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2 2024

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Workload control in flow shops with bottleneck shifting and process time variability

Prabhu Aruna, Raghunandana K, Yogesh Pai P

Production Engineering Archives

2024

Vol. 30, Iss. 1

48--56

Manufacturing industries struggle to devise precise planning and scheduling solutions due to unpredictable business situations. Additionally, uncertainties in production such as machine breakdowns, labour absenteeism, cycle time deviations, etc., would further deteriorate production plans and lead to uncertainty in decision-making processes. Flow shops with bottlenecks are particularly susceptible to these disturbances. Moreover, the random variations in cycle time variations can cause the bottleneck to shift between different stages. Literature indicates that conventional job release methods are ineffective in addressing these difficulties. In contrast, workload control methods would provide better solutions. Hence, a flow shop model has been developed and simulated using the variables like process time variations and bottleneck shifting on the discrete-event simulation software. The flow shop model incorporates realistic shop characteristics which are subjected to random process time variations, so as to assess the performance. The outcomes of the experimentation demonstrate that order release methods play a pivotal role in improving the performance of flow shops in more volatile situations.

Investigation of workload control methods for shops with re-entrant flows

Prabhu Aruna, Raghunandana K, Yogesh Pai P, Barboza Augustine B.V.

Management Systems in Production Engineering

2024

nr 1 (32)

145--155

The re-entrant flow with an unpredictable nature of arrival would apparently harm production plans and sched-ules in flow type of shops. The re-entrant flow with varied arrival frequencies in rotor blade manufacturing is quite complicated and results in disproportionate workloads. Hence, an attempt has been made to study the significant influence of disproportionate workloads and research on an innovative order release method to enhance perfor-mance. The manufacturing process was observed thoroughly to incorporate the uncertain events that cause dis-turbance in the production. A simulation model was developed on a discrete event simulation platform by ana-lysing problem phenomena right from the conceptualization phase. The model has been verified and validated to ensure the accuracy. The model was subjected to 288 experiments representing different scenarios that a flow shop undergoes in reality. The factors considered in the experimentation were re-entrant frequency, re-entrant proportions, order release methods and priority dispatching rules. A refined load release policy for disproportion-ate loads has been proposed to judge its effectiveness in terms of profit computation by comparing it with other relevant policies. Results of the experiment revealed that the order release methods contribute 95.93% to throughput performance, in addition, the use of the new re-entrant method policy in the above scenario was productive in improving the overall shop performance.