The Costs of Downtime Incidents in Serial Multistage Manufacturing Systems

2012 ◽  
Vol 134 (2) ◽  
Author(s):  
Jianbo Liu ◽  
Qing Chang ◽  
Guoxian Xiao ◽  
Stephan Biller
Keyword(s):  
Transient Analysis ◽  
Manufacturing Systems ◽  
Analytical Study ◽  
Manufacturing System ◽  
Accurate Estimation ◽  
Production Operation ◽  
Multistage Manufacturing ◽  
Plant Floor ◽  
The Impact ◽  
Permanent Production

Downtime is arguably the single most significant contributor to system inefficiency in a multistage manufacturing system. Achieving near-zero downtime has been the ultimate goal of production operation management at the plant floor. Accurate estimation of the impact of each downtime incident is of great importance for deciding where to allocate limited resources among various manufacturing stages. In this paper, we focus on quantitative analysis of the impact of each individual downtime event in terms of permanent production loss and financial cost. We start from the transient analysis of a single downtime event and later extend to more generic scenarios where downtime incidents occur concurrently at different stages. Apart from the analytical study, a practical computation procedure using real-time production records can be readily derived and implemented at the plant floor. Case studies are conducted to demonstrate its potential in facilitating the decision making at plant floor on project identification, prioritization, and budget allocation in a multistage manufacturing system.

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.

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 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.

Transient Analysis of Downtime Event in Manufacturing Systems

2010 ◽  
Author(s):  
Qing Chang ◽  
Jianbo Liu ◽  
Stephan Biller ◽  
Guoxian Xiao
Keyword(s):  
Cost Estimation ◽  
Transient Analysis ◽  
Manufacturing Systems ◽  
Manufacturing Industry ◽  
Complete Characterization ◽  
Production Performance ◽  
Impact Factors ◽  
Serial Transfer ◽  
Personnel Staffing ◽  
The Impact

In manufacturing industry, downtimes have been considered as major impact factors of production performance. To improve the system performance in real-time and properly allocate limited resources/efforts to different stations, it is necessary to quantify the impact of each station downtime event on the production throughput of the whole transfer line. Complete characterization of the impact requires a careful investigation of the transients of the line dynamics disturbed by the downtime event. We study in this paper, the impact of single isolated downtime event on the performance of inhomogeneous serial transfer lines. Our mathematical analysis suggests that the impact of any isolated downtime event is only apparent in the relatively long run when the duration exceeds a certain threshold called opportunity window. The size of the opportunity window not only depends on the initial buffer levels but also depends on the location and the processing speed of the slowest station. Analytical solutions of the opportunity window and the loose upper bounds for the recovery time are also provided in the paper as two separate theorems. Despite the fact that the paper focuses on the transient analysis of single isolated downtime event, the results are applicable to opportunistic maintenance scheduling, personnel staffing and downtime cost estimation.

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.

Particle Swarm Optimization Using Various Inertia Factor Variants

2011 ◽  
Vol 460-461 ◽  
pp. 54-59
Author(s):  
Jun Tang
Keyword(s):  
Optimal Control ◽  
Particle Swarm Optimization ◽  
Manufacturing Systems ◽  
Manufacturing System ◽  
Particle Swarm ◽  
Optimal Solution ◽  
Pso Algorithm ◽  
Time Varying ◽  
Swarm Optimization ◽  
The Impact

This paper presents an alternative and efficient method for solving the optimal control of manufacturing systems. Three different inertia factor, a constant inertia factor (CIF), time-varying inertia factor (TVIF), and global-local best inertia factor (GLbestIF), are considered with the particle swarm optimization(PSO) algorithm to analyze the impact of inertia factor on the performance of PSO algorithm. The PSO algorithm is simulated individually with the three inertia factor separately to compute the optimal control of the manufacturing system, and it is observed that the PSO with the proposed inertia factor yields better resultin terms of both optimal solution and faster convergence. Several statistical analyses are carried out from which can be concluded that the proposed method is superior to all the other methods considered in this paper.

Group Scheduling Technique for Multiproduct, Multistage Manufacturing Systems

1977 ◽  
Vol 99 (3) ◽  
pp. 759-765 ◽  
Author(s):  
K. Hitomi ◽  
I. Ham
Keyword(s):  
Manufacturing Systems ◽  
Manufacturing System ◽  
Group Technology ◽  
Flow Time ◽  
Group Scheduling ◽  
Total Production ◽  
Total Flow ◽  
Multistage Manufacturing ◽  
Operations Scheduling ◽  
Scheduling Technique

“Group Scheduling,” which is operations scheduling based on the Group Technology concept, was analyzed in a multistage manufacturing system. In the case of fabricating multiple parts (jobs) grouped into several group cells, both optimal group and optimal job sequences were determined such that the total flow time (makespan) was minimized, by means of the branch-and-bound method. In addition, optimal machining speeds to be utilized on multiple stages (machines) for each job were determined to reduce the total production cost as much as possible. Optimizing algorithms for this Group Scheduling Technique were also presented with numerical examples.

scholarly journals Quality Evaluation in Flexible Manufacturing Systems: A Markovian Approach

2007 ◽  
Vol 2007 ◽  
pp. 1-24 ◽  
Author(s):  
Jingshan Li ◽  
Ningjian Huang
Keyword(s):  
Product Quality ◽  
Flexible Manufacturing ◽  
Flexible Manufacturing Systems ◽  
Manufacturing Systems ◽  
Manufacturing System ◽  
Flexible Manufacturing System ◽  
Research Effort ◽  
Productivity Cost ◽  
Markovian Approach ◽  
The Impact

The flexible manufacturing system (FMS) has attracted substantial amount of research effort during the last twenty years. Most of the studies address the issues of flexibility, productivity, cost, and so forth. The impact of flexible lines on product quality is less studied. This paper intends to address this issue by applying a Markov model to evaluate quality performance of a flexible manufacturing system. Closed expressions to calculate good part probability are derived and discussions to maintain high product quality are carried out. An example of flexible fixture in machining system is provided to illustrate the applicability of the method. The results of this study suggest a possible approach to investigate the impact of flexibility on product quality and, finally, with extensions and enrichment of the model, may lead to provide production engineers and managers a better understanding of the quality implications and to summarize some general guidelines of operation management in flexible manufacturing systems.

scholarly journals Scalability analysis of selected structures of a reconfigurable manufacturing system taking into account a reduction in machine tools reliability

2021 ◽  
Vol 23 (2) ◽  
pp. 242-252
Author(s):  
Arkadiusz Gola ◽  
Zbigniew Pastuszak ◽  
Marcin Relich ◽  
Łukasz Sobaszek ◽  
Eryk Szwarc
Keyword(s):  
Manufacturing Process ◽  
Machine Tools ◽  
Manufacturing Systems ◽  
Manufacturing System ◽  
Production Capacity ◽  
Cost Effective ◽  
Simulation Software ◽  
Reconfigurable Manufacturing ◽  
Product Demand ◽  
The Impact

Scalability is a key feature of reconfigurable manufacturing systems (RMS). It enables fast and cost-effective adaptation of their structure to sudden changes in product demand. In principle, it allows to adjust a system's production capacity to match the existing orders. However, scalability can also act as a "safety buffer" to ensure a required minimum level of productivity, even when there is a decline in the reliability of the machines that are part of the machine tool subsystem of a manufacturing system. In this article, we analysed selected functional structures of an RMS under design to see whether they could be expanded should the reliability of machine tools decrease making it impossible to achieve a defined level of productivity. We also investigated the impact of the expansion of the system on its reliability. To identify bottlenecks in the manufacturing process, we ran computer simulations in which the course of the manufacturing process was modelled and simulated for 2-, 3-, 4- and 5-stage RMS structures using Tecnomatix Plant Simulation software.

scholarly journals New models and algorithms to solve integrated problems of production planning and control taking into account worker skills in flexible manufacturing systems

2021 ◽  
Vol 12 (4) ◽  
pp. 381-400 ◽  
Author(s):  
Norbert Tóth ◽  
Gyula Kulcsár
Keyword(s):  
Production Planning ◽  
Optimization Model ◽  
Flexible Manufacturing ◽  
Manufacturing Systems ◽  
Manufacturing System ◽  
Production Systems ◽  
Planning And Control ◽  
Processing Times ◽  
Availability Constraints ◽  
The Impact

The paradigm of the cyber-physical manufacturing system is playing an increasingly important role in the development of production systems and management of manufacturing processes. This paper presents an optimization model for solving an integrated problem of production planning and manufacturing control. The goal is to create detailed production plans for a complex manufacturing system and to control the skilled manual workers. The detailed optimization model of the problem and the developed approach and algorithms are described in detail. To consider the impact of human workers performing the manufacturing primary operations, we elaborated an extended simulation-based procedure and new multi-criteria control algorithms that can manage varying availability constraints of parallel workstations, worker-dependent processing times, different product types and process plans. The effectiveness of the proposed algorithms is demonstrated by numerical results based on a case study.

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