Bottleneck shifting in serial line production: An investigation with different order release methods

Prabhu, Aruna; Raghunandana, K; Pai, Padmini

doi:10.1016/j.matpr.2021.11.337

Cited by 2 publications

(2 citation statements)

References 24 publications

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“…Kadipasaoglu et al (2000) revealed that the placement of extra capacity upstream of the production line accommodating the random fluctuations diminishes the contrary effects of varying process parameters. Prabhu et al (2022) observed that CONWIP outperforms other release methods like DBR, pull from a bottleneck (PFB) in unbalanced shops with dual bottlenecks having process time variability. However, DBR is consistently superior concerning flow time at certain levels of process time variability and CONWIP provided consistent throughput regardless of the bottleneck station in a four-station line with bottleneck shift phenomena.…”

Section: Literature Reviewmentioning

confidence: 99%

Workload Control in Flow Shops with Bottleneck Shifting and Process Time Variability

Prabhu,

Raghunandana,

Pai

2024

Production Engineering Archives

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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.

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Section: Literature Reviewmentioning

confidence: 99%

Workload Control in Flow Shops with Bottleneck Shifting and Process Time Variability

Prabhu,

Raghunandana,

Pai

2024

Production Engineering Archives

Self Cite

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“…WLC is a mechanism that helps to integrate input and output [8,9,10], thereby improving delivery performance [11,12]. Literature on WLC research has focused on complex flow shops having diverse kind of aspects such as breakdown aspects [13], bottleneck issues [1,14] uncertain process times in production [15,16] capacity adjustments [17,18,19], and due date settings that assimilate customer enquiry management [20]. The flow shop consists of workstations with materials flowing from upstream to downstream in a pre-defined sequence by approaching the workstation only once [7].…”

Section: Introductionmentioning

confidence: 99%

Investigation of Workload Control Methods for Shops with Re-Entrant Flows

Prabhu,

Raghunandana,

Yogesh

et al. 2024

Management Systems in Production Engineering

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The re-entrant flow with an unpredictable nature of arrival would apparently harm production plans and schedules 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 performance. The manufacturing process was observed thoroughly to incorporate the uncertain events that cause disturbance in the production. A simulation model was developed on a discrete event simulation platform by analysing 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 disproportionate 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.

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Bottleneck shifting in serial line production: An investigation with different order release methods

Cited by 2 publications

References 24 publications

Workload Control in Flow Shops with Bottleneck Shifting and Process Time Variability

Workload Control in Flow Shops with Bottleneck Shifting and Process Time Variability

Investigation of Workload Control Methods for Shops with Re-Entrant Flows

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