MANE3300U Integrated Manufacturing Systems

Instructor: Dr. Sayyed Ali Hosseini

Lecture #12

Quantitative Analysis of Flexible Manufacturing Systems

Todays lecture:
Quantitative Analysis of FMS
Bottleneck model: basic terminology, parameters, performance measures

1.0 Bottleneck Model

FMS analysis techniques:
Deterministic models initial cut at design of FMS
Queuing models provides more detail, dynamic view, analytical approach
Discrete event simulation provides most detail, dynamic view, simulation approach
Heuristics and other approaches

Bottleneck model developed by Solberg is a deterministic approach.

2.0 Basic Terminology

Part mix
P = total # of different parts
pj = fraction of the total system output that is of style j, j = 1, 2, 3P
P

p j = 1 .0
j =1

Workstations and Servers

n distinct workstations
Each station has si number of servers (machines), i = 1, 2, 3 n
Load and unloading station is also consider to be a workstation.

Process routing/plan
Each part or product has a process plan or sequence of operations.
tijk = processing time, not counting any waiting time at the station
i = station, j = part, k = sequence of operation (eg. 4th step) in the routing

Work handling system

Designated as special station called station number n+1.
# of carriers in system (eg. carts) is analogous to # of servers.

sn+1 = # of carriers in work handling system

Transport time
Usually just use an average for all moves.
tn+1 = mean transport time to move a part from one station to next in the process routing.

Operation frequency
Expected # of times a given operation is performed for each work unit.
Inspection might perform once every 4 units frequency = 0.25
Calibration procedure that has to be perform twice frequency > 2.0

fijk = operation frequency for operation k in process plan j at station i.

3.0 FMS Parameters

Workload at each station

WLi = Workload for station i (min) = total time spend at that station per part
WLi =
j

tijk f ijk p j
k

Workload of handling system

Workload for handling system (station n+1) = (mean transport time)*(average # of transports
required to process a work part)

nt = Average # of transports required to process a work part

nt = (
i

fijk p j ) 1
j

Workload of handling system = WLn+1 = nttn+1

The bottle neck station is the one with the largest workload.

4.0 Performance measures

The bottleneck station is largest WLi/si ratio. Let WL*, s*, t* equal the workload, servers and
processing time for the bottleneck station.

Maximum production rate of all parts (pc/min): R p * =

s*
WL *

Individual part production rates (pc/min): R pj * = p j ( R p *) = p j

Utilization at each work station: U i =

s*
WL *

WLi
WLi s *
( R p *) =
si
si WL *
n +1

U i
Average station utilization (include handling system): U =

i =1

n +1

siU i
Overall FMS utilization (omit handling system): U s =

i =1
n

si
i =1

Number of busy servers at each station: BSi = WLi ( R p *) = WLi

s*
WL *