Optimal Planning of Plant Flexibility: Problem Formulation and Performance Analysis

Manufacturing systems are becoming more and more flexible to confront uncertainty in demands of multiple product types. In this paper, we study the properties of flexible manufacturing systems from the perspective of demand shortfall and service level as functions of setup time, nonhomogeneous capacities, and demand distributions. Closed-form bounds as well as an accurate estimate of the service level are obtained. Sensitivity analyses of service level with respect to reductions in setup time, downtime, and cycle time are carried out, and the impact of new product launch and product correlation on system flexibility is investigated.

[1]  Ramandeep S. Randhawa,et al.  Optimal Flexibility Configurations in Newsvendor Networks: Going Beyond Chaining and Pairing , 2010, Manag. Sci..

[2]  C. Robert.  Simulation of truncated normal variables , 2009, 0907.4010.

[3]  Cong Zhao,et al.  Analysis and improvement of multi-product assembly systems: an application study at a furniture manufacturing plant , 2014 .

[4]  Cong Zhao,et al.  Efficient Algorithms for Analysis and Improvement of Flexible Manufacturing Systems , 2016, IEEE Transactions on Automation Science and Engineering.

[5]  P. Adler,et al.  Flexibility Versus Efficiency? a Case Study of Model Changeovers in the Toyota Production System , 1999 .

[6]  Jingshan Li,et al.  Analysis of multi-product manufacturing systems with arbitrary processing times , 2015 .

[7]  Tullio Tolio,et al.  A Review on Manufacturing Flexibility , 2009 .

[8]  Suresh P. Sethi,et al.  Flexibility in manufacturing: A survey , 1990 .

[9]  Manoj K. Malhotra,et al.  A theoretical framework for analyzing the dimensions of manufacturing flexibility , 1999 .

[10]  Ronald G. Askin,et al.  Scheduling flexible flow lines with sequence-dependent setup times , 2004, Eur. J. Oper. Res..

[11]  Dennis E. Blumenfeld,et al.  Designing production systems for quality: Research opportunities from an automotive industry perspective , 2003 .

[12]  Nguyen Van Hop,et al.  Approach to measure the mix response flexibility of manufacturing systems , 2004 .

[13]  Wallace J. Hopp,et al.  Benefits of Skill Chaining in Serial Production Lines with Cross-Trained Workers , 2004, Manag. Sci..

[14]  David Simchi-Levi,et al.  Understanding the Performance of the Long Chain and Sparse Designs in Process Flexibility , 2012, Oper. Res..

[15]  Stephan Biller,et al.  Managing Flexible Capacity in a Make-to-Order Environment , 2005, Manag. Sci..

[16]  Li Zheng,et al.  The robustness of scheduling policies in multi-product manufacturing systems with sequence-dependent setup times and finite buffers , 2012, Comput. Ind. Eng..

[17]  Zuo-Jun Max Shen,et al.  Process flexibility design in unbalanced networks , 2013, IEEE Engineering Management Review.

[18]  Jingshan Li,et al.  Analysis of Multiproduct Manufacturing Systems With Homogeneous Exponential Machines , 2014, IEEE Trans Autom. Sci. Eng..

[19]  Ebru K. Bish,et al.  Optimal Investment Strategies for Flexible Resources, Considering Pricing and Correlated Demands , 2004, Oper. Res..

[20]  Yash P. Gupta,et al.  Flexibility of manufacturing systems: Concepts and measurements , 1989 .

[21]  John A. Sharp,et al.  A review of manufacturing flexibility , 2000, Eur. J. Oper. Res..

[22]  Jingshan Li,et al.  Scheduling policies in multi-product manufacturing systems with sequence-dependent setup times and finite buffers , 2012 .

[23]  Georg N. Krieg,et al.  Analysis of Multi-Product Kanban Systems with State-Dependent Setups and Lost Sales , 2004, Ann. Oper. Res..

[24]  Chung-Piaw Teo,et al.  Design for Process Flexibility: Efficiency of the Long Chain and Sparse Structure , 2010, Oper. Res..

[25]  J. V. Mieghem.  Investment Strategies for Flexible Resources , 1998 .

[26]  Cong Zhao,et al.  Analysis and Improvement of Multiproduct Bernoulli Serial Lines: Theory and Application , 2015, IEEE Transactions on Systems, Man, and Cybernetics: Systems.

[27]  Chung-Piaw Teo,et al.  Process Flexibility Revisited: The Graph Expander and Its Applications , 2011, Oper. Res..

[28]  Stephan Biller,et al.  Quality bottleneck transitions in flexible manufacturing systems with batch productions , 2013 .

[29]  Wallace J. Hopp,et al.  Vertical Flexibility in Supply Chains , 2010, Manag. Sci..

[30]  J. A. Buzacott,et al.  Flexible manufacturing systems: a review of analytical models , 1986 .

[31]  S. Minner.  Multiple-supplier inventory models in supply chain management: A review , 2003 .

[32]  D. Gerwin.  Manufacturing flexibility: a strategic perspective , 1993 .

[33]  Jingshan Li,et al.  Throughput analysis of production systems: recent advances and future topics , 2009 .

[34]  William C. Jordan,et al.  Principles on the benefits of manufacturing process flexibility , 1995 .

[35]  Stephen C. Graves,et al.  Process Flexibility in Supply Chains , 2003, Manag. Sci..

[36]  Stephan Biller,et al.  Indicators for quality improvability and bottleneck sequence in flexible manufacturing systems with batch production , 2012 .

[37]  Nicola Bateman.  Measuring the mix response flexibility of manufacturing systems , 1999 .