Fast reactive scheduling to minimize tardiness penalty and energy cost under power consumption uncertainties

•We optimize energy cost and tardiness penalty under power consumption uncertainties.•We propose an integrated control and deadlock-free reactive scheduling framework.•It is easy to implement and it reduces model complexity for large-scale systems.•Reduced deviation from optimality is achieved as compared to dispatching rules.•Minimal production interruption is achieved as compared to rescheduling approaches.

Motivated by the need to deal with uncertainties in energy optimization of flexible manufacturing systems, this paper considers a dynamic scheduling problem which minimizes the sum of energy cost and tardiness penalty under power consumption uncertainties. An integrated control and scheduling framework is proposed including two modules, namely, an augmented discrete event control (ADEC) and a max-throughput-min-energy reactive scheduling model (MTME). The ADEC is in charge of inhibiting jobs which may lead to deadlocks, and sequencing active jobs and resources. The MTME ensures the fulfillment of the innate constraints and decides the local optimal schedule of active jobs and resources. Our proposed framework is applied to an industrial stamping system with power consumption uncertainties formulated using three different probability distributions. The obtained schedules are compared with three dispatching rules and two rescheduling approaches. Our experiment results verify that MTME outperforms three dispatching rules in terms of deviation from Pareto optimality and reduces interrupted time significantly as compared to rescheduling approaches. In addition, ADEC and MTME are programmed using the same matrix language, providing easy implementation for industrial practitioners.