The integration of discrete simulations, artificial intelligence methods, and the theory of probability in order to obtain a high flexibility of the production system is crucial. In this paper, the concept of a smart factory operation is proposed along with the idea of data exchange architecture, simulation creation, performance optimization, and predictive analysis of the production process conditions. A Digital Twin for a hybrid flow shop from the automotive industry is presented as a case study. In the paper, the Ant Colony Optimization (ACO) algorithm is developed for multi-criteria scheduling problems in order to obtain a production plan without delays and maximum resource utilization. The ACO is compared to the immune algorithm and genetic algorithm. The best schedules are achieved with low computation time for the Digital Twin. By predicting the reliability parameters of the limited resources of the Digital Twin, stable deadlines for the implementation of production tasks are achieved. Mean Time To Failure and Mean Time of Repair are predicted for a real case study of an electric steering gear production line. The presented integration and data exchange between the elements of the smart factory: a Digital Twin, a computing module including an optimization, prediction, and simulation methods fills the gap between theory and practice for Industry 4.0. The paper presents measurable benefits of integration of discrete simulation tools, historical data analysis, and optimization methods.

In this paper a solution of soft real time scheduling in manufacturing systems is presented. The basic requirements of scheduling as a real time system are discussed. The proposed rescheduling method uses predictive-reactive strategy and multi thread searching approach with rule-based heuristics, meta-heuristics and random modules.

The method for determining dispatching rules for transient phases, based on designation of a local dispatching rule for steady state, which determines the rest of its components has been presented in the paper. The algorithm for determining the transient rules has been presented and dependencies resulting from the presented sufficient conditions have been formulated. For the proposed transitional-rules generation algorithm the simulation model has been prepared. Simulation experiments to verify the correctness and effectiveness of the presented method have been conducted. The experiments have been prepared for input data describing the production system and the production order. In the verification process Enterprise Dynamics computer simulation system has been used. The results were compared with the results obtained for transitional phases realized through the S0 state of the production system.

Petri nets are a useful tool for the modeling and performance evaluation of discrete event systems. Literature reveals that the Petri Net models of real-world discrete event systems are most frequently event graphs (a subclass of Petri nets). Literature also reveals that there are some simple methods for the performance evaluation of event graphs. The general-purpose Petri Net simulator (GPenSIM) is a new simulator that runs on the MATLAB platform. GPenSIM provides a Petri net language, with which Petri net classes and extensions can be developed. GPenSIM also provides functions for performance analysis. Since real-world discrete event systems usually possess a large number of resources, the Petri net models of these systems tend to become huge. Activity-Oriented Petri Nets (AOPN) is an approach that reduces the size of the Petri nets. In addition to the simulator functions, GPenSIM also realizes the AOPN approach on the MATLAB platform. Thus, AOPN is an integral part of GPenSIM. As a running example, a flexible manufacturing system is firstly modeled as an event graph, and then the size of the model is reduced with the AOPN approach. The advantages of GPenSIM and AOPN are discussed in this paper.