Heuristic Algorithm-based Action Masking Reinforcement Learning (HAAM-RL) with Ensemble Inference Method

Abstract: This paper presents a novel reinforcement learning (RL) approach called HAAM-RL (Heuristic Algorithm-based Action Masking Reinforcement Learning) for optimizing the color batching re-sequencing problem in automobile painting processes. The existing heuristic algorithms have limitations in adequately reflecting real-world constraints and accurately predicting logistics performance. Our methodology incorporates several key techniques including a tailored Markov Decision Process (MDP) formulation, reward setting including Potential-Based Reward Shaping, action masking using heuristic algorithms (HAAM-RL), and an ensemble inference method that combines multiple RL models. The RL agent is trained and evaluated using FlexSim, a commercial 3D simulation software, integrated with our RL MLOps platform BakingSoDA. Experimental results across 30 scenarios demonstrate that HAAM-RL with an ensemble inference method achieves a 16.25% performance improvement over the conventional heuristic algorithm, with stable and consistent results. The proposed approach exhibits superior performance and generalization capability, indicating its effectiveness in optimizing complex manufacturing processes. The study also discusses future research directions, including alternative state representations, incorporating model-based RL methods, and integrating additional real-world constraints.