This EArly-concept Grant for Exploratory Research (EAGER) award supports fundamental research on the design of an agile manufacturing exchange system (MES) in which suppliers of raw materials, assemblers, transportation companies, etc., will participate through standardized protocols to fulfill complex manufacturing orders. This design will provide the foundation for a smart software mediation layer (i.e., a "broker") that will enable a MES to be self-learning and adaptive to dynamic/diverse service requests and resource availability, as well as support a large network of service providers and users within a complex information ecosystem. The economic competitiveness of the U.S. depends on new and innovative methods for intelligent mass customization systems for the manufacturing sector, which will enable the processing of small-sized and diverse orders that demand almost instant fulfillment. The MES will enable this transformation by supporting on-demand integration of resources, graceful recovery from failures, and dynamic adaptation without any disruption in operations. In order to meet these goals, research will be focused on adaptation to emerging system behaviors by dynamically evolving optimization strategies in real-time. Users and providers will be connected in a dynamic manufacturing network that will accommodate multiple product flows, uncertainty in links between providers and themselves, and fault tolerance to provide service despite failed network components. This level of adaptation, seamless efficiency, and uninterrupted service will constitute a significant step forward towards a smart MES. The research goals will be accomplished through the design of a distributed real-time optimization and knowledge discovery framework that will address workflow optimization, resource allocation, and data-driven performance prediction in a dynamic manufacturing network of users, brokers, and providers. The specific research tasks include online admission control policies, dynamic production planning, analysis and prediction of service-level performance for forecasting, distributed methods for dynamic resource allocation under uncertainty, and visual analytics techniques to support human decision makers and situational awareness.

Software-Defined Control (SDC) is a revolutionary methodology for controlling manufacturing systems that uses a global view of the entire manufacturing system, including all of the physical components (machines, robots, and parts to be processed) as well as the cyber components (logic controllers, RFID readers, and networks). As manufacturing systems become more complex and more connected, they become more susceptible to small faults that could cascade into major failures or even cyber-attacks that enter the plant, such as, through the internet. In this project, models of both the cyber and physical components will be used to predict the expected behavior of the manufacturing system. Since the components of the manufacturing system are tightly coupled in both time and space, such a temporal-physical coupling, together with high-fidelity models of the system, allows any fault or attack that changes the behavior of the system to be detected and classified. Once detected and identified, the system will compute new routes for the physical parts through the plant, thus avoiding the affected locations. These new routes will be directly downloaded to the low-level controllers that communicate with the machines and robots, and will keep production operating (albeit at a reduced level), even in the face of an otherwise catastrophic fault. These algorithms will be inspired by the successful approach of Software-Defined Networking. Anomaly detection methods will be developed that can ascertain the difference between the expected (modeled) behavior of the system and the observed behavior (from sensors). Anomalies will be detected both at short time-scales, using high-fidelity models, and longer time-scales, using machine learning and statistical-based methods. The detection and classification of anomalies, whether they be random faults or cyber-attacks, will represent a significant contribution, and enable the re-programming of the control systems (through re-routing the parts) to continue production. The manufacturing industry represents a significant fraction of the US GDP, and each manufacturing plant represents a large capital investment. The ability to keep these plants running in the face of inevitable faults and even malicious attacks can improve productivity -- keeping costs low for both manufacturers and consumers. Importantly, these same algorithms can be used to redefine the production routes (and machine programs) when a new part is introduced, or the desired production volume is changed, to maximize profitability for the manufacturing operation .

Software-Defined Control (SDC) is a revolutionary methodology for controlling manufacturing systems that uses a global view of the entire manufacturing system, including all of the physical components (machines, robots, and parts to be processed) as well as the cyber components (logic controllers, RFID readers, and networks). As manufacturing systems become more complex and more connected, they become more susceptible to small faults that could cascade into major failures or even cyber-attacks that enter the plant, such as, through the internet. In this project, models of both the cyber and physical components will be used to predict the expected behavior of the manufacturing system. Since the components of the manufacturing system are tightly coupled in both time and space, such a temporal-physical coupling, together with high-fidelity models of the system, allows any fault or attack that changes the behavior of the system to be detected and classified. Once detected and identified, the system will compute new routes for the physical parts through the plant, thus avoiding the affected locations. These new routes will be directly downloaded to the low-level controllers that communicate with the machines and robots, and will keep production operating (albeit at a reduced level), even in the face of an otherwise catastrophic fault. These algorithms will be inspired by the successful approach of Software-Defined Networking. Anomaly detection methods will be developed that can ascertain the difference between the expected (modeled) behavior of the system and the observed behavior (from sensors). Anomalies will be detected both at short time-scales, using high-fidelity models, and longer time-scales, using machine learning and statistical-based methods. The detection and classification of anomalies, whether they be random faults or cyber-attacks, will represent a significant contribution, and enable the re-programming of the control systems (through re-routing the parts) to continue production. The manufacturing industry represents a significant fraction of the US GDP, and each manufacturing plant represents a large capital investment. The ability to keep these plants running in the face of inevitable faults and even malicious attacks can improve productivity -- keeping costs low for both manufacturers and consumers. Importantly, these same algorithms can be used to redefine the production routes (and machine programs) when a new part is introduced, or the desired production volume is changed, to maximize profitability for the manufacturing operation .