Digital twin-based multi-granularity synchronisation for production-warehousing under batch processing mode

Batch production is a cost-effective way that boosts efficiency in manufacturing systems. As customer demands become increasingly customised, there is a growing need to consolidate numerous small-batch orders. However, if batch production exceeds the optimal level, it may lead to the premature completion of customer orders, causing temporary congestion in the finished goods warehouse and prolonged resource occupation. Consequently, an essential focus of this study pertains to coordinating decision-making units like workshops and warehouses within batch production setups to ensure stable system operation amidst dynamic customer demands. The proposed solution encompasses a Digital Twin-based Multi-level Synchronised Control System (DTMCS) framework, featuring the Multi-granularity Synchronised Control Mechanism (MgSCM) and a collaborative optimisation model for batch production and warehouse planning. By examining a practical case study from a paint manufacturing company, the research delves into the effects of four synchronised control patterns on various system performance metrics, such as operating costs, equipment and warehouse utilisation rates, and system stability. Overall, this study provides an adaptable and cost-effective solution for enhancing production-logistics synchronisation.