Transient and Steady-State Analysis of Multistage Production Lines With Residence Time Limits
Transient and Steady-State Analysis of Multistage Production Lines With Residence Time Limits
复制标题
DOI：
10.1109/tase.2020.2979179
复制
发表时间：
2021-01
影响因子：
5.6
通讯作者：
Feifan Wang;Feng Ju
中科院分区：
文献类型：
--
作者：
Feifan Wang;Feng Ju
由于质量要求，中间产品的停留时间限制在生产系统中很常见。如果零件在缓冲器中的停留时间超过允许的最大停留时间，则通常需要报废或返工，而如果零件的停留时间小于所需的最小停留时间，则需要在缓冲器中继续等待。这样的限制可能需要在生产线的多个阶段，使得难以分析稳态和瞬态生产系统的性能。所研究的问题被表述为具有停留时间限制的多阶段几何系列生产线。针对多阶段几何系列生产线的大状态空间，首先分析了从多阶段几何系列生产线分离出来的两机一缓冲子系统的稳态和瞬态性能。在此基础上，提出了一种综合稳态分析和暂态分析的综合评价方法。所提出的聚合方法大大降低了问题的复杂性，使问题的分析变得易于处理。与仿真结果相比，该方法在稳态和暂态性能指标的估计上都保持了较高的精度。这种方法为有效的工厂现场绩效评估和预测提供了定量工具。从业人员注意：众所周知，如果不控制中间产品的停留时间，可能会出现潜在的质量问题，并可能增加生产成本。停留时间限制成为人们关注的问题，特别是在汽车工业、食品工业和半导体工业中，中间产品停留在一个容易出现缺陷的阶段。这些限制也适用于热塑性聚合物的大规模增材制造。每一层的沉积都受到表面温度的下限和上限的限制，在实践中，这两个上限分别相当于最小要求停留时限和最大允许停留时限。考虑停留时间后，随着系统规模的增大，整个生产系统模型的状态空间大小将呈指数级增长，这给系统的短期和长期评估都带来了巨大的挑战。在本文中，我们提出了一种新的具有停留时间限制的多阶段几何系列生产线建模方法，并提出了一种大大降低系统复杂性的方法。该方法为有效评价具有停留时间限制的多级几何线的性能提供了定量工具。
Residence time limits for the intermediate products are commonly seen in production systems due to quality requirements. A part in a buffer typically needs to be scrapped or reworked if its residence time exceeds the maximum allowable residence time, while a part needs to keep waiting in the buffer if its residence time is less than the minimum required residence time. Such limits could be required at multiple stages of the production line, making it difficult to analyze both the steady-state and transient production system performance. The problem under study is formulated as a multistage geometric serial production line with residence time limits. To deal with its large state space, a two-machine-one-buffer subsystem isolated from a multistage geometric serial production line is first analyzed for both steady-state and transient performance. Furthermore, a novel aggregation method, including the steady-state analysis and transient analysis, is proposed to evaluate the overall system performance. The proposed aggregation method substantially reduces the complexity of the problem and makes the analysis of the problem tractable. Compared with the simulation, the aggregation method maintains high accuracy in estimating both steady-state and transient performance measures. Such a method provides quantitative tools for effective performance evaluation and prediction on the factory floor. Note to Practitioners—It is well known that potential quality problems may occur and production cost may increase if the residence time of intermediate products is left uncontrolled. The residence time limits become a concern, especially in the automotive industry, food industry, and semiconductor industry, where intermediate products stay in a stage susceptible to defects. The limits also apply to large scale additive manufacturing of thermoplastic polymers. The deposition of each layer is subject to lower and upper bounds of surface temperature, which, in practice, are equivalent to minimum required residence time limit and maximum allowable residence time limit, respectively. With residence time considered, the size of state space for the overall production system model will grow exponentially, as the system’s size increases, which brings tremendous challenges to evaluate such a system both in the short term and in the long run. In this article, we introduce a novel modeling approach for a multistage geometric serial production line with residence time limits and propose a method that drastically reduces the complexity of the system. Such a method provides a quantitative tool to effectively evaluate the performance of multistage geometric lines with residence time limits.