Optimal dynamic routing in Flexible Manufacturing Systems with limited buffers

An optimal routing policy is obtained for Flexible Manufacturing Systems (FMSs) with limited buffers at the work stations. This policy is used to effectively drive a robotic material handling system. The routing decisions are made by a supervising computer on a real-time basis in order to avoid any work station running out of inputs and to control the blocking of the material handling system. Using our model, general material handling times can be assumed. The optimal policy and several key performance measures are computed, following the problem formulation as a continuous-time, semi-Markovian decision process. Fast convergence and computational stability are ensured by the ergodic solution algorithm augmented to solve the functional equations of the renewal process. The solution algorithm was implemented, tested on an extensive range of problems regarding the structure and the performance of the optimal policy. Complex environments involving diverse processing times, as well as very limited buffer storage, were examined. The interaction between the allocation of buffer spaces to work stations, the structural properties of the optimal monotone (threshold-type) policy and the system performance are also investigated.