (DSS), the gap remains between the academia
and industry. Moreover, making the proper decisions
at the right time is a key solution for companies to
survive in the era of industry 4.0. Consequently, there
is an urgent need to provide the literature body and the
industry sector with a structured framework for a DSS
that can be used in conjunction with the emerging
cyber-physical systems to facilitate managerial duties.
The main objectives of this study are as follows;
• Propose a DSS architecture based on CPS to
assist in tactical and operational planning
activities.
• Demonstrate how simulation modelling can
be coupled with a design of experiments
techniques within the framework of a DSS.
• Illustrate how a DSS based on metamodeling
optimization approach can be used to
facilitate the duties and responsibilities of
decision-makers.
 Shady Salama et al. / Procedia Manufacturing 26 (2018) 1147–1158
Author name / Procedia Manufacturing 00 (2018) 000–000
• Evaluate the practicality of the proposed DSS
using an empirical real-world case study.
• Elaborate how the manufacturing companies
can adopt IoT technologies.
The rest of this paper is structured as follows; the next
section demonstrates the literature review related to the
integration between DES and DOE. The third section
provides a detailed description of the proposed
decision support system. Then, the forth section
illustrates a real case-study to evaluate the efficiency
of the proposed approach. The fifth section offers some
proposals to transform a conventional assembly line to
a smart one using the cyber-physical systems
paradigm. The last section illustrates the outcomes of
this study and future research directions.
2. Literature survey
Discrete event simulation is extensively addressed
in the literature as an essential tool for studying
operational and tactical problems in manufacturing
systems. DES has demonstrated its superiority in
providing satisfactory solutions to practitioners
compared to algebraic models that use excessive
assumptions to simplify the real systems and threaten
the validity of the results [10]. Jahangirian et al. (2010)
[6] presented a systematic survey of the published
papers between 1997 and 2006 in the context of
simulation in manufacturing and business. They
reported that the DES is the most common technique
for solving production problems. In a follow-up study,
Negahban and Smith (2014) [5] addressed the DES
papers from 2002 to 2013. They declared that there is
an upward trend in the adoption of DES in
manufacturing companies due to increasing
computational capabilities and credibility of the
solutions. Recently, Prajapat and Tiwari (2017) [11]
surveyed the articles related to the use of DES and
optimization techniques to improve the efficiency of
assembly lines. They concluded that DES is an
effective tool for investigating the performance of
assembly lines, eliminating bottlenecks, and increasing
productivity. Many researchers reported that the
design of experiments can eliminate the drawbacks of
simulation by using organized designs to reduce the
computational time, study factors that affect the system
performance, and formulate a metamodel for the
system response [8].
In the simulation optimization literature, the
metamodeling approach has been illustrated many
1149
3
times to clarify its advantages and limitations, for
instance, Freidman et al. [12], and Henderson et al.
[13]. Dengiz and Akbay (2000) [14] addressed the
problem of achieving the best combination of input
parameters in an electronics company in Turkey using
throughput rate and cycle time as performance
indicators. Two metamodels were developed for
evaluating different scenarios on the current push
system and the proposed pull system. Tsai (2002) [15]
coupled an Arena model with a Taguchi L27
orthogonal array to identify the impact of operational
factors on the production cost in a steel production
plant. Aase et al. (2004) [16] employed analysis of
variance and a full factorial design to support decision-
makers in understanding the impacts, limitations, and
required conditions to switch from functional to U-
shaped layout in assembly lines. Durieux and Pierreval
(2004) [17] developed a DES model for an automated
production line, then a fractional factorial design was
applied to obtain more knowledge about the factors
that influence the resources utilization. Noguera and
Watson (2006) [18] employed response surface
methodology in a multi-products chemicals company.
A DES model was integrated with a central composite
design to formulate a metamodel and surface plot for
optimizing the plant throughput under technological
and environmental constraints. Kumar and Nottestad
(2006) [19] used DES alongside response surface
method to maximize throughput, limit the buffer stock
size, and evaluate different strategies before
implementation in a plastic parts production line.
Dengiz et al. (2006) [20] employed sensitivity analysis
for five factors which may affect throughput rate of
diamond tools in a production line in Turkey. They
built a mathematical model including the developed
metamodel as an objective function as well as many
physical and technological constraints to obtain an
optimum resources arrangement.
Ekren and Ornek (2008) [21] combined Arena
simulation software with SPSS statistical package to
assess the effect of predefined factors, including
layouts, breakdowns, batch and transporter sizes, and
scheduling rules on the average flow time of parts
throughout the manufacturing line. They concluded
that the future work is directed to add more parameters
for evaluation and use response surface methodology
to formulate a metamodel for the optimization purpose.
Santos and Santos (2009) [22] proposed an approach
to replace some parts of the simulation model with
metamodels to reduce simulation time and obtain high-
1150 Shady Salama et al. / Procedia Manufacturing 26 (2018) 1147–1158
4 Author name / Procedia Manufacturing 00 (2018) 000–000
resolution models. As a result, they reduced simulation
time by about 40 % with reliable results. Ekren et al.
(2010) [23] adopted simulation-based experimental
design approach to identify the most dominant factors
affecting transaction cycle time and utilization per
vehicle in an automated storage and retrieval
warehouse in France. They reported that the future
research may be geared towards the formulation of a
metamodel in order to achieve the optimal
configuration of the number of lifts and vehicles for
different arrival rates.
Song et al. (2010) [24] employed simulation
metamodeling methodology in a multi-echelon supply
chain to minimize average total cost by investigating
nine decision variables. Joseph and Sridharan (2011)
[25] developed multiple regression metamodels to
evaluate the effect of parts routing and sequencing
rules on the performance of flexible manufacturing
system. María et al. (2013) [26] developed a DES
model using SIMUL8 simulation software for a
painting line, then a central composite design was
utilized to obtain a metamodel for the line productivity.
Therefore, they obtained the optimal configuration of
resources leading to a remarkable increase in
throughput. Dengiz and Belgin (2014) [27] used DES
along with design of experiments to reveal the factors
which significantly affect the productivity of an
automotive factory, then a metamodel for the system
response was formulated. The optimum working
conditions were estimated, resulting in an increase in
daily productivity by 28%. Zahraee et al. (2014) [28]
developed a simulation model for a color production
line to evaluate different scenarios, after that 25 full
factorial design was employed to identify factors that
influence productivity. From the developed regression
model, optimal levels of predefined parameters were
determined and led to an increase in productivity with
better use of resources. Hsieh et al. (2014) [29]
proposed a progressive simulation metamodeling
approach to formulate the response surface plot of
input variables by adding more design points into the
critical region. Their approach was applied in a
semiconductor firm to evaluate its validity. Dengiz et
al. (2016) [30] used a hybrid simulation optimization
method to re-configure a paint shop production line in
an automotive company. After formulating a
metamodel for the line productivity and defining
economical and physical constraints, the model was
solved to achieve optimal resources arrangement
increasing productivity by 15%. Zahraee et al. (2016)
[31] proposed an integration between DES and
Taguchi method to fine-tune the controllable factors,
reduce the impact of noise factors, and maximize
throughput in a welding department of manufacturing
company.
Recent advances in information and communication
technologies resulted from the ever-increasing use of
Radio Frequency Identifications (RFIDs), sensors,
mechatronic systems and wireless communication
have paved the way for the fourth industrial revolution
entirely dependent on cyber-physical systems (CPS)
and IoT [32]. The term cyber-physical systems was
first formulated at the national science foundation
workshop that was held in Texas, US in October 2006.
CPS are in essence a combination of computing
systems and the physical factory floor in a
synchronized manner encompassed by IoT. Lee et al.
(2015) [33] proposed five hierarchical stages for
guiding companies to implement cyber-physical
systems. The fourth level of their architecture is the
cognition level where there is an urgent need for DSS
to provide the knowledge and assist in making
enlightened decisions. Monostori et al. (2016) [34]
surveyed the papers published in the CPS context, then
they formulated a relationship network between CPS
and other terms related to recent technologies. They
reported a dramatic increase in the number of papers
published between 2010 and 2015, and there is a
notable relationship between DSS and CPS.
To sum up, the simulation metamodeling approach
combines the benefits of simulation and design of
experiments in an attempt to overcome DES
simulation imperfections and make it adaptable to
upcoming speedy era. Moreover, it is obvious that the
integration between simulation modeling and
metamodeling optimization approach can provide a
promising tool for solving industry-related issues and
making enlightened decisions in the shortest possible
time. In the future, data and information will be easily
accessible and affordable but the market competition
will be more ferocious. Therefore, the urgent question
now is how to utilize the data availability in achieving
the maximum benefit for making informed decisions
within acceptable time frames. To the best of our
knowledge, there is no research paper proposed a
paradigm for the development of a decision support
system based on simulation metamodel optimization
using the emerging technologies of industry 4.0.
 Shady Salama et al. / Procedia Manufacturing 26 (2018) 1147–1158
Author name / Procedia Manufacturing 00 (2018) 000–000
3. The proposed decision support system
architecture
The proposed model-driven DSS is an interactive
computer-based platform that can be used to aid in
complex decision-making by employing data
management, communication technologies, and
modeling capabilities. The decision-making process
involves three interconnected components; the
decision makers, central cloud storage database, and
the decision support system. The three components
interact to support planning and operational control
decisions as illustrated in Fig. 1. The production
system is fully automated where sensors, actuators,
RFID tags and other ICTs are used to collect process-
related data, such as production cycle, processing
times, production line configuration, breakdowns,
inventory status, production capacity, required
materials, etc. The aforementioned data is
synchronously uploaded to the cloud storage that is
properly protected and accessible to both decision-
makers and the DSS. The cloud provides decision-
makers with the status quo in the production facility
using user-friendly interfaces and real-time tracking of
each physical element involved in the production
cycle. Accordingly, decision-makers can use the
knowledge and intuition to suggest some improvement
scenarios for obtaining the best proposal according to
predefined performance indicators. Furthermore, they
may propose a set of decision variables with their
possible ranges based on certain economic and
technological restrictions, and the DSS determines the
Fig. 1. The proposed decision-making process
1151
5
optimal solution which can be presented using
performance schemas. Moreover, the DSS can directly
acquire the real-time data from the cloud storage to
update the decision modules with the related
operational behavior. The DSS can be used for three
purposes; to gain more knowledge about the
production line performance in current settings, to
evaluate different scenarios for expansions or
improvement targets, and to obtain the optimal set of
decision variables from a wide range of feasible
solutions in a relatively short time.
The proposed approach is based on three main
modules representing the core of the DSS; DES
module, DOE module, and optimization module as
shown in Fig. 2. The DES model is a cyberspace of a
physical system that includes digital twins of the
different manufacturing system resources (machines,
lifts, conveyers, robots, automated guided vehicles,
etc.) present in the actual system. The DES model is
used to predict the system performance under various
settings, thus the DES model performs three major
functions in the DSS. First, when there is a limited
number of scenarios required for investigation, the
simulation model can be employed separately to
estimate the system response and assist in selecting the
best proposal. Second, it estimates the performance
indicators for each treatment in the design matrix
provided by the DOE module. Third, the DES model
is used to estimate the system response for the optimal
settings of decision variables obtained from the
optimization module.
1152 Shady Salama et al. / Procedia Manufacturing 26 (2018) 1147–1158
6 Author name / Procedia Manufacturing 00 (2018) 000–000
The decision-makers define the candidate variables
which can be changed and their permissible ranges,
then the DOE module generates a design matrix
including combinations of these factors. After the
evaluation stage in a DES module, many statistical
techniques and sensitivity analysis are introduced in
the DOE module to formulate the metamodel. The
developed metamodel is utilized as the objective
function of the simulation-optimization problem, and
the predefined allowable range of decision variables
are the constraints. Consequently, the optimization
module determines the best set of decision variables
without conducting time-consuming simulation runs
for the entire solution space. Thus, the simulation
model is used to evaluate other performance metrics
for the obtained settings, for instance, utilization of
resources, cycle time, and Work in Progress (WIP).
Finally, the DSS collects the results acquired from the
simulation module and the DOE module to
appropriately present them to decision-makers.
Regarding the DSS outcomes, the DES module
provides information about process-related metrics,
such as productivity, utilization of resources, WIP,
costs, etc. for the proposed modifications. Whilst the
DOE module supports the decision-makers in gaining
more knowledge about the factors that significantly
impact the system behavior for future investment.
Finally, based on the DSS outputs, the decision-makers
can make timely and informed tactical and operational
decisions. The proposed management and planning
approach is suitable for any manufacturing facility, and
it is not strictly associated with the nature of the
production process itself.
Fig. 2. The decision support system architecture
4. The empirical study
4.1. Problem statement
To demonstrate the functionality and practicality of
the proposed DSS architecture, it has been
implemented in a conventional leading home appliance
production line. Although the manufacturing line
under-study doesn’t exhibit the emerged technologies
and characteristics of industry 4.0, it still provides
reliable results about the applicability of the proposed
approach. The company produces a large portfolio of
white goods including, but not limited to, refrigerators,
washing machines, heaters, air conditioners, etc. In this
study, we focused on the refrigerator final assembly
line. This semi-automated line consists of two main
sections; pre-injection section and injection section. As
depicted in Fig. A.1. for the layout of the refrigerator
assembly line, there are several manual operations
engaged with the pre-injection section to assemble the
fridge main components. Thereafter, the fridges are
transferred to the injection section to remove humidity
using an oven, in addition, the Urethane Foaming
Machine (UFM) fills the fridge boundaries with the
isolation foam.
The productivity of the pre-injection section is
greater than the injection section, therefore a large
buffer stock is kept to prevent blocking in the pre-
injection section. The intermediate buffer stock
represents unexploited resources and the fridges are
vulnerable to defects. Resulting from the forecasted
increase in demand, the decision-makers are seeking to
achieve the optimal future investment with two
 Shady Salama et al. / Procedia Manufacturing 26 (2018) 1147–1158
Author name / Procedia Manufacturing 00 (2018) 000–000
objectives; increase the productivity of the assembly
line and eliminate the intermediate buffer stock. Based
on the fluctuating demand, the planning engineers need
to reconfigure resources within the assembly line to
achieve the desired output in the shortest possible time.
4.2. Solution approach
The DES model was developed using Arena™
software for one working shift of the assembly line.
Processing times and other operational data were
collected from a field study and the inputs of subject
matter experts. After verification, output analysis and
validation stages, the simulation model was ready to
provide credible results. The roadmap for the steps that
we have followed to construct the simulation model is
outlined in [10]. Production planners have identified
five factors that may contribute to the performance of
the assembly line based on the analysis of the
developed model and their knowledge. The decision
variables and their permissible ranges are presented in
Table 1. The five factors are; the time interval between
the arrival of two consecutive metal frames (A), the
curing time of the isolation foam (B), the drying time
of the fridge in the oven (C), the number of fridges
entering the oven simultaneously (D), and the number
of injection jigs attached to the UFM (E). Each jig can
serve only one fridge. The factors (A), (B), and (C) are
operational decision variables that need to be
frequently adjusted based on demand fluctuation and
the availability of raw materials. Whereas, factors (D)
and (E) are tactical decision variables which require a
large investment for any adjustment.
Table 1. The decision variables with allowable ranges.
The Factors Possible Values
Time Between Arrivals (A) 25 - 45 seconds
Curing Time (B) 230 - 290 seconds
Drying Time (C) 60 - 90 seconds
Oven Capacity (D) 2 - 3 fridges at the same time
Number of Jigs (E) 7 - 8 jigs
® 1209 -8.99XA +1.179X𝐵𝐵 -19.55XC +17.2XD -49.2 X𝐸𝐸
Minitab software was employed for statistical
analysis, a 25 full factorial design was used to estimate
the main effects and the two-way interactions of the
defined factors. The developed DES model was
utilized to evaluate the throughput per shift and the
required buffer stock for the 32 treatments. The Pareto
charts for the standardized effects on the system
performance at 95 % confidence level are shown in
Appendix B. From these charts, the decision makers
1153
7
concluded that the curing time (B) and the number of
jigs (E) are the most significant factors affecting the
line productivity, whereas the oven capacity and the
drying time don't have a tangible impact. Furthermore,
all defined factors have a remarkable impact on the size
of the buffer stock. Many results from the DOE module
that support the decision-making process were not
included in this paper due to space limitations. The
main effects and the two-way interaction plots for the
system response are shown in Appendix B. Also,
samples of the surface plots of the performance
indicators versus a combination of factors that have a
significant interaction effect are illustrated.
Based on the weight of the important factors in the
system response, two metamodels were formulated for
the average throughput per shift and the required buffer
stock size. The coefficient of determination (𝑅𝑅2 ) and
predicted 𝑅𝑅2 were calculated for the developed
metamodels to examine their validity in abstracting the
simulation model. 𝑅𝑅2 and predicted 𝑅𝑅2 were 97.6%,
and 94.4% respectively for the average throughput per
shift, as well as 93.5%, and 87.3% respectively for the
required buffer stock size. Consequently, it was
concluded that the metamodels are valid in imitating
the behavior of the simulation model. The average
throughput per shift metamodel was used as the
objective function in the optimization mathematical
model as illustrated in equation (1). Moreover, the
required buffer stock metamodel was employed as a
constraint to limit its size, in equation (2). Constraints
(3-7) specify the lower and upper bounds of the
decision variables. Constraint (8) ensures the decision
variables are integers. The mathematical model is built
to achieve the best configuration of decision variables
in order to maximize the productivity per shift, and
eliminate the required buffer stock size as follows:
Objective function:
Max Z = 2472 -1.265X𝐴𝐴 -8.28X𝐵𝐵 -2.958X𝐶𝐶 +91.6X𝐷𝐷
-219.3XE +0.02765X𝐴𝐴 X 𝐶𝐶 -0.818XA XD +0.00751X𝐵𝐵 XC
-0.2373XB XD +0.981X𝐵𝐵 XE (1)
Constraints:
+0.2179X𝐴𝐴 X𝐶𝐶 -6.56X𝐴𝐴 X 𝐷𝐷 +3.798X 𝐶𝐶 X𝐷𝐷 ≤ 0 (2)
25 ≤ X𝐴𝐴 ≤ 45 (3)
230 ≤ X𝐵𝐵 ≤ 290 (4)
60 ≤ XC ≤ 90 (5)
2 ≤ XD ≤ 3 (6)
7 ≤ XE ≤ 8 (7)
Xi ≥ 0, and integer. (8)
1154 Shady Salama et al. / Procedia Manufacturing 26 (2018) 1147–1158
8 Author name / Procedia Manufacturing 00 (2018) 000–000
The pure integer nonlinear mathematical model was
solved on a DELL OptiPlex 9020 computer with an
Intel Core i7 and 16 GB RAM using LINGO 12.0
optimization software. The optimal configuration for
scenario (1) was reached in 2 seconds only of
computational time, instead of running 2.88* 106
simulation runs for the whole solution domain.
Regarding scenario (2), the decision-makers desired to
evaluate the optimal configuration without the large
investment of adding more injection jig. The optimal
solutions for the two tactical planning scenarios (1),
and (2) are depicted in Table 2 with the corresponding
performance measures. Therefore, the productivity
was increased by 17%, and 14% for the two suggested
scenarios compared to the current situation with the
elimination of buffer stock. Although scenario 1 can
raise the productivity by 3% compared to scenario 2, it
requires a considerable investment to add one more jig
in the UFM. Therefore, the decision makers need to
consider the return on investment to select between the
two suggested scenarios. Furthermore, the decision-
makers seek to rapidly adjust the production line to
cope with the demand fluctuation and the availability
of raw materials which are the daily basis issues.
Subsequently, scenarios (3) and (4) have proposed to
verify the capability of the DSS in reconfiguring the
operational decision variables for different demand
sizes. For scenarios (3) and (4), the required demand
was defined as 540 and 550 fridges in a shift
respectively with the elimination of buffer stock using
the existing resources in the shop floor. The optimal
solutions for the operational scenarios (3), and (4) are
shown in Table 2 with the corresponding performance
measures. From the obtained results, decision-makers
can make informed decisions based on the expected
outcomes for each scenario. The achieved solutions
have been validated using the DES model to evaluate
other performance indicators.
Table 2. The optimal configurations for the proposed
scenarios compared to the current situation.
The Factors Current Scenario Scenario Scenario Scenario
Situation 1 2 3 4 or personal PCs. Many attributes are related to cloud
A 45 26 38 45 45
B 290 230 230 244 236
C 90 87 90 90 85
D 2 2 2 2 2
E 7 8 7 7 7
Productivity 490 572 560 540 550
Buffer Stock 70 0 fridge 0 fridge 0 fridge 0 fridge
5. Towards the introduction of cyber-physical
systems
Today's manufacturing systems have a large number
of decision variables with wide ranges, thus it is
necessary to collect real-time data about the changes
and uncertainties from business environment to make
proper decisions at different domains and levels [35].
IoT is a dynamic network infrastructure to measure,
identity, position, track and monitor physical objects
in order to facilitate interactions between human and
human, human and thing, and thing and thing. IoT data
acquisition means, including embedded sensors,
RFIDs, and near field communications, collect and
share process related data instantly about the state of a
manufacturing system from the different decision-
making sections (machines, stock, robots, etc.) [36].
Thereafter, all acquired data can be stored in cloud
servers to be accessed anywhere and anytime online.
5.1. IoT enabling technologies
1. RFID Technology: RFID tags are extensions of the
optical barcodes that define an electronic product code
to the attached items [37]. Many benefits can be gained
by using RFID tags and readers, such as the flow of
products can be tracked in real-time, inventory control
can be enhanced, and the amount of human
involvement in the production cycle can be reduced.
2. Wireless Sensor Network (WSN): sensor nodes are
devices or subsystems containing a small memory,
limited computational power, and communication
capabilities to detect states or monitor changes in their
environment (e.g., temp., pressure) and convert them
into signals. Then, the WSN gathers and organizes the
obtained data about physical conditions of a certain
phenomenon in order to transmit it to one or more base
stations using an ad-hoc communication channel [37].
3. Cloud Computing: it is an IT paradigm to deliver
on-demand computing resources to store, manage, and
process data over the internet rather than a local server
computing, for instance, ubiquitous network access,
on-demand self-service, pay per use, and location
independent resource pooling [35].
4. Smart Product: it is an embedded system composed
of a product (thing), microprocessor, controller,
sensors, and a communication unit. The smart object
can monitor its own operation, diagnose physical
errors, and call for maintenance to bridge the gap
between the physical world and the cyber world [38].
 Shady Salama et al. / Procedia Manufacturing 26 (2018) 1147–1158
Author name / Procedia Manufacturing 00 (2018) 000–000
5.2. Migrating the conventional manufacturing
system to the cyber-physical system
Several proposals were suggested to the decision-
makers in the refrigerator production line for the sake
of migrating the current conventional line to cope with
the upcoming speedy era and harvest the benefits of
the IoTs. These suggestions followed the three-layered
architecture for implementing IoT technologies in
industrial firms proposed by Jia et al. (2012) [39].
A. Sensing (perception) Layer: the manual intensive
activities in the pre-injection section can be replaced
by assembly robots which will lead to a significant
reduction in production costs and cycle time, improve
quality and reliability, and enhance safety and
automation in the shop floor. Moreover, it is crucial to
insert electrical sensors into the existing hardware
located in the injection section (oven, UFM) as well as
the continuous conveyor to control and monitor their
operations remotely. Lastly, passive RFID tags must
be attached to each fridge during its life cycle at the
production facility. RFID readers can be placed at each
processing point to activate the tags, transfer data from
inserted tags to assembly robots, and orchestrate the
communication sequence between tags.
B. Network Layer: Access and core network
infrastructure platforms were suggested using many
communication methods, including wireless or wired
local area network, General Packet Radio Services
(GPRS), IPv6, and WSN in order to aggregate
information from the RFID readers and sensors that
are integrated into the assembly line and support data
transmission to the upper layer. The collected data can
be fed into the proposed DSS to update the DES
module with the real-time status quo of the shop floor.
C. Service (application) Layer: It was recommended
that a suitable platform encompassing data
management and service-oriented applications to be
implemented. The data management function employs
cloud computing technologies to process complex
data, provide directory service, and search engines. On
the other hand, the online service applications can
support the collaboration between different partners,
such as designers, manufacturers, sellers, and
customers using advanced analytics modules.
Consequently, product-centered services can be
released which will help in providing the possibility to
place, change, and customize production orders based
on the individual need of customers (e-commerce),
and thus enhancing customer satisfaction.
1155
9
Regarding the introduction of intelligent objects, it
was suggested to the company's Research and
Development (R&D) department to begin working on
the development of a smart refrigerator programmed
to sense stored products, and track food stock through
barcode scanning. Smart fridges include distinctive
features compared to traditional ones, for example,
signals can be sent from the factory to the fridge to
identify defective parts for rapid maintenance, better
food management and home life experience by
alerting the homeowner with the expiration dates of
saved products and identifying shopping list [38].
Finally, it is expected that the aforementioned
proposals can offer many merits for the refrigerators
company over the current state, for instance, real-time
control, transparency, flexibility, predictability,
autonomous navigation, integration of customers,
remote diagnosis, reducing labor cost, in addition to
increasing the company's competitiveness and
sustainability in the fourth industrial revolution.
6. Conclusions and future directions
This paper proposed a new architecture for an IoT
based decision support system for planning and
operational control of cyber-physical production
facilities. The DSS uses an integrated framework of
simulation-based optimization approach to overcome
the limitations of simulation, and to harness the
benefits of design of experiments and mathematical
modeling in making fast, and accurate decisions. The
concept was applied to an actual assembly line that
produces home appliances. The proposed approach
was adopted for the sake of increasing productivity
and eliminating buffer stock. Four scenarios have
suggested to verify the capability of DSS in dealing
with tactical and operational planning decisions. The
results of the DSS provide the decision-makers more
insight into the factors that significantly affect the
system performance, and the relationship between
them to make future informed investments. Also, the
optimal configuration of a wide range of decision
variable can be achieved in a time-effective manner.
Finally, some recommendations were suggested to the
decision makers in order to introduce IoT
infrastructure, and CPS paradigm in their
manufacturing facility. In terms of future directions,
the implementation should be directed to an actual
cyber-physical system to illustrate the full features and
limitations of the proposed DSS.
1156 Shady Salama et al. / Procedia Manufacturing 26 (2018) 1147–1158
10 Author name / Procedia Manufacturing 00 (2018) 000–000

Appendix A.

Fig. A.1. The layout of the refrigerator assembly line and model logic of the developed simulation model.
Assembly of the Cabinet and the Metal Frame

Fridge Attach Reinforcement in both Right and Left Sides

Fix the Lower Part with Side Plates

Connect Cabinet Pipes

Fix Cabinet Housing with Lower Part

Fix Leveling Leg

Fix the Cabinet Front Side with Side Plates

Intermediate Buffer Stock Put Rear Plate and Stick the Barcode

Fix Rear Plate

Paint Welding Flux

Weld Cooling Pipes JIG

Quality Inspection

Fix the U-protection Plate

Urethane Foaming Machine

Oven

Remove the U-protection Plate

Clean and Fast Repair

Start Final Assembly Sector

Appendix B.

Fig. B.1. The DOE outputs for the throughput/shift in the left side and the buffer stock size in the right side.
 Author name / Procedia Manufacturing 00 (2018) 000–000 11

Shady Salama et al. / Procedia Manufacturing 26 (2018) 1147–1158 1157

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