Determining buffer location and size in production lines using tabu search

In this paper, we address the problem of buffer location and storage size in a manufacturing line. A simulation-search heuristic procedure based on tabu search, combined with simulation, was developed and tested. Simulation is used to model the manufacturing process and tabu search is used to guide the search to overcome the problem of being trapped at local optimal solutions. The procedure employs a Swap Search routine and a Global Search routine. With the Swap Search routine, the procedure identifies good performing buffer profiles and determines the maximum output level for any given storage level. With the Global Search routine, the procedure can locate promising neighborhood of buffer profiles quickly. The results obtained are then used to plot a line specific output curve. The procedure is capable of modeling a variety of manufacturing processes with a variety of scheduling policies and dispatching rules.