Showing papers in "Iie Transactions in 1992"
TL;DR: A review of research in this area to date, discuss the applicability of the various approaches and suggest directions for future research is presented in this article, where the authors describe the characteristics of the semiconductor manufacturing environment and review models related to performance evaluation and production planning.
Abstract: Although the national importance of the semiconductor industry is widely acknowledged, it is only recently that the production planning and scheduling problems encountered in this environment have begun to be addressed using industrial engineering and operations research.techniques. These problems have several features that make them difficult and challenging: random yields and rework, complex product flows, and rapidly changing products and technologies. Hence their solution will contribute considerably to die theory and practice of production planning and control. In a two-part project we present a review of research in this area to date, discuss the applicability of the various approaches and suggest directions for future research. In this paper, Part I, we describe the characteristics of the semiconductor manufacturing environment and review models related to performance evaluation and production planning. Part II will review research on shop-floor control in this industry to date.
599 citations
TL;DR: In this article, a generic framework for controlling the work flow in computer controlled manufacturing systems is presented based on a market-like model and a combination of objective and price mechanism, which allows heterogeneous job objectives, admits job priorities, recognizes multiple resources types, and allows multiple step negotiation between parts and resources.
Abstract: In this paper, we present a generic framework for controlling the work flow in computer controlled manufacturing systems. Based on a market-like model and a combination of objective and price mechanism, the framework allows heterogeneous job objectives, admits job priorities, recognizes multiple resources types, and allows multiple step negotiation between parts and resources. The framework is designed to accommodate frequent changes in the environment such as machine failures, tool shortages, and process requirement variations. An object-oriented simulation system is built to demonstrate the flexibility and effectiveness of die proposed framework. The results show that the proposed framework provides a foundation for highly adaptive, real time shop floor control.
315 citations
TL;DR: In this article, the authors summarized the statistical methods for planning and analyzing robust design experiments originally proposed by Taguchi; then reviewed newly developed statistical methods and identified areas and problems where more researches are needed.
Abstract: Robust Design is an important method for improving product quality, manufacturability, and reliability at low cost. Taguchi's introduction of this method in 1980 to several major American industries resulted in significant quality improvement in product and manufacturing process design. While the robust design objective of making product performance insensitive to hard-to-control noise was recognized to be very important, many of the statistical methods proposed by Taguchi, such as the use of signal-to-noise ratios, orthogonal arrays, linear graphs, and accumulation analysis, have room for improvement. To popularize me use of robust design among engineers, it is essential to develop more effective, statistically efficient, and user-friendly tech niques and tools. This paper first summarizes the statistical methods for planning and analyzing robust design experiments originally proposed by Taguchi; then reviews newly developed statistical methods and identifies areas and problems where more resear...
285 citations
TL;DR: In this paper, the authors present a framework for the printed circuit card assembly process planning problem and assess the current state of the research on appropriate models and solution methods, and propose a decision hierarchy, survey the published literature, and identify needs for future research.
Abstract: Printed circuit card assemblies form the core of a vast array of contemporary manufactured products. The technologies for assembling printed circuit cards require a hierarchy of complex decisions for grouping card types and processes, staging components at assembly machines, arranging feeders, and sequencing placement operations. This paper is motivated by the largely unmet needs of industrial process planners for computer aids. Our objective is to develop a framework for the printed circuit card assembly process planning problem and to assess the current state of the research on appropriate models and solution methods. We first provide an overview of the essential elements of printed circuit card terminology, assembly technologies, and assembly system operations. Then we propose a decision hierarchy, survey the published literature, and identify needs for future research.
130 citations
TL;DR: In this article, a framework for incorporating machine learning capabilities in intelligent scheduling is developed for a flexible manufacturing system, which adopts a state-dependent dispatching rule selection policy, and a pattern-directed method, with a built-in inductive learning module, was developed for heuristic acquisition and refinement.
Abstract: Dynamic scheduling of manufacturing systems has primarily involved the use of dispatching rules. In the context of conventional job shops, the relative performance of these rules has been found to depend upon the system attributes, and no single rule is dominant across all possible scenarios. This indicates die need for developing a scheduling approach which adopts a state-dependent dispatching rule selection policy. The importance of adapting the dispatching rule employed to the current state of the system is even more critical in a flexible manufacturing system because of alternative machine routing possibilities and me need for increased coordination among various machines. This study develops a framework for incorporating machine learning capabilities in intelligent scheduling. A pattern-directed method, with a built-in inductive learning module, is developed for heuristic acquisition and refinement. This method enables the scheduler to classify distinct manufacturing patterns and to generate...
129 citations
TL;DR: In this article, the authors argue for a fundamental paradigm shift in the development and utilization of models within a CEM framework and propose a new approach to modeling based on object-oriented programming and related technologies.
Abstract: Traditional approaches to the modeling of complex manufacturing systems are expensive, time consuming, and of limited value. Recent developments in several areas (i.e., knowledge engineering, software engineering, modeling formalisms, engineering workstations, and database systems) are now to the point that a meaningful convergence can be crafted to yield a modeling environment far superior to any we have known in the past. Fundamental to this new approach to modeling are the recent developments in object-oriented programming and related technologies. A research team at Oklahoma State University has been exploring alternative approaches to the modeling and simulation of complex manufacturing systems since 1985. This paper argues for a fundamental paradigm shift in the development and utilization of models within a CEM framework.
118 citations
TL;DR: In this article, the capacity limitations of alternative machine types are modeled using a formulation that is typically not much larger than the basic linear programming formulation that does not admit alternative resource types.
Abstract: Analyzing the capacity of production facilities in which manufacturing operations may be performed by alternative machine types presents a seemingly complicated task. In typical enterprise-level production planning models, capacity limitations of alternative machine types are approximated in terms of some single artificial capacitated resource. In this paper we propose procedures for generating compact models that accurately characterize capacity limitations of alternative machine types. Assuming that processing times among alternative machine types are identical or proportional across operations they can perform, capacity limitations of the alternative machine types can be precisely expressed using a formulation that is typically not much larger than the basic linear programming formulation that does not admit alternative resource types. These results have important implications for industrial practice, suggesting that in the case that processing times are nearly proportional among alternatives, the prev...
112 citations
TL;DR: In this paper, the authors review some recent developments in statistical methodology that have application in product and process improvement, concentrating on statistical process control and design of experiments, and some directions for future research are identified.
Abstract: Quality and productivity improvement has become an essential element of the overall strategic plan for most organizations. This has sparked renewed interest in statistical methods for quality improvement. This paper reviews some recent developments in statistical methodology that have application in product and process improvement, concentrating on statistical process control and design of experiments. Some directions for future research are identified.
93 citations
TL;DR: In this article, a hybrid push/pull strategy is developed with the aim of gaining the advantages of both approaches, and the results indicate that the hybrid approach has lower inventory levels and a better response to demand changes than the pure pull system.
Abstract: Approaches to multistage production scheduling can be conveniently classified into push type (i.e., Materials Requirements Planning (MRP) systems) or pull type (i.e., kanban systems). Each is generally thought to have both advantages and disadvantages. In this paper, a hybrid push/pull strategy is developed with the aim of gaining the advantages of both approaches. Material flow between work centers is regulated using the standard single card kanban/pull arrangement. Superimposed on this is the MRP-type information flow which feeds forward demand information directly to one or more (but not necessarily all) work centers. A general N-stage hybrid push/pull model is developed. The use of the approach is illustrated using 3-stage and 4-stage serial flowlines. The results indicate that the push/pull approach has lower inventory levels and a better response to demand changes than the pure pull system. The hybrid approach seems to combine many of die advantages of MRP approaches while retaining much of the simp...
86 citations
TL;DR: In this article, the authors examined different properties of the subsample means in the presence of autocorrelation, using aggregation and systematic sampling theory, and investigated the Type I error rate for the X¯ chart.
Abstract: Autocorrelation of quality-control measurements violates one of the basic assumptions underlying the use of statistical control charts for process mean. Several investigators have studied the impact of autocorrelation on charting procedures based on single observations, however, little work has been directed to charts with subsampling. This paper examines different properties of the subsample means in the presence of autocorrelation. Specifically, using aggregation and systematic sampling theory, we show the time-series behavior of the subsample means. We also investigate the Type I error rate for the X¯ chart and present recommendations for statistical process control in the presence of autocorrelation. Our investigation of the Type I error provides additional insights of the impact of autocorrelation on the subsample range statistic.
77 citations
TL;DR: In this paper, the authors present an optimal solution procedure for the single period stochastic plant layout problem, which only requires solving a "deterministic" from-to flow matrix.
Abstract: In this paper we present an optimal solution procedure for the single period stochastic plant layout problem. The procedure only requires solving a “deterministic” from-to flow matrix. This “deterministic” matrix is a weighted-average of all from-to flow matrices. Since it may be difficult to estimate the probabilities of occurrence of the various states of nature, we developed a simulation model to test the robustness of our approach. For over 26,000 problems examined, the average error of using our approach was very small, only about one-sixth of one percent. Handled by the Department of Facilities Design/Material Handling.
TL;DR: In this article, an empirical study that was employed in analyzing the operating productivities of a set of 44 bank branches of a major commercial bank offering relatively homogeneous products in a multi-market business environment was conducted.
Abstract: Productivity analysis and its strategic implications are not only important for manufacturing sector but equally essential for other sectors as well Branch banking sector is no exception in this sense and banks have to operate more efficiently and effectively in an increasingly competitive environment to sustain or improve their relative positions This paper discusses the methodology of an empirical study that was employed in analyzing the operating productivities of a set of 44 bank branches of a major commercial bank offering relatively homogeneous products in a multi-market business environment The methodology was based on the concepts and principles of Data Envelopment Analysis (DEA) The results of the study have indicated that this kind of productivity analysis is not only complementary to traditionally used financial ratios but also is a useful bank management tool in reallocating resources between the branches in order to achieve higher efficiencies
TL;DR: In this article, the authors used knowledge of future arrivals to control bulk service diffusion and oxidation processes, which can reduce the average time that lots of customers spend waiting to be processed.
Abstract: This paper demonstrates how knowledge of future arrivals can be used to control bulk service diffusion and oxidation processes. The objective of the research reported herein is to reduce the average time that lots spend waiting to be processed. A review of the current literature reveals that several researchers have dealt with the control of bulk service queueing systems; however, only one has addressed the use of knowledge of future arrivals and it only considered the case of a single product and a single server. This research reexamines the single product-single server case, and men explores the multiple products-single server case. For both cases, a control strategy is devised and evaluated through the use of systems simulation. The steady-state performance of each control strategy is then compared to the steady-state performance of the theoretical optimal control strategy not considering the timing of any future arrivals (i.e. a Minimum Batch Size strategy). The experimental results indicate that the ...
TL;DR: In this article, a mathematical model for scheduling mixed-model multi-level production facilities is studied and techniques for determining good schedules are developed, with procedures for solving very large problems are given.
Abstract: Many companies are using Just-In-Time (JIT) control systems in their mixed-model multi-level production facilities. When scheduling these facilities the most important objective is to keep a constant rate of usage for every part used by the system. In this paper a mathematical model for scheduling these facilities is studied and techniques for determining good schedules are developed. Procedures for solving very large problems are given. Handled by the Department of Scheduling, Planning and Control.
TL;DR: In this article, a two-phase approach to the hospital layout problem is described, where the first phase involves a quadratic integer goal programming model that determines a configuration and recommended allocation of beds to hospital services, and detailed ramifications of the proposed layout are then evaluated in the second phase via a simulation model.
Abstract: The issues of facility layout and bed allocation in health care settings are typically evaluated separately using very different model-based approaches. This paper describes a two-phase approach to the hospital layout problem that incorporates a number of considerations from typical layout models and methods used in determining bed allocations. The first phase involves a quadratic integer goal programming model that determines a configuration and recommended allocation of beds to hospital services. The detailed ramifications of the proposed layout are then evaluated in the second phase via a simulation model. The application of the optimization-simulation approach in a general purpose hospital is described. Handled by the Department of Health Systems.
IBM1
TL;DR: In this paper, the feeder assignment models are used to determine the particular stations in which each component fixture is to be attached to the carrier and several nonlinear objectives are developed to minimize "excess delay" due to carrier movements.
Abstract: Consider computer numerically controlled placement machines which populate printed circuit boards with surface mounted components. These highly concurrent systems require a hierarchy of decision models to determine efficient machine setups and operational sequences so as to achieve effective throughput rates. The Feeder Assignment models developed here can be used to determine the particular stations in which each component fixture is to be attached to the carrier. Noninterference and space constraints may also need to be addressed. Several nonlinear objectives are developed to minimize "excess delay" due to carrier movements. These nonlinear formulations are then transformed to achieve equivalent Linear Mixed Integer Programming formulations. Carrier movements are often the slowest of the concurrent processes and therefore can cause significant deterioration in the overall system performance, if not adequately addressed and properly integrated into a hierarchical decision process. The methodology is illu...
TL;DR: In this paper, structural results and an approximation for the throughput of an assembly system fed by multi-station fabrication lines where releases are governed by the CONWIP protocol and all machines have deterministic processing times but are subject to random outages.
Abstract: We develop structural results and an approximation for the throughput of an assembly system fed by multi-station fabrication lines where releases are governed by the CONWIP protocol and all machines have deterministic processing times but are subject to random outages. This formulation is motivated by a printed circuit board manufacturing process. We demonstrate that while throughput of such systems is nondecreasing in machine speed, there are cases where throughput declines when mean time between failures (MTBF) increases or mean time to repair (MTTR) decreases. Using the concept of "deterministic steady state," which describes the behavior of the system in die absence of failures, we derive a simple, closed-form approximation for throughput. Comparisons with simulation show that this approximation is robust over a wide range of conditions. Finally, we observe that throughput tends to be higher when the bottleneck is located in fabrication rather than assembly.
TL;DR: The design principles of a new knowledge-based on-line simulation (KBOLS) architecture for the purpose of integrating the supervisory decision making process with a shop floor control system is discussed and the requirements for implementing the KBOLS architecture in a computer integrated manufacturing environment are presented.
Abstract: In this paper, the design principles of a new knowledge-based on-line simulation (KBOLS) architecture for the purpose of integrating the supervisory decision making process with a shop floor control system is discussed. The requirements for implementing the KBOLS architecture in a computer integrated manufacturing environment are presented. The special features of the KBOLS architecture include a knowledge-based controller capable of interacting with the shop floor and a manufacturing simulator, a shared blackboard data structure for knowledge bases, and a learning module. The KBOLS architecture is implemented in a flexible manufacturing system for analyzing interruptions due to machine breakdowns and rush orders.
TL;DR: In this article, the authors investigated the effect of a reduction in process variance on the production cost and developed approximate relationships for cost reduction as a function of economic parameters when the fill is a normally distributed random variable and process settings are optimized.
Abstract: We investigate a canning problem (Golhar and Pollock [2]) to study the effect of a reduction in process variance on the production cost. Exact and approximate relationships are developed for cost reduction as a function of economic parameters when the fill is a normally distributed random variable and process settings are optimized.
TL;DR: In this article, the optimal ordering rules in response to supplier restrictions on special order sizes that accompany temporary price reductions are derived in the context of temporary price reduction, where buyers may purchase a compulsory minimum order size or select from a limited number of available order quantities at the reduced price.
Abstract: Suppliers offering temporary price reductions may impose restrictions on special order sizes at die temporarily-reduced price Buyers may be restricted to purchase a compulsory minimum order size or select from a limited number of available order quantities at the reduced price This paper derives optimal ordering rules in response to supplier restrictions on special order sizes that accompany temporary price reductions Handled by the Department of Inventory
TL;DR: This paper presents the results of a study in which two prominent multicritena methodologies were used to evaluate a discrete set of technological alternatives, and Saaty's Analytic Hierarchy Process and Keeney and Raiffa's Multiattribute Utility Theory were used.
Abstract: This paper presents the results of a study in which two prominent multicritena methodologies were used to evaluate a discrete set of technological alternatives. The first is Saaty's Analytic Hierarchy Process (AHP), and the second is Keeney and Raiffa's Multiattribute Utility Theory (MAUT). A case study designed to select the next generation of rough terrain cargo handlers for the U.S. Army provided the backdrop. Three alternatives were identified and ultimately ranked using the two methodologies. The intent was to detennine the strengths and weaknesses of each, and to characterize the conditions under which one might be more appropriate than the other. The evaluation team consisted of five program managers and engineers from the Belvoir Research, Development & Engineering Center. The objective hierarchy used in both cases contained twelve attributes. In general, the AHP was found to be more accessible and conducive to consensus building. Once the attributes were defined, the decision makers had little di...
TL;DR: In this article, the authors developed an efficient analytical method for the analysis of an n-machine production line with unreliable machines and random processing times based on the decomposition of the (n − l) two-machine lines.
Abstract: This paper develops an efficient analytical method for the analysis of an n-machine production line with unreliable machines and random processing times. The behavior of the n-machine line is approximated by the behaviors of the (n — l) two-machine lines based on the decomposition. Simulation and numerical experiment show that the analytical method works well and is very efficient.
TL;DR: A growing collection of parsimonious models and theories can form a basis for the design, analysis and control of complex manufacturing systems as discussed by the authors. But they may lack the precision of their classical counterparts.
Abstract: Are there “laws” of manufacturing? If so, what do they look like? If not, what other forms of knowledge might comprise intellectual foundations for a discipline of manufacturing? We differentiate among mathematical tautologies, laws, models, and theories, giving examples of each. Laws closely analogous to those of nineteenth century physics appear to be unlikely but empirical models offer the prospect of building new understanding of manufacturing, even if they may lack the precision of their classical counterparts. Descriptive models serving scientific goals tend to differ from prescriptive models for problem-solving. The latter must be complete enough to solve the practical problem at hand and yet be selective in their detail so as not to paralyze problem-solving with irrelevant complication. A growing collection of parsimonious models and theories can form a basis for the design, analysis and control of complex manufacturing systems.
TL;DR: In this article, the minimum friction levels between the floor and footwear required in cart pushing and pulling to reduce accidents caused by slipping were determined for eight subjects with different body weights (ranging from 50 to 80 kilograms).
Abstract: This paper presents results of a study conducted to determine minimum friction levels between the floor and footwear required in cart pushing and pulling to reduce accidents caused by slipping Experiments involving pushing and pulling a cart were con ducted in the laboratory Eight subjects with different body weights (ranging from 50 to 80 kg) were tested for three different hand forces (98, 196 and 294 newton), three different cart handle heights (66, 109 and 152 cm high) and two different moving speeds (18 and 36 km/hour) A low handle required less friction level (av 03) than a high handle (av 06) in pulling A high handle required less friction level (av 03) than a low handle (av 07) for all test conditions The required friction increased significantly as hand force increased As expected a heavy person exerting a light force (required for the task) and using a slow speed of movement proved to reduce the slip potential
TL;DR: In this article, a multi-period replacement model is developed in the context of an incremental implementation of flexible automation investments, taking into account die costs, benefits and effective utilization of several types of flexibility, in deriving optimal machine replacement sequences and cost-effective production plans during the transition and later periods.
Abstract: In this paper a multiperiod replacement model is developed in the context of an incremental implementation of flexible automation investments. The model takes into account die costs, benefits and effective utilization of several types of flexibility, in deriving optimal machine replacement sequences and cost-effective production plans during the transition and later periods. Handled by the Department of Manufacturing and Automated Production.
TL;DR: This paper uses a model of human functioning in inspection and deriving an optimum speed of working so as to balance the cost of time against the costs of errors, to provide optimum inspection speed.
Abstract: Choosing a standard speed for visual inspection is difficult using standard work measurement techniques. This paper uses a different approach, taking a model of human functioning in inspection and deriving an optimum speed of working so as to balance the cost of time against the cost of errors. Random search is used as the model and both self-paced and externally-paced conditions are derived for multiple fault types. Optimization using a Golden Section search is used to provide optimum inspection speed.
TL;DR: In this article, an economic order quantity model with the assumptions that demand rate is deterministic and linearly changes with time, shortages are allowed, deterioration rate is constant, planning horizon is finite and known, and replenishment periods are not equal.
Abstract: This paper considers an economic order quantity model with the assumptions that (1) demand rate is deterministic and linearly changes with time, (2) shortages are allowed, (3) deterioration rate is constant, (4) planning horizon is finite and known, and (5) replenishment periods are not equal. The model is solved using a dynamic programming method. The result is applicable to the cases of both increasing and decreasing demand. A numerical example is provided to illustrate the results.
TL;DR: In this article, a new approach to maximize the steady-state availability of a closed queuing multiechelon repairable system with cold standbys is presented based on the use of the Taguchi inner array design in simulation modeling of this problem.
Abstract: This paper presents a new approach to maximize the steady-state availability of a closed queuing multiechelon repairable system with cold standbys. The new method is based on the use of the Taguchi inner array design in simulation modeling of this problem. Regression models are developed based on the results generated from the balanced simulation design. Two special cases of the exponential and Erlang-2 service distributions are presented. These models were validated and shown to provide good approximations to simulation results. Within the specified domain of the problem's parameters, the total operating cost of this system is minimized to determine the optimum spare and repair units.
TL;DR: This paper points out that an encompassing perspective on Taguchi's philosophy can be provided by statistical decision analysis, and prescribes that an optimum decision is one that maximizes expected utility.
Abstract: An impetus for the new revolution in quality technology has been Professor Genichi Taguchi's approach to quality engineering, best exemplified by his call for off-line quality control. However, much of the literature on this topic appears to be fragmented between engineering, statistics and quality control journals, each emphasizing a point of view that is pertinent to its readership. A consequence of the above is that there has been some difficulty in developing an appreciation for the totality of die approach, its key ingredients, and the several excellent contributions of many others in this important subject. In this paper, we attempt to help alleviate this difficulty by pointing out that an encompassing perspective on Taguchi's philosophy can be provided by statistical decision analysis. The subject deals with decision making in the face of partial or no information, and prescribes that an optimum decision is one that maximizes expected utility. The role of experimental design is to obtain p...
TL;DR: In this article, the relationship between optimal order quantity and the magnitude of the price change is investigated, and a present value analysis is performed to evaluate the relationship among the two variables.
Abstract: The conventional approach for setting order quantities when prices change does not incorporate a present value analysis, and does not distinguish inventory storage costs from the cost of money. These factors cause optimal order quantities to be overestimated when prices are reduced by more man 30%. Following a present value analysis, this paper evaluates the relationship between optimal order quantity and the magnitude of the price change. Handled by the Department of Engineering Economics.