Skill-Constrained Model Predictive Control for Resilient Manufacturing Supply Chains

Production planning increasingly has to treat workforce capability as a decision variable: certifications lapse when skills are not maintained, new products require skills the current workforce does not hold, and reskilling competes for the same worker hours needed for production. Existing operations benchmarks usually treat labor as exogenous, while workforce-planning models with skills and learning are rarely released as reusable testbeds. We introduce SkillChain-Gym, a benchmark specification for reskilling-aware production-inventory control: a single-site environment with stylized worker skill-state dynamics, hard threshold certification, forgetting, and capacity-consuming training actions constrained by the same per-worker time budget as production. The benchmark includes seed-controlled disruption scenarios, three feasibility modes with projection diagnostics, deterministic replay, and metrics covering operations, resilience, capability growth, and training-access distribution. We evaluate production-only, reactive adaptive, water-filling adaptive, and static-insurance policies with budget variants over 60-shift horizons with paired statistical tests. The results are regime-dependent rather than a ranking. Training-capable policies dominate the production-only baseline, and maintenance training is necessary under forgetting even without disruptions. Among training-capable classes, adaptive training helps when bottlenecks are visible in the forecast, while a lean static cross-training plan, a deliberately favorable comparator whose structure encodes relevant skill contingencies, acts as strong insurance under surprise shocks and absenteeism. Capacity slack and the forgetting rate govern the boundary between these regimes. No policy class dominates across regimes, motivating forecast-driven controllers that decide when to buy skill insurance and when to react.

Educational support services often face a qualified-capacity problem: staff time is scarce, qualifications decay, new support needs can appear before anyone is prepared for them, and training consumes the same hours needed by current students. We introduce a synthetic benchmark and decision-support framework for qualified educational capacity planning. The model is a stylized single-institution service system with heterogeneous support-demand categories, backlog-only dynamics, continuous preparation states with hard threshold qualification and decay, and capacity-consuming training. The benchmark includes seed-controlled scenarios for announced and surprise new support categories, staff absences, and demand surges; exact feasibility discipline; declared per-policy information sets; requalification and greenfield-qualification counters; access-dispersion metrics; replay checksums; and paired statistics. We compare service-only, reactive, static-insurance, water-filling, and rolling-horizon mixed-integer controllers, with an attribution chain separating service planning, qualification maintenance, and acquisition, plus a perfect-foresight reference. The central result is a regime map governed by whether a newly required qualification can be acquired within the controller's reaction reach. When it can, the closed-loop controller wins across the core and adversarial suites, with value concentrated in just-in-time qualification acquisition. When the training lag exceeds the horizon, lean static insurance wins structurally, and a reactive trainer that starts after onset can be worse than no training. Backlog perishability shifts this boundary without erasing either regime. EduCapacity Studio reproduces exported scenarios bit-for-bit. All evidence is stylized and synthetic; the framework makes no claims about real student outcomes, compliance, or individual placements.

Multistage stochastic model predictive control (MPC) handles uncertainty by optimizing over a scenario tree, a finite branching approximation of future outcomes constructed from sampled forecasts. To build such a tree, conventional methods focus on matching the underlying probability distribution---e.g., via Wasserstein-based scenario reduction---but improved distributional accuracy does not necessarily yield better control performance. We propose a control-oriented approach that learns scenario tree construction directly from its impact on downstream decisions. Fixing the tree topology, we formulate tree construction as a sequential assignment of sampled scenarios to leaves. This assignment is parameterized by an attention-based policy over the scenario set and trained using reinforcement learning, with closed-loop control profit as the objective. Training is stabilized by an asymmetric critic that leverages realized future trajectories. We evaluate the method on a risk-averse battery arbitrage problem. Across a range of forecast set sizes, the learned construction consistently achieves the highest profit, outperforming classical forward and backward reduction methods and certainty-equivalent (single-trajectory forecast) control. The learned policy also exhibits greater robustness on challenging instances, consistently demonstrating better tail-risk characteristics. Analysis of the resulting trees indicates that our method constructs compact, selectively branching structures that capture high-impact events while keeping most trajectories nearly deterministic. These findings highlight that the value of a scenario tree depends critically on the decisions it supports, and provide an effective framework to train scenario tree constructors merely based on the closed-loop control optimization signal.