Decomposition and Aggregation-Based Real-Time Analysis of Assembly Systems with Geometric Machines and Small Batch-Based Production Tasks

Steady-state analysis on production systems, especially serial lines with rigid production mode, have been carried out in a large amount of research literature. With the development of the advanced manufacturing technologies, as well as the national strategies, for example, Made in China 2025, real-time performance evaluation, prediction, production management, and efficient control of systems with flexible production mode are gradually becoming important issues. Under the assumption of assembly systems with small batch-based production tasks, we develop a mathematical model for the real-time performance analysis of such systems with the geometric machine reliability model, which is applicable in many manufacturing environments. The formulas for real-time performance analysis are derived first using the Markovian approach for three-machine assembly systems. Then, based on the idea of decomposition and aggregation, an algorithm with high accuracy and efficiency for system real-time performance approximation is proposed. Finally, the decomposition and aggregation-based real-time analysis approach is extended to the generalized assembly systems. Note to Practitioners - As the concept of manufacturing intelligence being proposed and promoted, system flexibility appears frequently in production in recent years. A flexible production refers to the implementation of small batch-based production with multitype of products on the same production line, by quick setup or machine adjustments. The steady-state analysis method that is traditionally used might be not applicable in this case since most of the production process is in transient state. An approximation-based analytical method, for real-time performance evaluation of assembly systems with small batch-based production tasks and with machines having the geometric reliability model, is proposed. The algorithm developed in this article can be utilized by production managers and engineers, with which the real-time performance of the systems can be predicted with high accuracy. It can also provide assistance for decision-making on activities of production control.