Performance Evaluation of Remanufacturing Systems

Implementation of new environmental legislation and public awareness has increased the responsibility on manufacturers. These responsibilities have forced manufacturers to begin remanufacturing and recycling of their goods after they are disposed or returned by customers. Ever since the introduction of remanufacturing, it has been applied in many industries and sectors. The remanufacturing process involves many uncertainties like time, quantity, and quality of returned products. Returned products are time sensitive products and their value drops with time. Thus, the returned products need to be remanufactured quickly to generate the maximum revenue. Every year millions of electronic products return to the manufacturer. However, only 10% to 20% of the returned products pass through the remanufacturing process, and the remaining products are disposed in the landfills. Uncertainties like failure rate of the servers, buffer capacity and inappropriate preventive maintenance policy would be highly responsible the delays in remanufacturing. In this thesis, a simulation based experimental methodology is used to determine the optimal preventive maintenance frequency and buffer allocation in a remanufacturing line, which will help to reduce the cycle time and increase the profit of the firm. Moreover, an estimated relationship between preventive maintenance frequency and MTBF (Mean Time Between Failure) is presented to determine the best preventive maintenance frequency for any industry. The solution approach is applied to a computer remanufacturing and a cell phone remanufacturing industry. Analysis of variance and regression analysis are performed to denote the influential factors in the remanufacturing line, and optimization is done by using the regression techniques and ANOVA results

Throughput enhancement with parallel redundancy in multi-product flow line system

We develop a new analytic approximation method to replace a set of parallel machines by an equivalent machine in a series-parallel flow line with finite buffer. We develop our method based on discrete state Markov chain. The proposed technique replaces a set of parallel machines at a work centre by an equivalent machine in order to obtain a traditional flow line with machines in series separated by intermediate buffers. We derive equations for the parameters of the equivalent machine when it operates in isolation as well as in flow line. The existing analytic methods for series-parallel systems can tract only lines with a maximum of two machines in series and a buffer in-between them. The method we propose in this thesis can be used in conjunction with an approximation method or simulation to solve flow lines of any length. We also model and evaluate the performance of series-parallel systems manufacturing more than one product types with predefined sequence and lot size. We address this issue for a considerable longer flow line system with finite buffer which is common in industry. We consider the set-up time of the machines as the product type changes, deterministic processing times and operation dependent failures of the machines. We analyze the effects of buffer and number of machines in parallel on the performance of series-parallel systems

Analytical evaluation of the output variability in production systems with general Markovian structure

Performance evaluation models are used by companies to design, adapt, manage and control their production systems. In the literature, most of the effort has been dedicated to the development of efficient methodologies to estimate the first moment performance measures of production systems, such as the expected production rate, the buffer levels and the mean completion time. However, there is industrial evidence that the variability of the production output may drastically impact on the capability of managing the system operations, causing the observed system performance to be highly different from what expected. This paper presents a general methodology to analyze the variability of the output of unreliable single machines and small-scale multi-stage production systems modeled as General Markovian structure. The generality of the approach allows modeling and studying performance measures such as the variance of the cumulated output and the variance of the inter-departure time under many system configurations within a unique framework. The proposed method is based on the characterization of the autocorrelation structure of the system output. The impact of different system parameters on the output variability is investigated and characterized. Moreover, managerial actions that allow reducing the output variability are identified. The computational complexity of the method is studied on an extensive set of computer experiments. Finally, the limits of this approach while studying long multi-stage production lines are highlighted. © 2013 Springer-Verlag Berlin Heidelberg

An Aggregation Procedure for Simulating Manufacturing Flow Line Models

We develop a formal method for specifying an aggregate discrete-event simulation model of a production flow line manufacturing system. The methodology operates by aggregating production stations or resources of a flow line. Determining the specifications for representing the aggregated resources in a simulation model is the focus of our presentation. We test the methodology for a set of flow lines with exponentially distributed arrival and service times. Comparisons between analytical and simulation results indicate the aggregation approach is quite accurate for estimating average part cycle time

Factory Models for Manufacturing Systems Engineering

We review MIT research in manufacturing systems engineering, and we describe current and possible future research activities in this area. This includes advances in decomposition techniques, optimization, token-based control systems analysis, multiple part types, inspection location, data collection and several other topics.Singapore-MIT Alliance (SMA

Real-Time Analysis and Control of Serial Production Lines for Energy Efficient Manufacturing

Productivity analysis, operation control and energy consumption reduction have been the central topics in manufacturing research and practice. They are closely related to each other. Control of production operations is considered as one of the most economical methods to improve energy efficiency in manufacturing systems, while system performance analysis serves as the base of production control. On the other hand, effective operation control can result to energy efficiency in manufacturing. Steady state analysis has been investigated extensively; however, transient analysis remained largely unexplored. Our research focuses on system modeling, performance analysis, and real-time operation control of serial production lines with unreliable machines and finite buffers, especially in transient period, with Bernoulli or geometric reliability. Analytical results, practical case studies and applications for energy efficient manufacturing are provided. A simulation using ARENA software to reproduce and analyze brewery production line is performed

Multi-job production systems: definition, problems, and product-mix performance portrait of serial lines

This paper pursues two goals: (a) Define a class of widely used in practice flexible manufacturing systems, referred to as Multi-Job Production (MJP) and formulate industrially motivated problems related to their performance. (b) Provide initial results concerning some of these problems pertaining to analysis of the throughput and bottlenecks of MJP serial lines as functions of the product-mix. In MJP systems, all job-types are processed by the same sequence of manufacturing operations, but with different processing time at some or all machines. To analyse MJP with unreliable machines, we introduce the work-based model of production systems, which is insensitive to whether single- or multi-job manufacturing takes place. Based on this model, we investigate the performance of MJP lines as a function of the product-mix. We show, in particular, that for the so-called conflicting jobs there exists a range of product-mixes, wherein the throughput of MJP is larger than that of any constituent job-type manufactured in a single-job regime. To characterise the global behaviour of MJP lines, we introduce the Product-Mix Performance Portrait, which represents the system properties for all product-mixes and which can be used for operations management. Finally, we report the results of an application at an automotive assembly plant

Online Modeling and Tuning of Parallel Stream Processing Systems

Writing performant computer programs is hard. Code for high performance applications is profiled, tweaked, and re-factored for months specifically for the hardware for which it is to run. Consumer application code doesn\u27t get the benefit of endless massaging that benefits high performance code, even though heterogeneous processor environments are beginning to resemble those in more performance oriented arenas. This thesis offers a path to performant, parallel code (through stream processing) which is tuned online and automatically adapts to the environment it is given. This approach has the potential to reduce the tuning costs associated with high performance code and brings the benefit of performance tuning to consumer applications where otherwise it would be cost prohibitive. This thesis introduces a stream processing library and multiple techniques to enable its online modeling and tuning. Stream processing (also termed data-flow programming) is a compute paradigm that views an application as a set of logical kernels connected via communications links or streams. Stream processing is increasingly used by computational-x and x-informatics fields (e.g., biology, astrophysics) where the focus is on safe and fast parallelization of specific big-data applications. A major advantage of stream processing is that it enables parallelization without necessitating manual end-user management of non-deterministic behavior often characteristic of more traditional parallel processing methods. Many big-data and high performance applications involve high throughput processing, necessitating usage of many parallel compute kernels on several compute cores. Optimizing the orchestration of kernels has been the focus of much theoretical and empirical modeling work. Purely theoretical parallel programming models can fail when the assumptions implicit within the model are mis-matched with reality (i.e., the model is incorrectly applied). Often it is unclear if the assumptions are actually being met, even when verified under controlled conditions. Full empirical optimization solves this problem by extensively searching the range of likely configurations under native operating conditions. This, however, is expensive in both time and energy. For large, massively parallel systems, even deciding which modeling paradigm to use is often prohibitively expensive and unfortunately transient (with workload and hardware). In an ideal world, a parallel run-time will re-optimize an application continuously to match its environment, with little additional overhead. This work presents methods aimed at doing just that through low overhead instrumentation, modeling, and optimization. Online optimization provides a good trade-off between static optimization and online heuristics. To enable online optimization, modeling decisions must be fast and relatively accurate. Online modeling and optimization of a stream processing system first requires the existence of a stream processing framework that is amenable to the intended type of dynamic manipulation. To fill this void, we developed the RaftLib C++ template library, which enables usage of the stream processing paradigm for C++ applications (it is the run-time which is the basis of almost all the work within this dissertation). An application topology is specified by the user, however almost everything else is optimizable by the run-time. RaftLib takes advantage of the knowledge gained during the design of several prior streaming languages (notably Auto-Pipe). The resultant framework enables online migration of tasks, auto-parallelization, online buffer-reallocation, and other useful dynamic behaviors that were not available in many previous stream processing systems. Several benchmark applications have been designed to assess the performance gains through our approaches and compare performance to other leading stream processing frameworks. Information is essential to any modeling task, to that end a low-overhead instrumentation framework has been developed which is both dynamic and adaptive. Discovering a fast and relatively optimal configuration for a stream processing application often necessitates solving for buffer sizes within a finite capacity queueing network. We show that a generalized gain/loss network flow model can bootstrap the process under certain conditions. Any modeling effort, requires that a model be selected; often a highly manual task, involving many expensive operations. This dissertation demonstrates that machine learning methods (such as a support vector machine) can successfully select models at run-time for a streaming application. The full set of approaches are incorporated into the open source RaftLib framework

Production Systems with Deteriorating Product Quality : System-Theoretic Approach

Manufacturing systems with perishable products are widely seen in practice (e.g., food, metal processing, etc.). In such systems, the quality of a part is highly dependent on its residence time within the system. However, the behavior and properties of these systems have not been studied systematically, and, therefore, is carried out in this dissertation. Specifically, it was assumed that the probability that each unfinished part is of good quality is a decreasing function of its residence time in the preceding buffer. Then, in the framework of serial production lines with machines having Bernoulli and geometric reliability models, closed-form formulas for performance evaluation in the two-machine line case were derived, and develop an aggregation-based procedure to approximate the performance measures in M\u3e2-machine lines. In addition, the monotonicity properties of these production lines using numerical experiments were studied. A case study in an automotive stamping plant is described to illustrate the theoretical results obtained. Also, Bernoulli serial lines with controlled parts released was analyzed for both deterministic and stochastic releases. Finally, bottleneck analysis in Bernoulli serial lines with deteriorating product quality were studied