System reliability of a manufacturing network with reworking action and different failure rates

From the perspective of network analysis, the manufacturing system can be constructed as a stochastic-flow network, since the capacity of each machine is stochastic (i.e. multistate) owing to the failure, partial failure, and maintenance. Considering reworking action and different failure rates of machines, the input flow (raw materials/work in process) processed by each machine might be defective, and therefore the output flow (work in process/products) would be less than the input amount. To evaluate the capability of the manufacturing system, we measure the probability that the manufacturing network can satisfy demand. Such a probability is defined as the system reliability. A decomposition method is first proposed to divide the manufacturing network into one general processing path and one reworking path. Subsequently, two algorithms are utilised for different network models to generate the lower boundary vector of machine capacity to guarantee that the manufacturing network is able to produce sufficient products fulfilling the demand. The system reliability of the manufacturing network can be derived in terms of such a capacity vector afterwards.

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