Flexible Serial Lines with Setups: Analysis, Improvement, and Application

Cong Zhao; Jingshan Li; Ningjian Huang; John A. Horst

doi:10.1109/LRA.2016.2556078

Flexible Serial Lines with Setups: Analysis, Improvement, and Application

Cong Zhao, Jingshan Li, Ningjian Huang, John A. Horst

Research output: Journal Publications and Reviews › RGC 21 - Publication in refereed journal › peer-review

22 Citations (Scopus)

Abstract

Setup times commonly exist in many flexible manufacturing lines to adjust tools and carry out safety and quality check during product changeovers. In this paper, a Markov chain model is introduced to study flexible manufacturing lines with setups. An aggregation-based recursive procedure is introduced to evaluate system performance. The convergence of the procedure is proved analytically and the accuracy is justified numerically. Using such a method, the impact of setups is analyzed and the effectiveness of downtime and setup time reduction is investigated. Indicators are derived to identify the setup bottlenecks with respect to machine and product type, whose setup time reduction can lead to the largest improvement in line production rate. Finally, an application study at a furniture manufacturing plant is introduced. © 2016 IEEE.

Original language	English
Article number	7456253
Pages (from-to)	120-127
Journal	IEEE Robotics and Automation Letters
Volume	2
Issue number	1
DOIs	https://doi.org/10.1109/LRA.2016.2556078
Publication status	Published - 1 Jan 2017
Externally published	Yes

Bibliographical note

Publication details (e.g. title, author(s), publication statuses and dates) are captured on an “AS IS” and “AS AVAILABLE” basis at the time of record harvesting from the data source. Suggestions for further amendments or supplementary information can be sent to [email protected].

Funding

This paper was recommended for publication by Associate Editor M. Dotoli and Editor Y. Sun upon evaluation of the Reviewers’ comments. This work was supported in part by NSF Grant No. CMMI-1063656 and NIST Grant No. 70NANB14H260.

UN SDGs

This output contributes to the following UN Sustainable Development Goals (SDGs)

SDG 9 Industry, Innovation, and Infrastructure

Research Keywords

Factory Automation
Intelligent and Flexible Manufacturing
Markov Chain
Setups

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10.1109/LRA.2016.2556078

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abstract = "Setup times commonly exist in many flexible manufacturing lines to adjust tools and carry out safety and quality check during product changeovers. In this paper, a Markov chain model is introduced to study flexible manufacturing lines with setups. An aggregation-based recursive procedure is introduced to evaluate system performance. The convergence of the procedure is proved analytically and the accuracy is justified numerically. Using such a method, the impact of setups is analyzed and the effectiveness of downtime and setup time reduction is investigated. Indicators are derived to identify the setup bottlenecks with respect to machine and product type, whose setup time reduction can lead to the largest improvement in line production rate. Finally, an application study at a furniture manufacturing plant is introduced. {\textcopyright} 2016 IEEE.",

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AU - Zhao, Cong

AU - Li, Jingshan

AU - Huang, Ningjian

AU - Horst, John A.

N1 - Publication details (e.g. title, author(s), publication statuses and dates) are captured on an “AS IS” and “AS AVAILABLE” basis at the time of record harvesting from the data source. Suggestions for further amendments or supplementary information can be sent to [email protected].

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N2 - Setup times commonly exist in many flexible manufacturing lines to adjust tools and carry out safety and quality check during product changeovers. In this paper, a Markov chain model is introduced to study flexible manufacturing lines with setups. An aggregation-based recursive procedure is introduced to evaluate system performance. The convergence of the procedure is proved analytically and the accuracy is justified numerically. Using such a method, the impact of setups is analyzed and the effectiveness of downtime and setup time reduction is investigated. Indicators are derived to identify the setup bottlenecks with respect to machine and product type, whose setup time reduction can lead to the largest improvement in line production rate. Finally, an application study at a furniture manufacturing plant is introduced. © 2016 IEEE.

AB - Setup times commonly exist in many flexible manufacturing lines to adjust tools and carry out safety and quality check during product changeovers. In this paper, a Markov chain model is introduced to study flexible manufacturing lines with setups. An aggregation-based recursive procedure is introduced to evaluate system performance. The convergence of the procedure is proved analytically and the accuracy is justified numerically. Using such a method, the impact of setups is analyzed and the effectiveness of downtime and setup time reduction is investigated. Indicators are derived to identify the setup bottlenecks with respect to machine and product type, whose setup time reduction can lead to the largest improvement in line production rate. Finally, an application study at a furniture manufacturing plant is introduced. © 2016 IEEE.

KW - Factory Automation

KW - Intelligent and Flexible Manufacturing

KW - Markov Chain

KW - Setups

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M3 - RGC 21 - Publication in refereed journal

SN - 2377-3766

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EP - 127

JO - IEEE Robotics and Automation Letters

JF - IEEE Robotics and Automation Letters

IS - 1

M1 - 7456253

ER -

Flexible Serial Lines with Setups: Analysis, Improvement, and Application

Abstract

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UN SDGs

Research Keywords

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