Performance modeling of a closed loop material handling system

Pourbabai, Behnam

doi:10.1016/s0377-2217(87)80003-6

Cited by 20 publications

(12 citation statements)

References 16 publications

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“…Control of a flow shop line based on the pallet system has been the subject of interest in numerous studies. The most focused objectives, initiated by the lean philosophy [6], are minimization of lead times and resources [5], [7]- [10], and enhancement of the line performance [11]- [14].…”

Section: A a Cyclic Flow Shop Plant Based On A One-loop Pallet Systemmentioning

confidence: 99%

“…Hopp and Spearman in [39] formulated a modified form of Little's law [40] for such a plant as (14) which presents the important factors affecting the average throughput . In this expression, the work in process is the average number of parts in the plant, and the flow time is the average time the parts spend as .…”

Section: B Pallet System Design Constraint Modelsmentioning

confidence: 99%

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Energy Reduction in a Pallet-Constrained Flow Shop Through On–Off Control of Idle Machines

Mashaei

Lennartson

2013

IEEE Trans. Automat. Sci. Eng.

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For flexible manufacturing systems, there are normally some durations in which a number of machines are idle and do not process any parts. Devising a control policy to turn off the idle machines and reduce their level of energy consumption is a significant contribution towards the green manufacturing paradigm. This paper addresses the design of such a control strategy for a closed-loop flow shop plant based on a one-loop pallet system. The main goal is to coordinate running of the machines and motion of pallets to gain the minimal energy consumption in idle machines, as well as to obtain the desired throughput for the plant. To fulfill this goal, first mathematical conditions, which economically characterize the on-off control for machines, are presented. Constrained to these conditions and the mathematical models describing the pallet system, a mixed integer nonlinear minimization problem with the energy monitor as the objective function is then developed. Provided that the problem computation time can be managed, the optimal control for the operation of the plant and the minimal energy consumption in the idle machines are computed. To deal with the time complexity, a linearized form of the model and a heuristic approach are introduced. These methods are applied to some examples of industrial size, and their impacts in practice are discussed and verified by using a discrete event simulation tool.Note to Practitioners-Control of a flexible manufacturing plant in order to produce a set of part types in a determined production cycle time is a challenging problem. In addition, the problem is more complicated if energy efficiency is considered as an important key in the plant control design. This study provides methods which tackles this complex problem for an industrial size of a pallet-constrained flow shop. The outcome is an optimal switching control strategy, which reduces energy consumption for idle processing machines and maintains a desired throughput for the flow shop plant.Index Terms-Energy model, flow shop plant, heuristic algorithm, optimization, pallet system.

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Section: A a Cyclic Flow Shop Plant Based On A One-loop Pallet Systemmentioning

confidence: 99%

Section: B Pallet System Design Constraint Modelsmentioning

confidence: 99%

Energy Reduction in a Pallet-Constrained Flow Shop Through On–Off Control of Idle Machines

Mashaei

Lennartson

2013

IEEE Trans. Automat. Sci. Eng.

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“…, (8), (9), (10), (16), (17), (18) Solving (19), the plant control set point (N * p , T * c ), which gives the desired cycle time and the minimal tension force, is obtained.…”

Section: Optimal Controlmentioning

confidence: 99%

“…A paradigm shift from mass production to mass customization has reflected a variety of objectives in these studies. Researchers have devised models based on optimization frameworks [1], [2], queuing theory [3], [4], analytical methods [5], [6], [7], and discrete event formalism [8], [9], [10], [11], [12] to enhance the system performance [13], [14], [15], [16], minimize the makespan [17], [18], [19], and reduce the cycle time and work in process (WIP) [20], [21], [22], [23], [24]. These studies show the significant impact of the lean philosophy, [25], on control strategies of pallet systems.…”

Section: Introductionmentioning

confidence: 99%

Sustainable and robust control of cyclic pallet systems

Mashaei

Lennartson

2012

2012 IEEE International Conference on Automation Science and Engineering (CASE)

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A proper control of a system to get a desired function and increase the system lifetime is a crucial step towards the sustainable paradigm. In this paper, such a control is designed for a cyclic pallet system to achieve a minimal force on its drive unit, meet safety conditions on the system chain tension force and the momentum of pallets, and fulfill the desired production rate. The optimal values of the control parameters, namely number of pallets and conveyor velocity, are obtained through solving a linear optimization model. The objective function in the model defines the average force on the drive unit in a cycle production. In addition, the related constraints characterize the pallet system properties such as cyclic and dynamic behavior, buffer size, constant work in process, and safety specifications. The robustness of the optimal control is analyzed, using a worst but safe control strategy. The optimal control and the robustness analysis are applied to some case studies, and the results are evaluated and discussed.

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“…Numerous real-time modelling designs with theoretical approaches to control the single or multiple conveyor system have been built [5,6,7], but none achieves the maximum profit. The profit and the production efficiency are mostly concerned with problems challenging the manufacturing industry.…”

Section: Introductionmentioning

confidence: 99%

The design of a multi-conveyor system for profit maximisation

Lan

2003

The International Journal of Advanced Manufacturing Technology

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The design of a multi-conveyor system in supporting machine loading and unloading has become crucial to management. However, through the mathematical model proposed in this paper, this issue becomes realistically and concretely solvable. This study not only mediates the concept of balancing the number of parallel machines, the conveyor speed for adjacent pallets, the overall relevant costs and the determination of the number of conveyors into the objective, but also develops a two-staged method to optimise the combined problem to reach a maximum profit. Additionally, the versatility of this study is exemplified through a numerical example. Moreover, the computerised sensitivity analyses are discussed in this study. This paper contributes an applicable scheme for production design in manufacturing, and provides a valuable tool to conclusively obtain the optimal profit of a given production quantity for operations research engineers in today's manufacturing with profound insight.

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Performance modeling of a closed loop material handling system

Cited by 20 publications

References 16 publications

Energy Reduction in a Pallet-Constrained Flow Shop Through On–Off Control of Idle Machines

Energy Reduction in a Pallet-Constrained Flow Shop Through On–Off Control of Idle Machines

Sustainable and robust control of cyclic pallet systems

The design of a multi-conveyor system for profit maximisation

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