Capacity choice, work-in-progress inventory and throughput: a simulation study

ABSTRACT

We investigate in this paper alternative configuration choices of serial assembly lines. In particular, we analyze the impact on throughput and work-in-process inventory levels from several design choices. These are the number of work-stations, tasks allocated to various stations and buffers between workstations. A simulation model is used to evaluate the sensitivity of various designs to variability in the operating environment arising due to process time variations (operator variability) as well as variations due to breakdowns and repair (machine variability). Insights of the tradeoffs for making capital investment and setting operating policies are also discussed.

REFERENCES

• 1: Buzacott, J. A. (1967). Automatic Transfer Lines with Buffer Stocks. international Journal of Production Research 5, 184.
• 2: Chow, We-rain (~987). Buffer Capacity Analysis for Sequential Production Lines with Variable Process Times. International Journal of Production Research 25, 1183-1196.
• 3: Richard Conway , William Maxwell , John O. McClain , L. Joseph Thomas, The role of work-in-process inventory in serial production lines, Operations Research, v.36 n.2, p.229-241, March-April 1988 [doi>10.1287/opre.36.2.229]
• 4: Hackman, J. R. and Oldham, G. R. (1980). Work Redesign. Addision Wesley, Reading, MA.
• 5: Lyama, T. and Ito, S. (1987). The Maximum Production Rate for an Unbalanced Multi-Server Flow Line System with Finite Buffer Storage. International Journal of Production Research 25, 1157-1170.
• 6: JoneJa, D., Maxwell, W. L. (1986). Buffer Placement in Sequential Production Lines: Issues of Processing Time Variability, Tech. Report 700, SURIE, Cornell University.
• 7: Karmarkar, U. S. and Kekre, S. (1987). Manufacturing Configuration, Capacity and Mix Considering Operational Costs. Journal of Manufacturing Systems 6, 315~324.
• 8: Hillier, F. S. and Boiling, R. N. (1966). The Effect of Some Design Factors on the Efficiency of Production Lines with Variable Operations. Journal of Industrial Engineering 17, 651-658.
• 9: Rao, N. P. (1975). Two Stage Production Systems with Internal Storage. AITE Transactions 7, 4~4-221.
• 10: Rao, N. ~. (1985}. A Viable Alternative to the Method of Stages Solution of Series Production Systems with Erlang Services Times. International Journal of Production Research 14, 699-702.

INDEX TERMS

Primary Classification:
  J. Computer Applications
  J.1 ADMINISTRATIVE DATA PROCESSING
      Subjects: Manufacturing

Additional Classification:
  I. Computing Methodologies
  I.6 SIMULATION AND MODELING

General Terms:
Design, Experimentation, Management, Measurement, Performance, Theory