A robust decomposition method for the analysis of production lines with unreliable machines and finite buffers

We consider production lines consisting of a series of machines separated by finite buffers. The processing time of each machine is deterministic and all the machines have the same processing time. All machines are subject to failures. As is usually the case for production systems we assume that the failures are operation dependent [3,7]. Moreover, we assume that the times to failure and the repair times are exponentially distributed. To analyze such systems, a decomposition method was proposed by Gershwin [13]. The computational efficiency of this method was later significantly improved by the introduction of the socalled DDX algorithm [5,6]. In general, this method provides fairly accurate results. There are, however, cases for which the accuracy of this decomposition method may not be acceptable. This is the case when the reliability parameters (average failure time and average repair time) of the different machines have different orders of magnitude. Such a situation may be encountered in real production lines. In [8], an improvement of Gershwin's original decomposition method has been proposed that in general provides more accurate results in the above mentioned situation. This other method is referred to as the Generalized Exponential (GE) method. The basic difference between the GEmethod and that of Gershwin is that it uses a twomoment approximation instead of a singlemoment approximation of the repair time distributions of the equivalent machines. There are, however, still cases for which the accuracy of the GEmethod is not as good as expected. This is the case, for example, when the buffer sizes are too small in comparison with the average repair time. We present in this paper a new decomposition method that is based on a better approximation of the repair time distributions. This method uses a threemoment approximation of the repair time distributions of the equivalent machines. Numerical results show that the new method is very robust in the sense that it seems to provide accurate results in all situations.     

Simulation optimization of buffer allocations in production lines with unreliable machines

We use a recent simulationbased optimization method, sample path optimization, to find optimal buffer allocations in tandem production lines where machines are subject to random breakdowns and repairs, and the product is fluidtype. We explore some of the functional properties of throughput of such systems and exploit these properties to prove the almost sure convergence of our optimization technique, under a regularity condition on the steady state. Utilizing a generalized semiMarkov process (GSMP) representation of the system, we derive recursive expressions to compute onesided directional derivatives of throughput, from a single simulation run. Finally, we give computational results for lines with up to 50 machines. We also compare results for smaller lines with the results from a more conventional method, stochastic approximation, whenever applicable. In these numerical studies, our method performed quite well on problems that are considered difficult by current computational standards.     

Approximate analysis of unreliable transfer lines with splits in the flow of material

This paper presents a Markov process model and an approximate decomposition technique for a discrete material transfer line with limited buffer capacity. A fraction of the parts processed at some stations in the line may be scrapped or reworked at dedicated machines to meet product quality requirements. Reworked parts are not sent back into the main line. This leads to splits in the flow of material. Processing times are deterministic and identical for all machines and are taken as the time unit. Machine specific times to failure and to repair are geometrically distributed. The model is analyzed through a decomposition into twomachine systems. We develop new decomposition equations for machines performing split operations. Production rates and inventory levels are computed and compared to simulation results. The results indicate that the method produces useful results for a variety of systems.     

Optimal lot sizing with unreliable production system

The classical lot sizing model deals with economic lot sizing for production in a deterministic framework. In real life, various forms of uncertainty affect the production. These include machine breakdown, quality variations, and so on. This paper develops a model with unreliable production systems and under alternative repair option strategies.     

Optimal design of unreliable production–inventory systems with variable production rate

In this article, we study an economic manufacturing quantity (EMQ) problem for an unreliable production facility where the production rate is treated as a decision variable. As the stress condition of the machine changes with the production rate, the failure rate of the machine is assumed to be dependent on the production rate. The unit production cost is also taken as a function of the production rate, as the machine can be operated at different production rates resulting in different unit production costs. The basic EMQ model is formulated under general failure and general repair time distributions and the optimal production policy is derived for specific failure and repair time distributions viz., exponential failure and exponential repair time distributions. Considering randomness of the time to machine failure and corrective repair time, the model is extended to the case where certain safety stocks in inventory may be useful to improve service level to customers. Optimal production policies of the proposed models are derived numerically and the sensitivity of the optimal results with respect to those parameters which directly influence the machine failure and repair rates is also examined.     

Sensitivity analysis for the generalized singular value decomposition

In this paper, we discuss the sensitivity of multiple nonzero finite generalized singular values and the corresponding generalized singular matrix set of a real matrix pair analytically dependent on several parameters. From our results, the partial derivatives of multiple nonzero singular values and their left and right singular vector matrices are obtained.Copyright © 2012 John Wiley & Sons, Ltd.     

Approximate mean value performance analysis of cyclic queueing networks with production blocking

A simple approximation method is developed for performance analysis of exponential cyclic queues with production blocking. With a modified Arrival Instant Theorem to cater for finite queue capacity, a set of equations involving the mean values of performance measures are established and an efficient algorithm is proposed. Numerical experiments show that the approximation method is very efficient in providing results with good accuracy.     

Performance analysis of assembly systems with unreliable machines and finite buffers

An unreliable assembly system is studied in which different types of components are processed by two separate work centers before merging to an assembly station with random breakdown. Blocking at the work centers and starvation at the assembly station may occur because of finite buffer sizes and uncertainties in job arriving times and processing/assembly times. We derive the system stability condition, and obtain formulas for the system state probabilities, blocking probabilities, starvation probability, stockout probability, system availability in the steady state. We also obtain the distributions of blocking times and first failure times, respectively. Through numerical examples, we elaborate on the monotonous properties of the performance measures, and draw the insights into the impacts of the system parameters on its various performance indices, which provide important guidance for design of assembly systems.     

Age-dependent production planning and maintenance strategies in unreliable manufacturing systems with lost sale

In this paper, we formulate an analytical model for the joint determination of an optimal age-dependent buffer inventory and preventive maintenance policy in a production environment that is subject to random machine breakdowns. Traditional preventive maintenance policies, such as age and periodic replacements, are usually studied based on simplified and non-realistic assumptions, as well as on the expected costs criterion. Finished goods inventories and the age-dependent likelihood of machine breakdowns are usually not considered. As a result, these policies could significantly extend beyond the anticipated financial incomes of the system, and lead to crises. In order to solve this problem, a more realistic analysis model is proposed in this paper to consider the effects of both preventive maintenance policies and machine age on optimal safety stock levels. Hence, a unified framework is developed, allowing production and preventive maintenance to be jointly considered. We use an age-dependent optimization model based on the minimization of an overall cost function, including inventory holdings, lost sales, preventive and corrective maintenance costs. We provide optimality conditions for the manufacturing systems considered, and use numerical methods to obtain an optimal preventive maintenance policy and the relevant age-dependent threshold level production policy. In this work, this policy is called the multiple threshold levels hedging point policy. We include numerical examples and sensitivity analyses to illustrate the importance and the effectiveness of the proposed methodology. Compared with other available optimal production and maintenance policies, the numerical solution obtained shows that the proposed age-dependent optimal production and maintenance policies significantly reduce the overall cost incurred.     

Joint effect of stock threshold level and production policy on an unreliable production environment

In this article we develop an economic manufacturing quantity (EMQ) model subject to stochastic machine breakdown, repair and stock threshold level (STL). Instead of constant production rate, in this model production rate is considered as a decision variable. Since, the stress of the machine depends on the production rate, failure rate of the machine will be a function of the production rate. Again, in this article consideration of safety stock in all existing literature is replaced by the concept of stock threshold level (STL). Further, extra capacity of the machine is considered to buffer against the possible uncertainties of the production process where machine capacity is predetermined. The basic model is developed under general failure and general repair time distributions. Since, the assumption of variable production rate makes the objective function quite complex, so main emphasis is given on computational methodology to solve the present problem. We suggest two computational algorithms for the determination of production rate and stock threshold level which minimize the expected cost rate in the steady state. Finally, through numerical examples we illustrate the key insights of our model from managerial point of view.     

服务台不可靠的重试排队系统均衡分析

本文研究服务台不可靠的M/M/1常数率重试排队系统中顾客的均衡进队策略, 其中服务台在正常工作和空闲状态下以不同的速率发生故障。在该系统中, 服务台前没有等待空间, 如果到达的顾客发现服务台处于空闲状态, 该顾客可占用服务台开始服务。否则, 如果服务台处于忙碌状态, 顾客可以选择留下信息, 使得服务台在空闲时可以按顺序在重试空间中寻找之前留下信息的顾客进行服务。当服务台发生故障时, 正在被服务的顾客会发生丢失, 且系统拒绝新的顾客进入系统。根据系统提供给顾客的不同程度的信息, 研究队长可见和不可见两种信息情形下系统的稳态指标, 以及顾客基于收入-支出函数的均衡进队策略, 并建立单位时间内服务商的收益和社会福利函数。比较发现, 披露队长信息不一定能提高服务商收益和社会福利。     

Coupling method for asymptotic analysis of queues with regenerative input and unreliable server

First we define a regenerative flow and describe its properties. Then a single-server queueing system with regenerative input flow and an unreliable server are considered. By applying coupling we establish the ergodicity condition and prove the limit theorem in the heavy traffic situation (traffic coefficient $\rho <1, \rho \uparrow 1$ ). The asymptotic analysis of the super-heavy traffic situation ( $\rho \ge 1$ ) is also realized.     

Optimal transportation policies for production/inventory systems with an unreliable and a reliable carrier

In this paper, we consider a periodic-review make-to-order production/inventory system with two outbound transportation carriers: One carrier is reliable, the other carrier is less reliable but more economical. The objective is to find the optimal shipping policy that minimizes the total discounted transportation, inventory, and customer waiting costs. Under several scenarios, we characterize the optimal policy and present the structural properties for the optimal control parameters and the key performance measures. Our results provide managerial insights on how a manufacturer can effectively manage its transportation carriers and product shipment. We also discuss several possible extensions of the model.     

Exact analysis of a two-workstation one-buffer flow line with parallel unreliable machines

This paper examines a model of a serial flow line with two workstations and an intermediate buffer. Each workstation consists of multiple unreliable parallel machines which are not necessarily identical, viz., the processing times, failure times and repair times of the parallel machines at each workstation are assumed to be exponentially distributed with non-identical mean rates. The system under consideration is solved via exact Markovian analysis. More specifically, a recursive algorithm that generates the transition matrix for any value of the intermediate buffer capacity is developed and all possible transition equations are derived and solved analytically. Once the transition equations are solved the performance measures of the model under consideration can be easily evaluated. This model may be used as a decomposition block for solving larger flow lines with parallel unreliable machines at each workstation.     

Exact formulation of stochastic EMQ model for an unreliable production system

The purpose of this paper is to present an exact formulation of stochastic EMQ model for an unreliable production system under a general framework in which the time to machine failure, corrective (emergency) and preventive (regular) repair times are assumed to be random variables. For exact financial implications of the lot-sizing decisions, the EMQ model is formulated based on the net present value (NPV) approach. Then, by taking limitation on the discount rate, the traditional long-run average cost model is obtained. The criteria for the existence and uniqueness of the optimal production time in both the models are derived under general failure and specific repair time distributions. Numerical examples are devoted to find the optimal production policies of the developed models and examine the sensitivity of the parameters involved. Computational results show that the optimal decision based on the NPV approach is superior to that based on the long-run average cost approach, though the performance level strongly depends on the pertinent failure and repair time distributions.     

A production planning model for an unreliable production facility: Case of finite horizon and single demand

We study a two-level inventory system that is subject to failures and repairs. The objective is to minimize the expected total cost so as to determine the production plan for a single quantity demand. The expected total cost consists of the inventory carrying costs for finished and unfinished items, the backlog cost for not meeting the demand due-date, and the planning costs associated with the ordering schedule of unfinished items. The production plan consists of the optimal number of lot sizes, the optimal size for each lot, the optimal ordering schedule for unfinished items, and the optimal due-date to be assigned to the demand. To gain insight, we solve special cases and use their results to device an efficient solution approach for the main model. The models are solved to optimality and the solution is either obtained in closed form or through very efficient algorithms.     

Stochastic decomposition in production inventory with service time

We study an (s, S) production inventory system where the processing of inventory requires a positive random amount of time. As a consequence a queue of demands is formed. Demand process is assumed to be Poisson, duration of each service and time required to add an item to the inventory when the production is on, are independent, non-identically distributed exponential random variables. We assume that no customer joins the queue when the inventory level is zero. This assumption leads to an explicit product form solution for the steady state probability vector, using a simple approach. This is despite the fact that there is a strong correlation between the lead-time (the time required to add an item into the inventory) and the number of customers waiting in the system. The technique is: combine the steady state vector of the classical M/M/1 queue and the steady state vector of a production inventory system where the service is instantaneous and no backlogs are allowed. Using a similar technique, the expected length of a production cycle is also obtained explicitly. The optimal values of S and the production switching on level s have been studied for a cost function involving the steady state system performance measures. Since we have obtained explicit expressions for the performance measures, analytic expressions have been derived for calculating the optimal values of S and s.     

Approximate analysis of exponential tandem queues with blocking

In this paper, an approximate method for the analysis of open networks of queues in tandem and with blocking is proposed. The network consists of M single server queuing stations with exogenous Poisson arrival processes and exponentially distributed service times. The analysis is based on the method of decomposition where the total network is broken down into queues which are analyzed as M/C₂/1/N queues assuming Poisson arrival and departure processes to find the steady-state probabilities of the number of customers at each station. The procudure reduces the problem to a number of elementary operations which can be performed efficiently with the aid of a computer. We also compare different definitions of blocking. Numerical results are given to demonstrate the accuracy of the new method.