Modeling and Analysis of Manufacturing Systems

by Askin, Ronald G.; Standridge, Charles R.

• ISBN13: 9780471514183
• ISBN10: 0471514187
• Edition: 1st
• Format: Paperback
• Copyright: 1993-01-19
• Publisher: Wiley

Summary

Unique in its focus on design and analysis methodologies for all areas of material flow management and system resource usage. Features research techniques that demonstrate the difference between opinions and findings, leading-edge approach to facility layout and a comprehensive queueing network. Progressive examples illustrate that there is more than one model for a system and case studies show integration of multiple techniques for realistic model building and problem solving.

Author Biography

Ronald G. Askin is the author of Modeling and Analysis of Manufacturing Systems, published by Wiley. Charles R. Standridge is the author of Modeling and Analysis of Manufacturing Systems, published by Wiley.

Table of Contents

PART I MANUFACTURING SYSTEMS AND MODELS
Manufacturing Models	3	(28)
Introduction	3	(5)
Types of Manufacturing Systems	8	(4)
Principles of Manufacturing Systems	12	(5)
Types and Uses of Manufacturing Models	17	(9)
Physical Models	18	(1)
Mathematical Models	18	(3)
Model Uses	21	(2)
Model Building	23	(3)
Summary	26	(5)
References	27	(1)
Problems	27	(4)
PART II MATERIAL FLOW SYSTEMS
Assembly Lines: Reliable Serial Systems	31	(36)
Introduction	31	(5)
Problem Formulation	36	(2)
Approaches to Line Balancing	38	(16)
COMSOAL Random Sequence Generation	38	(5)
Ranked Positional Weight Heuristic	43	(1)
Optimal Solutions	44	(10)
Some Practical Issues	54	(2)
Sequencing Mixed Models	56	(4)
Unpaced Lines	60	(1)
Summary	61	(6)
References	61	(1)
Problems	62	(5)
Transfer Lines and General Serial Systems	67	(28)
Introduction	67	(2)
Paced Lines Without Buffers	69	(4)
Operation-Dependent Failures	69	(3)
Time-Dependent Failures	72	(1)
Two-Stage Paced Lines with Buffers	73	(8)
Operation-Dependent Failures	74	(4)
Deterministic Failures and Repairs	78	(1)
System Reduction	79	(2)
Approximate Three-Stage Model	81	(3)
Unpaced Lines	84	(6)
Identical Workstations, Random Processing Times, No Buffers, No Breakdowns	85	(1)
Identical Workstations, Random Service, Equal Buffers, No Breakdowns	86	(2)
Constant Processing Times, Random Breakdown and Repair Times	88	(1)
Buffers and Production Control	89	(1)
Summary	90	(5)
References	90	(1)
Problems	91	(4)
Shop Scheduling with Many Products	95	(30)
Introduction	95	(3)
Order Release	98	(5)
Bottleneck Scheduling	101	(2)
Flow Shop Sequencing	103	(10)
Single-Machine Scheduling	106	(5)
Two-Machine Flow Shops	111	(2)
Job Shop Scheduling	113	(8)
Dispatching Rules	115	(2)
Schedule Generation	117	(4)
Summary	121	(4)
References	121	(1)
Problems	122	(3)
Flexible Manufacturing Systems	125	(38)
Introduction	125	(4)
System Components	129	(3)
Machines	129	(1)
Part Movement System	130	(1)
Supporting Workstations	131	(1)
System Controller	131	(1)
Planning and Control Hierarchy	132	(21)
System Design	134	(5)
System Setup	139	(13)
Scheduling and Control	152	(1)
Flexible Assembly Systems	153	(2)
Summary	155	(8)
References	155	(2)
Problems	157	(6)
Group Technology	163	(41)
Introduction	163	(6)
Principles of Groups	169	(2)
Coding Schemes	171	(5)
Assigning Machines to Groups	176	(16)
Production Flow Analysis	177	(2)
Binary Ordering Algorithm	179	(3)
Single-Pass Heuristic	182	(3)
Similarity Coefficients	185	(2)
Graph Partitioning	187	(5)
Assigning Parts to Machines	192	(3)
An Economic, Mathematical Program for Group Formation	195	(3)
Summary	198	(6)
References	198	(1)
Problems	199	(5)
Facility Layout	204	(57)
Introduction	204	(6)
Systematic Layout Planning	210	(14)
Quadratic Assignment Problem Approach	224	(8)
VNZ Heuristic	226	(1)
Branch and Bound	227	(5)
Graph Theoretic Approach	232	(8)
General Graph Theoretic Approach	235	(1)
Finding a Maximally Planar Weighted Graph	235	(5)
Decomposition of Large Facilities	240	(1)
Net Aisle and Department Layout	240	(4)
Locating New Facilities	244	(8)
Single Facility Location	244	(6)
Multifacility Location	250	(2)
Further Reading	252	(1)
Summary	252	(9)
References	253	(1)
Problems	254	(7)
PART III SUPPORTING COMPONENTS
Machine Setup and Operation Sequencing	261	(29)
Introduction	261	(1)
Task Assignment	262	(4)
Task Sequencing	266	(10)
Complete Changeovers--Traveling Salesman Problem	266	(5)
Partial Changeovers	271	(5)
Integrated Assignment and Sequencing	276	(9)
Assembly Cell Layout and Sequencing	276	(6)
Cell Layout and Sequencing with Interdependent Tools	282	(3)
Summary	285	(5)
References	286	(1)
Problems	286	(4)
Material Handling Systems	290	(37)
Introduction	290	(7)
Basic Equipment Types	292	(4)
Principles of Material Handling	296	(1)
Equipment Selection	297	(5)
Receiving Bulk Loads	302	(1)
Conveyor Analysis	303	(4)
Closed Loop Conveyers	303	(4)
AGV Systems	307	(13)
AGV System Design	308	(3)
Estimating Vehicle Requirements	311	(6)
AGVS Operation	317	(3)
Pallet Sizing and Loading	320	(1)
Summary	321	(6)
References	322	(1)
Problems	323	(4)
Warehousing: Storage and Retrieval Systems	327	(36)
Introduction	327	(5)
Warehouse Components	327	(5)
Warehouse Design	332	(4)
Stacking Patterns	336	(1)
Location in Warehouses	337	(9)
Dedicated Storage	337	(5)
Random (Open) Storage	342	(3)
Class-Based Storage	345	(1)
Storing Complementary Items	346	(1)
Order Picking	346	(9)
Forming Pick Lists	347	(7)
Pick Sequencing	354	(1)
Summary	355	(8)
References	355	(1)
Problems	356	(7)
PART IV GENERIC MODELING APPROACHES
General Manufacturing Systems: Analytical Queueing Models	363	(46)
Introduction	363	(1)
A Single Workstation	364	(7)
Poisson Arrivals, Exponential, FCFS Service	364	(2)
Poisson Arrivals, General, FCFS Service	366	(3)
General, Part-Based, Priority Service	369	(1)
Finite Population Models	370	(1)
Open Networks	371	(14)
Poisson Arrivals and Exponential FCFS Service	373	(7)
Relaxing Assumptions	380	(5)
Closed Networks	385	(15)
Mean Value Analysis	385	(8)
Product Form Solution	393	(7)
Limited WIP: A Hybrid System	400	(2)
Summary	402	(7)
References	403	(1)
Problems	404	(5)
General Manufacturing Systems: Empirical Simulation Models	409	(24)
Introduction	409	(2)
Event Models	411	(1)
Evaluation of Event Models	412	(1)
Process Models	412	(2)
Evaluation of Process Models	413	(1)
Manufacturing Specific Modeling	414	(1)
Simulation Systems	415	(1)
Simulation Results for Manufacturing Systems	415	(6)
Example Manufacturing System Models	421	(7)
Serial Lines	421	(4)
Flexible Manufacturing	425	(3)
Summary	428	(5)
References	428	(2)
Problems	430	(3)
Case Studies	433	(20)
Problem Definition: WXYZ Company Processing Line	433	(1)
WXYZ Design Approach	434	(7)
Computing Cycle Time	435	(1)
Assigning Operations to Workstations	435	(1)
Part Sequencing	436	(1)
Number of Repair Workers	437	(1)
Buffer Allocation	437	(1)
Process Line Layout	438	(1)
Assessing System Performance	438	(3)
Problem Definition: Planar Company Cell Design	441	(1)
Planar Company Design Approach	441	(6)
References	446	(1)
Appendix A. REVIEW OF BASIC PROBABILITY
A.1 Random Variables and Probability Distributions	447	(3)
A.2 Stochastic Processes	450	(3)
Index	453