Dynamic Instabilities and Stabilization Methods in Distributed Real-Time Scheduling of Manufacturing Systems 1: Clearing Policies Are Unstable on a Re-Entrant Two-Machine Line, Even Without Set-UpsResearch Paper
Motivation
A flexible manufacturing system is a set of machines through which parts of several types travel along fixed routes; each machine serves several buffers and must pay a set-up time whenever it switches from one buffer to another. Real-time scheduling decides, as the system evolves, which buffer each machine works on. Perkins and Kumar (IEEE Trans. Automat. Control 34, 1989) introduced simple distributed policies for this problem, of which the most natural is the clearing policy: a machine keeps working on a buffer until it is empty, and only then switches. They proved that every clear-a-fraction policy, a subclass of clearing policies, keeps every buffer bounded on acyclic systems whenever each machine has spare capacity, and left open whether clear-a-fraction policies stabilize all systems in which material flows around cycles.
Kumar and Seidman (IEEE Trans. Automat. Control 35(3), 1990, doi:10.1109/9.50339) answered no. Their Example 1 is a single part type that visits two machines in the order 1, 2, 2, 1. Every machine has spare capacity, yet under the clearing policy the buffer levels grow without bound, and they do so even when all set-up times are zero, so the instability comes from machines starving each other rather than from time lost to set-ups. Until then, instability had been suspected to require positive set-up times. Shortly afterwards Lu and Kumar exhibited instability of a static buffer-priority rule in a re-entrant network (IEEE Trans. Automat. Control 36, 1991); together these examples started the study of stability of multiclass queueing networks.
Setting
A manufacturing system has part types arriving at rates . Parts of type follow a route of length : their -th operation is at machine , and they wait for it in buffer , where each part needs processing time . Machine serves the buffers , and switching from to costs set-up time .
Flows are continuous (fluid). The level of buffer at time is , where is its cumulative output and its cumulative input: for the first buffer of a route, and the output of the preceding buffer otherwise. Each machine works in runs: run is a set-up phase of length followed by a processing phase on buffer , during which the buffer is drained at rate while it is nonempty and passed through at its inflow rate when it is empty. The system is stable if for every buffer.
A clearing policy (Definition 1) is one in which a machine processing continues until the first time that is empty and some other buffer of the same machine is nonempty, and then commences a set-up for one of the nonempty buffers.
Example 1. One part type arrives at rate and visits machine 1, machine 2, machine 2 and machine 1; its buffers are , so and . Processing times are , and is the time to set up to buffer . The parameters satisfy the critical condition and the capacity condition
The initial state is , with machine 1 set up for buffer 4 and machine 2 set up for buffer 3. Write
Formalization targets
Goal: Example 1, both cases
Assume (3)–(5).
- If , there is such that for every () a clearing trajectory from exists, and every such trajectory has
- If , the same holds for every .
Milestone: the Case 1 cycle map
For large enough, every clearing trajectory from reaches, at ,
with machines 1 and 2 again set up for buffers 4 and 3.
Milestone: the Case 2 magnification
With zero set-up times and any , every clearing trajectory reaches, at ,
with machines 1 and 2 again set up for buffers 4 and 3.
Significance
The example shows that the condition on every machine, which is necessary for stability and sufficient for the existence of some stabilizing policy, does not make natural distributed policies stable once material flows around a cycle. The throughput of the line falls to part per unit time although each machine could handle the demand. This motivates the paper's two positive results: sufficient conditions under which clear-a-fraction policies are stable (Theorem 1), and a supervisory mechanism that stabilizes any policy (Theorem 2), which are the subjects of the other missions of this series. The example is also an early instance of the phenomenon later studied as instability of multiclass fluid networks under work-conserving policies.
The paper's argument is a stage-by-stage computation of piecewise linear trajectories. No machine-checked version of it exists. A formal proof has to make precise what the paper leaves to the reader: that the clearing rule determines the trajectory, that the stage formulas are what that trajectory does, and that the cycle can be restarted. The formal model of runs, set-ups and the clearing rule built here is the same as in the other missions of the series.
Difficulty
The arithmetic of each cycle is routine once the trajectory is known. The difficulty is in the universal quantifier: the claim covers every clearing trajectory, and the clearing rule is defined implicitly, through "the first time thereafter" at which a buffer is empty and another one is nonempty. At several switching instants the buffer a machine switches to is empty and only starts to fill at that instant, and with zero set-up times a machine may begin a run at an instant where the switching condition already holds. Showing that each switch happens exactly when the paper says, and that the fluid levels then follow the printed formulas (including the reduced rate of a machine working on an empty buffer), is a uniqueness argument for a hybrid system, not a simulation. The existence half asks for the converse: an explicit trajectory, defined for all time, with infinitely many runs whose start times tend to infinity.
Formalization scope
- Time is real (); flows are fluid; there are no transport delays or assembly.
- The system is a general structure (part types
Fin P, machinesFin M, buffers⟨p, i⟩withi : Fin (n p), paper index = Lean index ), instantiated as Example 1 with , route , and for ; staying on a buffer costs nothing. - A trajectory is a schedule of runs per machine (possibly finitely many, the last lasting forever), with only finitely many run starts in any bounded interval. Processing obeys a rate cap ( grows at most at rate , and only while machine is in a processing phase of ) and runs at full rate while the buffer is nonempty.
- In Definition 1, a target buffer counts as "nonempty" when it is demanding: positive level, or inflow starting at that instant. The no-early-exit condition is imposed on the open processing interval. Under the literal reading (positive level) or a closed interval, the paper's own trajectories are not clearing, and the goal would hold vacuously; the existence clause in the goal rules out that trivialization.
- "Set up for buffer at time " means the run in force on .
- Unboundedness is stated for buffer 1: for every there is with ; " large enough" is .
Useful contributions include lemmas about fluid trajectories that do not depend on the example (continuity of levels, the pass-through rate on an empty buffer, restarting a trajectory at a run boundary), which also serve the other missions of the series.
Selected references
- P. R. Kumar and T. I. Seidman, Dynamic instabilities and stabilization methods in distributed real-time scheduling of manufacturing systems, IEEE Trans. Automat. Control 35(3), 289–298, 1990. https://doi.org/10.1109/9.50339
- J. R. Perkins and P. R. Kumar, Stable, distributed, real-time scheduling of flexible manufacturing/assembly/disassembly systems, IEEE Trans. Automat. Control 34, 139–148, 1989 (reference [18] of the paper).
- S. H. Lu and P. R. Kumar, Distributed scheduling based on due dates and buffer priorities, IEEE Trans. Automat. Control 36, 1991.