Multi-level digital twin-driven kitting-synchronized optimization for production logistics system

Abstract

The kit production mode is favored by many manufacturing companies due to its ability to meet customized and personalized customer demands through versatile combinations. However, it also poses significant challenges to production management. In the production process, companies need to consider not only horizontal coordination between upstream and downstream stages of the production logistics system (production, transportation, warehousing) but also vertical coordination of production progress for different products within the kit. Moreover, they must address various dynamic disturbances during production operations. This paper proposes an intelligent kit production management platform to tackle these challenges. It adopts a multi-level digital twin architecture as the platform control structure, a “two-stage three-level” synchronization mechanism as the qualitative control mechanism, and the target cascade method based on genetic algorithms as the quantitative solution foundation. This platform enables synchronized control of kit production in dynamic environments. Finally, through a case study simulation, the feasibility and effectiveness of the proposed approach are verified. The study also explores the impact of varying magnitudes of dynamics at different times of occurrence on the production logistics system, providing valuable insights for management practices.