Transient analysis of production performance and energy consumption in geometric flexible production systems

To meet the growing need for customized products, flexible production systems are gaining widespread application in modern factories. The inherent complexity of these flexible systems poses new challenges for production management. In this paper, we intend to contribute an operation-level analytical model for such systems, thus providing an effective evaluation tool for productivity and energy consumption analysis. Specifically, a multi-type serial production line with machines obeying the geometric reliability model and intermediate buffers having limited capacity is considered, in which K batches of parts are processed sequentially in each shift. Analytical solutions for key operation metrics are first developed for small systems using a Markov model. For multi-machine lines, a semi-analytical method based on aggregation is proposed. The effectiveness of the proposed analysis method is verified through simulation experiments. Besides, system properties are analyzed to provide insights for continuous improvement and optimization.