Modeling and Simulation of a Serial Production Line with Constant Work-In-Process
This paper presents a model for an unreliable
production line, which is operated according to demand with constant
work-in-process (CONWIP). A simulation model is developed based
on the discrete model and several case problems are analyzed using
the model. The model is utilized to optimize storage space capacities
at intermediate stages and the number of kanbans at the last stage,
which is used to trigger the production at the first stage. Furthermore,
effects of several line parameters on production rate are analyzed
using design of experiments.
[1] Chu, C. and Shih, W. "Simulation Studies in JIT Production",
International Journal of Production Research, 30 (11), 1992, pp. 2573-
2586.
[2] Fukukawa, T. and Hong S.C., "The Determination of Optimal Number
of Kanbans in a Just-In-Time Production System", Computers Industrial
Engineering, 24 (4), 1993, pp. 551-559.
[3] Savsar, M. and Aljawini, A., "Simulation Analysis of Just-In-Time
Production Systems", International Journal of Production Economics,
42, 1995, pp. 67-78.
[4] Savsar, M., "Effects of Kanban Withdrawal Policies and Other Factors
on the Performance of JIT Systems: A Simulation Study", Int. Journal of
Prod. Res., 34 (10), 1996, pp. 2879-2899.
[5] Savsar, M., "Simulation Analysis of a Push-Pull System for an
Electronic Assembly Line", Int. Journal of Prod. Economics, 51, 1997,
pp. 205-214.
[6] Savsar, M. and Choueiki, H. M., "A Neural Network Procedure for
Kanban Allocation in JIT Production Control Systems", Int. Journal of
Prod. Research, 38 (14), 2000, pp.3247-3265.
[7] Olhager, J. and Ostlung, B., "An Integrated Push-Pull Manufacturing
Strategy" European Journal of Operational Research, 45, 1990, pp. 135-
142.
[8] Hodgson, T.J. and Wang, D., "Optimal Hybrid Push/Pull Control
Strategies for Parallel Multistage System: Part II", International Journal
of Production Research, 29 (7), 1991, pp. 1453-1460.
[9] Wang, H. and Xu, C., "Hybrid Push/Pull Production Control Strategy
Simulation and its Applications", Production Planning and Control, 8,
1997, pp. 142-151.
[10] Beamon, B.M. and Bermund, J.M., "A hybrid push-pull Ccontrol
algorithm for multi-stage, multi-line production systems", Production
Planning & Control,11(4), 2000, pp. 349-356.
[11] Duri, C., Frein, Y., and Dimascolo, M., "Comparison among three pull
control policies: Kanban, Base Stock and Generalized Kanban", Annals
of Operations Research, 93(1), 2000, pp. 41-47.
[12] Hillier, F.S. and So, K. C., "The Effect of the Coefficient of Variation
of Operation Times on the Allocation of Storage Space in Production
Line System", IIE Transactions, (23), 1991, pp. 198-206.
[13] Hillier, F.S., So, K. C., and Boling, R. W., "Notes: Toward
Characterizing the Optimal Allocation of Storage Space in Production
Line Systems with Variable Processing Times", Management Sci. 39(1),
1993, pp. 126-133.
[14] Papadopoulos, H. T. and Heavey, C., "Queuing Theory in
Manufacturing Systems Analysis and Design: A Classification of
Models for Production and Transfer Lines", European Journal of
Operational Research, (92), 1996, pp. 1-27.
[15] Papadopoulos, H. T., and Vouros, G. A., "A Model Management
System (MMS) for the Design and Operation of Production Lines", Int.
Journal of Production Research, 35(8), 1996, 2213-2236.
[16] Powel, S. G. and Pyke, D. F., "Allocation of buffers to serial production
lines with bottlenecks" IIE Transactions, 28, 1996, pp.18-29.
[17] Vouros, G. A. and Papadopoulos, H.T., "Buffer Allocation in Unreliable
Production Lines Using a Knowledge Based System", Computers &
Operations Research, 25(12), 1996, pp. 1055-1067.
[18] Vouros, G. A., Vidalis, M. I., and Papadopoulos, H. T., "A Heuristic
Algorithm for Buffer Allocation in Unreliable Production Lines",
International Journal of Quantitative Methods, 6(1), 2000, pp. 23-43.
[19] Spinellis, D.D. and Papadopoulos, C.T., "Stochastic Algorithms for
Buffer Allocation in Reliable Production Lines", Mathematical Problems
in Engineering, 5, 2000a, pp. 441-458.
[20] Spinellis, D.D. and Papadopoulos, C.T., "A Simulated Annealing
Approach for Buffer Allocation in Reliable Production Lines", Annals
of Operations Research, 93, 2000b, pp. 373-384.
[21] Gershwin, S.B. and Schor, J.E., "Efficient algorithms for buffer space
allocation", Annals of Operations Research, 93, 2000, pp. 117-144.
[22] Savsar, M. and Youssef, A. S., "An Integrated Simulation-Neural
Network Meta Model Application in Designing Production Flow Lines",
WSEAS Transactions on Electronics, 2 (1), 2004, pp. 366-371.
[23] Savsar, M. "Effects of Maintenance Policies on the Productivity of
Flexible Manufacturing Cells", OMEGA, Vol. 34, 2006, pp. 274-282.
[1] Chu, C. and Shih, W. "Simulation Studies in JIT Production",
International Journal of Production Research, 30 (11), 1992, pp. 2573-
2586.
[2] Fukukawa, T. and Hong S.C., "The Determination of Optimal Number
of Kanbans in a Just-In-Time Production System", Computers Industrial
Engineering, 24 (4), 1993, pp. 551-559.
[3] Savsar, M. and Aljawini, A., "Simulation Analysis of Just-In-Time
Production Systems", International Journal of Production Economics,
42, 1995, pp. 67-78.
[4] Savsar, M., "Effects of Kanban Withdrawal Policies and Other Factors
on the Performance of JIT Systems: A Simulation Study", Int. Journal of
Prod. Res., 34 (10), 1996, pp. 2879-2899.
[5] Savsar, M., "Simulation Analysis of a Push-Pull System for an
Electronic Assembly Line", Int. Journal of Prod. Economics, 51, 1997,
pp. 205-214.
[6] Savsar, M. and Choueiki, H. M., "A Neural Network Procedure for
Kanban Allocation in JIT Production Control Systems", Int. Journal of
Prod. Research, 38 (14), 2000, pp.3247-3265.
[7] Olhager, J. and Ostlung, B., "An Integrated Push-Pull Manufacturing
Strategy" European Journal of Operational Research, 45, 1990, pp. 135-
142.
[8] Hodgson, T.J. and Wang, D., "Optimal Hybrid Push/Pull Control
Strategies for Parallel Multistage System: Part II", International Journal
of Production Research, 29 (7), 1991, pp. 1453-1460.
[9] Wang, H. and Xu, C., "Hybrid Push/Pull Production Control Strategy
Simulation and its Applications", Production Planning and Control, 8,
1997, pp. 142-151.
[10] Beamon, B.M. and Bermund, J.M., "A hybrid push-pull Ccontrol
algorithm for multi-stage, multi-line production systems", Production
Planning & Control,11(4), 2000, pp. 349-356.
[11] Duri, C., Frein, Y., and Dimascolo, M., "Comparison among three pull
control policies: Kanban, Base Stock and Generalized Kanban", Annals
of Operations Research, 93(1), 2000, pp. 41-47.
[12] Hillier, F.S. and So, K. C., "The Effect of the Coefficient of Variation
of Operation Times on the Allocation of Storage Space in Production
Line System", IIE Transactions, (23), 1991, pp. 198-206.
[13] Hillier, F.S., So, K. C., and Boling, R. W., "Notes: Toward
Characterizing the Optimal Allocation of Storage Space in Production
Line Systems with Variable Processing Times", Management Sci. 39(1),
1993, pp. 126-133.
[14] Papadopoulos, H. T. and Heavey, C., "Queuing Theory in
Manufacturing Systems Analysis and Design: A Classification of
Models for Production and Transfer Lines", European Journal of
Operational Research, (92), 1996, pp. 1-27.
[15] Papadopoulos, H. T., and Vouros, G. A., "A Model Management
System (MMS) for the Design and Operation of Production Lines", Int.
Journal of Production Research, 35(8), 1996, 2213-2236.
[16] Powel, S. G. and Pyke, D. F., "Allocation of buffers to serial production
lines with bottlenecks" IIE Transactions, 28, 1996, pp.18-29.
[17] Vouros, G. A. and Papadopoulos, H.T., "Buffer Allocation in Unreliable
Production Lines Using a Knowledge Based System", Computers &
Operations Research, 25(12), 1996, pp. 1055-1067.
[18] Vouros, G. A., Vidalis, M. I., and Papadopoulos, H. T., "A Heuristic
Algorithm for Buffer Allocation in Unreliable Production Lines",
International Journal of Quantitative Methods, 6(1), 2000, pp. 23-43.
[19] Spinellis, D.D. and Papadopoulos, C.T., "Stochastic Algorithms for
Buffer Allocation in Reliable Production Lines", Mathematical Problems
in Engineering, 5, 2000a, pp. 441-458.
[20] Spinellis, D.D. and Papadopoulos, C.T., "A Simulated Annealing
Approach for Buffer Allocation in Reliable Production Lines", Annals
of Operations Research, 93, 2000b, pp. 373-384.
[21] Gershwin, S.B. and Schor, J.E., "Efficient algorithms for buffer space
allocation", Annals of Operations Research, 93, 2000, pp. 117-144.
[22] Savsar, M. and Youssef, A. S., "An Integrated Simulation-Neural
Network Meta Model Application in Designing Production Flow Lines",
WSEAS Transactions on Electronics, 2 (1), 2004, pp. 366-371.
[23] Savsar, M. "Effects of Maintenance Policies on the Productivity of
Flexible Manufacturing Cells", OMEGA, Vol. 34, 2006, pp. 274-282.
@article{"International Journal of Mechanical, Industrial and Aerospace Sciences:62110", author = "Mehmet Savsar", title = "Modeling and Simulation of a Serial Production Line with Constant Work-In-Process", abstract = "This paper presents a model for an unreliable
production line, which is operated according to demand with constant
work-in-process (CONWIP). A simulation model is developed based
on the discrete model and several case problems are analyzed using
the model. The model is utilized to optimize storage space capacities
at intermediate stages and the number of kanbans at the last stage,
which is used to trigger the production at the first stage. Furthermore,
effects of several line parameters on production rate are analyzed
using design of experiments.", keywords = "Production line simulator, Push-pull system, JIT
system, Constant WIP, Machine failures.", volume = "3", number = "5", pages = "629-9", }
