Analysis of Flow Control in Alternative Manufacturing Configurations

1980 ◽  
Vol 102 (3) ◽  
pp. 141-147 ◽  
Author(s):  
J. J. Solberg ◽  
S. Y. Nof
Keyword(s):  
Manufacturing Systems ◽  
Manufacturing System ◽  
Job Shop ◽  
Queueing Network ◽  
Process Time ◽  
Process Selection ◽  
Transport Time ◽  
Computerized Manufacturing ◽  
Product Layout ◽  
The Impact

A mathematical model of workflow, based on queueing network theory, is used to compare the performance of four alternative layout configurations for manufacturing systems: a product layout (or flowshop), a process layout (or job shop), and two layouts which have been used in computerized manufacturing system. It is shown that, under appropriate conditions, any one of the four layouts could be the preferred choice. The impact of part mix, process selection, and the ratio of mean process time to mean transport time on the layout design are revealed and quantified.

scholarly journals A Comparison between Dedicated and Flexible Manufacturing Systems: Optimization and Sensitivity Analysis

2021 ◽  
Vol 40 (1) ◽  
pp. 130-139
Author(s):  
Abdul Salam Khan ◽  
Khawer Naeem ◽  
Raza Ullah Khan
Keyword(s):  
Sensitivity Analysis ◽  
Flexible Manufacturing ◽  
Manufacturing Systems ◽  
Manufacturing System ◽  
Cost Minimization ◽  
Process Time ◽  
Future Research ◽  
Second Phase ◽  
Solution Approach ◽  
The Impact

An abrupt change requires a robust and flexible response from a manufacturing system. Dedicated Manufacturing System (DMS) has been a long practiced taxonomy for mass production and minimum varieties. In contrast, Flexible Manufacturing System (FMS) has been introduced for responding to quantity as well as variety issues. This study considers both production taxonomics by using a multi objective model of cost and time. An Integer Linear Programming (ILP) formulation is presented and subsequently validated. The analysis procedure is administered in two phases. In the first phase, comparison of production cost and process time in DMS and FMS is presented. The model is implemented by using an exact solution approach and results show that FMS is a viable option, compared to DMS, according to the criteria of cost, time, and productivity. In the second phase, sensitivity analysis is performed by using several FMS (n) and the impact of cells selection on the performance of system is studied. It is concluded that n=1 (single cell-based FMS) is more relevant for cost minimization; however, n = 6 is a suitable candidate for producing more quantity in given time horizon (process time minimization). Lastly, key findings are reported, and future research avenues are provided.

DECISION SUPPORT FOR A SUSTAINABLE PRODUCTION IN JOB SHOP MANUFACTURING SYSTEMS

10.6036/9917 ◽  
2021 ◽  
Vol 96 (5) ◽  
pp. 455-459
Author(s):  
MAHDI NADERI ◽  
ANTONIO FERNÁNDEZ ULLOA ◽  
JOSÉ ENRIQUE ARES GÓMEZ ◽  
GUSTAVO PELÁEZ LOURIDO
Keyword(s):  
Decision Making ◽  
Decision Support ◽  
Manufacturing Systems ◽  
Manufacturing System ◽  
Job Shop ◽  
Sustainable Production ◽  
Ease Of Use ◽  
Manufacturing Companies ◽  
Strategic Decisions ◽  
Production Environments

Despite the growing importance that is being given to the concepts of sustainability in many areas, not only in industry but also in the economy and public opinion in general, until now, most research has focused, practically, on the analysis of the concepts, but has not addressed, in a comprehensive way, its impact in decision making probably due to the complex relations of interdependence between its different aspects. In this context, MAPSAM (Methodology for the Assessment of Sustainability in Manufacturing Processes and Systems) was created to help the decision-making process, allowing a conscious and transparent assessment by administrators and managers at the different levels of the structure of companies and organisations. This article explains its development and application in a "job shop" type manufacturing system with an approach that allows the integration of economic, environmental and social criteria. MAPSAM is based on the use of various techniques and tools to quantify the importance of each aspect of sustainability and it has been applied in other production environments, being implemented in different systems, analysing their ease of use and evaluating their behaviour. The objective is to show how it helps to make operational, tactical and strategic decisions in the management on these type of manufacturing companies and, specifically, in this contribution we want to highlight its versatility and applicability, by validating it in a certain type of layout. With this new application, MAPSAM increases its possibilities as an innovative instrument that allows companies to make conscious and sustainable decisions in order to be more efficient, fair, supportive and respectful of the environment. Keywords: Manufacturing System, Simulation, Decision Support, Sustainable Production, Decision-Making

Seru Production System

2021 ◽  
pp. 113-138
Author(s):  
Emre Bilgin Sarı ◽  
Sabri Erdem
Keyword(s):  
Production System ◽  
Mass Production ◽  
Lean Manufacturing ◽  
Manufacturing Systems ◽  
Job Shop ◽  
Production Systems ◽  
Cost Effective ◽  
Opportunity To Respond ◽  
Manufacturing Management ◽  
The Impact

Seru production system is a flexible, cost-effective, workforce competence-oriented manufacturing management system that provides the opportunity to respond quickly to customer demand. As in parallel to technology and physical improvements, customer demands are also effective for development of production systems. The impact of change in demand has been seen on changeover from job shop to mass production, flexible, and lean manufacturing systems. Seru production system is more appropriate for targeting work both cost-effectively like mass production and maximum diversification like job shop production. This chapter clarifies the Seru production system and explain its use and benefits in the clothing industry. In the application, a shirt production is illustrated according to the principles of mass production, lean production, and Seru production. Thus, different types of production systems have been benchmarked. There will be potential study areas for proving the efficiency of Seru soon.

And The World Came To See: New Manufacturing System Designs and Industrial Revolutions

2002 ◽  
Author(s):  
J. T. Black ◽  
David S. Cochran
Keyword(s):  
System Design ◽  
Systems Engineering ◽  
Lean Manufacturing ◽  
Manufacturing Systems ◽  
Manufacturing System ◽  
Job Shop ◽  
Flow Shop ◽  
The World ◽  
Industrial Revolutions ◽  
New System

AND THE WORLD CAME TO SEE. When a new manufacturing system design (MSD) is developed by a company or a group of companies, the rest of the world comes to those factories to learn about the new system. In the last 200 years, three new factory designs have evolved, called the job shop, the flow shop and the lean shop. Each is based on a new system design — a functional design, a product flow design and a linked cell design. New factory designs lead to new industrial leaders and even new industrial revolutions (IR’s). Two appendixes are included: One outlines the implementation strategy for the lean shop and the other is a discussion of lean manufacturing from the viewpoint of K. Hitomi, Japanese professor of manufacturing systems engineering.

scholarly journals Simulation Modeling Approach for Collaborative Workplaces’ Assessment in Sustainable Manufacturing

2020 ◽  
Vol 12 (10) ◽  
pp. 4103 ◽  
Author(s):  
Robert Ojstersek ◽  
Borut Buchmeister
Keyword(s):  
Energy Consumption ◽  
Simulation Modeling ◽  
Manufacturing Systems ◽  
Manufacturing System ◽  
Block Diagram ◽  
Operation Mode ◽  
Sustainable Manufacturing ◽  
Electrical Energy ◽  
Modeling Approach ◽  
The Impact

The presented manuscript represents a new simulation modeling approach, which evaluates the impact of collaborative workplaces on manufacturing sustainability in terms of workplaces’ cost, flow times and electrical energy consumption. The impact of collaborative workplaces on the manufacturing system and on its sustainable viability as a whole has not yet been explored, despite the fact that collaborative workplaces are increasingly present in different manufacturing systems. In the past, researchers have devoted a lot of time to research individually examining the collaborative machines, workplaces and various aspects of Sustainable Manufacturing. Investigating the impact of collaborative workplaces on an enterprise’s financial, social and environmental points of view is a very complex task, since we are talking about a multicriteria evaluation of manufacturing systems. The simulation approach is based on a newly proposed block diagram structure that allows for an evaluation of the impact of collaborative workplaces on Sustainable Manufacturing in its entirety. Using the input data of the real-world manufacturing system characteristics and Eurostat statistical values, numerical and graphical results of the proposed simulation evaluation are given, which, with a high degree of evaluation credibility, influences the introduction of collaborative workplaces in manual workplaces. The results obtained show a 20% reduction in the cost of collaborative workstations compared to manual assembly workstations, a 13.2% reduction in order throughput times, a negligible increase in energy consumption in operation mode of 3.28% and a 4.57% reduction in the idle mode. The new evaluation approach allows for a comprehensive consideration of the influence of the collective workplace when developing new or modernizing existing manufacturing systems from a financial, social and environmental point of view.

scholarly journals Job shop scheduling considering material handling process

2018 ◽  
Vol 204 ◽  
pp. 07008
Author(s):  
Eka K.A. Pakpahan ◽  
Sonna Kristina ◽  
Ari Setiawan ◽  
Evelin Merlians
Keyword(s):  
Flexible Manufacturing ◽  
Material Handling ◽  
Manufacturing System ◽  
Flexible Manufacturing System ◽  
Job Shop ◽  
Job Shop Scheduling ◽  
Raw Material ◽  
Shop Scheduling ◽  
Material Handling Equipment ◽  
The Impact

This paper discussed job shop scheduling considering material handling process. This process is a very important aspect on a flexible manufacturing system, where raw material or semi-finished goods are delivered from one processing point unto another by utilizing automated material handling equipment, functioned as shared resources. The starting time of each process is affected by the ability of the material handling equipment to conduct timely delivery from one point to another, therefore considering this process unto scheduling is important to enable planner to get precise estimation of the process makespan. We take the case where the flexible manufacturing system is consisted of four identical machines; each has the capability of processing various jobs due to the various cutting tools installed on their tools magazine. Jobs are dispatched based on longest processing time rule and then allocated to machine which has minimum load. Being a shared resource, material handling equipment has pick-up and delivery priority rule when handling multiple requests. The two most common rules are longest waiting and closest entity. This paper will analyzed the impact of each rule to the process makespan and material handling equipment utilization. Simulation model were built using Promodel to give decision maker better visualization of the system under consideration.

scholarly journals Model Predictive Control for Flexible Job Shop Scheduling in Industry 4.0

2021 ◽  
Vol 11 (17) ◽  
pp. 8145
Author(s):  
Philipp Wenzelburger ◽  
Frank Allgöwer
Keyword(s):  
Model Predictive Control ◽  
Predictive Control ◽  
Flexible Manufacturing ◽  
Industry 4.0 ◽  
Flexible Manufacturing Systems ◽  
Manufacturing Systems ◽  
Manufacturing System ◽  
Job Shop ◽  
Special Cases ◽  
Production Problem

In the context of Industry 4.0, flexible manufacturing systems play an important role. They are designed to provide the possibility to adapt the production process by reacting to changes and enabling customer specific products. The versatility of such manufacturing systems, however, also needs to be exploited by advanced control strategies. To this end, we present a novel scheduling scheme that is able to flexibly react to changes in the manufacturing system by means of Model Predictive Control (MPC). To introduce flexibility from the start, the initial scheduling problem, which is very general and covers a variety of special cases, is formulated in a modular way. This modularity is then preserved during an automatic transformation into a Petri Net formulation, which constitutes the basis for the two presented MPC schemes. We prove that both schemes are guaranteed to complete the production problem in closed loop when reasonable assumptions are fulfilled. The advantages of the presented control framework for flexible manufacturing systems are that it covers a wide variety of scheduling problems, that it is able to exploit the available flexibility of the manufacturing system, and that it allows to prove the completion of the production problem.

scholarly journals Reactive Scheduling Based on Adaptive Manipulator Operations in a Job Shop Configuration with Two Machines

2021 ◽  
Vol 15 (5) ◽  
pp. 661-668
Author(s):  
Ryo Yonemoto ◽  
◽  
Haruhiko Suwa
Keyword(s):  
Machine Tools ◽  
Manufacturing Systems ◽  
Material Handling ◽  
Manufacturing System ◽  
Job Shop ◽  
Machining Processes ◽  
Operation Sequence ◽  
Machine Failure ◽  
Operation Schedule ◽  
Two Machines

Manufacturing systems are affected by uncertainties, such as machine failure or tool breakage, which result in system downtime and productivity deterioration. In machining processes, system downtime must be reduces. This study aims to establish an automated scheduling technique that flexibly responds to unforeseen events, such as machine failure, based on adaptive operations of the handling manipulator instead of an operation schedule for the machine tools. We propose an “adaptive manipulation” procedure for establishing a reactive revision policy. The reactive revision policy modifies a portion of the manipulator operation sequence, followed by the machine operation sequence. We conduct a physical scheduling simulation on a material-handling manipulator system imitating a job-shop manufacturing system. Through simulations involving machine breakdown scenarios, the applicability of the reactive revision policy based on adaptive manipulation is demonstrated.

scholarly journals The Impact of the Availability of Resources, the Allocation of Buffers and Number of Workers on the Effectiveness of an Assembly Manufacturing System

2017 ◽  
Vol 8 (3) ◽  
pp. 40-49 ◽  
Author(s):  
Sławomir Kłos ◽  
Peter Trebuna
Keyword(s):  
Computer Simulation ◽  
Production System ◽  
Manufacturing Systems ◽  
Manufacturing System ◽  
Simulation Methods ◽  
Manufacturing Cells ◽  
Work In Progress ◽  
Assembly Operations ◽  
Buffer Capacities ◽  
The Impact

AbstractThis paper proposes the application of computer simulation methods in order to analyse the availability of resources, buffers and the impact of the allocation of workers on the throughput andwork-in-progressof a manufacturing system. The simulation model of the production system is based on an existing example of a manufacturing company in the automotive industry. The manufacturing system includes both machining and assembly operations. Simulation experiments were conductedvis-à-visthe availability of the different manufacturing resources, the various allocations of buffer capacities and the number of employees. The production system consists of three manufacturing cells –each cell including two CNC machines– and two assembly stations. The parts produced by the manufacturing cells are stored in buffers and transferred to the assembly stations. Workers are allocated to the manufacturing cells and assembly stations, but the number of workers may be less than number of workplaces and are thus termed ‘multi-workstations’. Using computer simulation methods, the impact of the availability of resources, the number of employees and of the allocation of buffer capacity on the throughput andwork-in-progressof the manufacturing system is analysed. The results of the research are used to improve the effectiveness of manufacturing systems using a decision support system and the proper control of resources. Literature analysis shows that the study of the impact of buffer capacities, availability of resources and the number of employees on assembly manufacturing system performance have not been carried out so far.

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