Modeling, Analysis, and Improvement of Batch-Discrete Manufacturing Systems: A Systems Approach

Production systems include both discrete part and batch operations, where an individual part is manufactured in a discrete operation, and a group of parts are processed simultaneously, i.e., in a batch, on one machine for a batch operation. Many manufacturing industries, such as battery, aircraft, a...

Full description

Saved in:
Bibliographic Details
Published in:IEEE transactions on automation science and engineering 2022-07, Vol.19 (3), p.1-19
Main Authors: Liu, Lingchen, Yan, Chao-Bo, Li, Jingshan
Format: Article
Language:English
Subjects:
Aircraft
Analytical models
Assembly lines
Batch processing
Batch-discrete manufacturing
Bernoulli reliability model
bottleneck analysis
Buffers
Case studies
Defense industry
Discrete systems
Inspection
Manufacturing
Manufacturing systems
Modelling
Performance evaluation
Policies
Production
Production lines
production rate
Productivity
Quality control
quality inspection
Reliability
Reliability analysis
Systems analysis
Citations: Items that this one cites
Items that cite this one
Online Access:Get full text
Tags: Add Tag
No Tags, Be the first to tag this record!
Description
Summary:Production systems include both discrete part and batch operations, where an individual part is manufactured in a discrete operation, and a group of parts are processed simultaneously, i.e., in a batch, on one machine for a batch operation. Many manufacturing industries, such as battery, aircraft, and automotive, consist of mixed batch and discrete part operations, referred to as batch-discrete lines. Although such operations are widely encountered, analytical studies of these systems are limited in current literature. In this paper, a systems approach is presented to model and analyze batch-discrete lines. First, a Bernoulli machine reliability model for a two-machine batch-discrete system is introduced. Using a virtual buffer to represent the batch processing feature, performance evaluation formulae are derived and system properties are investigated. Using them, improvement analyses and bottleneck identification are presented. Then, the model is extended to systems with a quality inspection device under different control policies. To illustrate the applicability of the model, a case study in a composite part production process is described. Such a work delivers a quantitative tool for production engineers and managers to design, analyze, and improve batch-discrete manufacturing systems.
ISSN:1545-5955
1558-3783
DOI:10.1109/TASE.2021.3127048