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A method for aligning serial batching decisions in a two-level organization of factory and distributed workstations

Author

Listed:
  • Yon-Chun Chou

    (National Taiwan University
    National Taiwan University)

  • Yue-Lan Lin

    (National Taiwan University)

  • King-Fai Chun

    (National Taiwan University)

Abstract

Large factories that manufacture high mixes of complex products are usually composed of a number of workstations and the manufacturing control function is divided between a factory and a workstation level. While the management of individual workstations tends to focus on efficient machine utilization, the top-level factory management is usually concerned with job flow control. Integration of operation decisions between the two organization levels can recover productivity loss stemming from disparate objectives. This paper presents a method for aligning the job batching decision for serial-batch machines that require machine setup to serve stochastic arrivals of multiple job types. The effect of batching on flow time is first analyzed and closed-form formulas for the probability of setup are derived for a time-based batching policy. The misalignment in batching decisions at the two organization levels is next illustrated. Finally, a state-based performance measure is designed for decision integration. Numerical simulation and regression are used to test the proposed method. The main contribution of this paper is on developing a distributed vertical alignment method which compliments the approaches of horizontal coordinated scheduling and vertical functional decomposition in architecture design of distributed manufacturing control.

Suggested Citation

  • Yon-Chun Chou & Yue-Lan Lin & King-Fai Chun, 2016. "A method for aligning serial batching decisions in a two-level organization of factory and distributed workstations," Journal of Intelligent Manufacturing, Springer, vol. 27(6), pages 1287-1297, December.
    • Handle: RePEc:spr:joinma:v:27:y:2016:i:6:d:10.1007_s10845-014-0951-2
    DOI: 10.1007/s10845-014-0951-2
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    References listed on IDEAS

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    1. Miragliotta, Giovanni & Perona, Marco, 2005. "Decentralised, multi-objective driven scheduling for reentrant shops: A conceptual development and a test case," European Journal of Operational Research, Elsevier, vol. 167(3), pages 644-662, December.
    2. Li, Na & Zhang, Mike Tao & Deng, Shiming & Lee, Zu-Hsu & Zhang, Lawrence & Zheng, Li, 2007. "Single-station performance evaluation and improvement in semiconductor manufacturing: A graphical approach," International Journal of Production Economics, Elsevier, vol. 107(2), pages 397-403, June.
    3. Yuan, J.J. & Lin, Y.X. & Cheng, T.C.E. & Ng, C.T., 2007. "Single machine serial-batching scheduling problem with a common batch size to minimize total weighted completion time," International Journal of Production Economics, Elsevier, vol. 105(2), pages 402-406, February.
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