Real-Time Data-Driven Out-of-Order Synchronization for Production and Intralogistics in Multiresource-Constrained Assembly Systems

This study aims to address a novel production and intralogistics synchronization (PiLSync) problem in multiresource-constrained assembly systems (MRCASs). PiLSync is highly complex due to the presence of multiple resources (operators, workstations, and materials) and the dynamic interactions between the resources and decisions. Moreover, various uncertainties, such as new/urgent job arrivals, uncertain operating times, equipment failures, and operator absences, further complicate this problem. Emerging Industry 4.0 technologies help capture and monitor the real-time PiL workflow, while existing methods are typically formulated to handle static or periodically updated inputs. Thus, it is difficult to explicitly incorporate real-time data into models, leading to a gap between production and intralogistic (PiL) decisions and actual executions under various uncertainties. In this article, out-of-order synchronization (OoOSync) is developed to facilitate flexible, resilient, and coordinated PiL operations in MRCASs. A sliding synchronization window is proposed as an effective decomposition tool to limit system complexity and localize demand uncertainty. Ticket validation governs interactions between resources and constraints under uncertainty. Finally, real-time data-driven synchronization mechanisms are developed for PiL decision/adjustment. The superiority of OoOSync is confirmed in computational experiments. This article is a pioneering study considering multiresource-constrained PiL operations under uncertainty. Additionally, this article offers a new perspective on using real-time data for decisions and operations subject to the dynamic interactions of resources.