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Performance analysis for serial production lines with Bernoulli Machines and Real-time WIP-based Machine switch-on/off control

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  • Zhiyang Jia
  • Liang Zhang
  • Jorge Arinez
  • Guoxian Xiao

Abstract

In recent years, achieving high energy efficiency has become one of the primary goals in manufacturing, along with maintaining high productivity and quality. In many manufacturing systems, it is sometimes possible to temporarily switch off a machine to reserve energy, and switch it back on when a certain condition is met. Indeed, production control-based shop floor continuous improvement is recognised as one of the most cost-effective ways to achieve energy-efficient production. In this paper, we study serial production lines with Bernoulli machines and finite capacity buffers and assume that some of the machines in the line can be switched on and off during the production process according to a state-based feedback control policy. Mathematical models for the system under consideration are derived and analytical methods are developed for calculating the system performance measures during transients. Specifically, exact Markovian analysis is used for two- and three-machine lines in which the switch-on/off operations of only one machine is considered. For longer lines, the switch-on/off operations of multiple machines are considered and an aggregation-based approximation approach is applied to evaluate the system performance measures. Numerical experiments show that the method developed can be used to efficiently calculate the system’s performance with high accuracy.

Suggested Citation

  • Zhiyang Jia & Liang Zhang & Jorge Arinez & Guoxian Xiao, 2016. "Performance analysis for serial production lines with Bernoulli Machines and Real-time WIP-based Machine switch-on/off control," International Journal of Production Research, Taylor & Francis Journals, vol. 54(21), pages 6285-6301, November.
    • Handle: RePEc:taf:tprsxx:v:54:y:2016:i:21:p:6285-6301
    DOI: 10.1080/00207543.2016.1197438
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    References listed on IDEAS

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    1. Liang Zhang & Chuanfeng Wang & Jorge Arinez & Stephan Biller, 2013. "Transient analysis of Bernoulli serial lines: performance evaluation and system-theoretic properties," IISE Transactions, Taylor & Francis Journals, vol. 45(5), pages 528-543.
    2. Chan, Felix T.S. & Wang, Zheng & Zhang, Jie, 2007. "A two-level hedging point policy for controlling a manufacturing system with time-delay, demand uncertainty and extra capacity," European Journal of Operational Research, Elsevier, vol. 176(3), pages 1528-1558, February.
    3. Charles J. Corbett & Robert D. Klassen, 2006. "Extending the Horizons: Environmental Excellence as Key to Improving Operations," Manufacturing & Service Operations Management, INFORMS, vol. 8(1), pages 5-22, March.
    4. Jeffrey M. Alden & Lawrence D. Burns & Theodore Costy & Richard D. Hutton & Craig A. Jackson & David S. Kim & Kevin A. Kohls & Jonathan H. Owen & Mark A. Turnquist & David J. Vander Veen, 2006. "General Motors Increases Its Production Throughput," Interfaces, INFORMS, vol. 36(1), pages 6-25, February.
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    Cited by:

    1. Özkan, Erhun & Tan, Barış, 2025. "Asymptotically optimal energy consumption and inventory control in a make-to-stock manufacturing system," European Journal of Operational Research, Elsevier, vol. 320(2), pages 375-388.
    2. Seokgi Lee & Mona Issabakhsh & Hyun Woo Jeon & Seong Wook Hwang & Byung Chung, 2020. "Idle time and capacity control for a single machine scheduling problem with dynamic electricity pricing," Operations Management Research, Springer, vol. 13(3), pages 197-217, December.
    3. Junfeng Wang & Zicheng Fei & Qing Chang & Shiqi Li, 2019. "Energy Saving Operation of Manufacturing System Based on Dynamic Adaptive Fuzzy Reasoning Petri Net," Energies, MDPI, vol. 12(11), pages 1-17, June.
    4. Alberto Loffredo & Marvin Carl May & Andrea Matta & Gisela Lanza, 2024. "Reinforcement learning for sustainability enhancement of production lines," Journal of Intelligent Manufacturing, Springer, vol. 35(8), pages 3775-3791, December.
    5. Viktor Ložar & Neven Hadžić & Tihomir Opetuk & Vedran Slapničar, 2021. "Accuracy of Semi-Analytical and Numerical Approaches in the Evaluation of Serial Bernoulli Production Lines," Mathematics, MDPI, vol. 9(13), pages 1-25, June.
    6. Junfeng Wang & Yaqin Huang & Qing Chang & Shiqi Li, 2019. "Event-Driven Online Machine State Decision for Energy-Efficient Manufacturing System Based on Digital Twin Using Max-Plus Algebra," Sustainability, MDPI, vol. 11(18), pages 1-17, September.
    7. Peiqi Yang & Zhi Pei, 2022. "Energy-Saving Manufacturing System Design with Two Geometric Machines," Sustainability, MDPI, vol. 14(18), pages 1-21, September.
    8. Wen-Hsien Tsai & Yin-Hwa Lu, 2018. "A Framework of Production Planning and Control with Carbon Tax under Industry 4.0," Sustainability, MDPI, vol. 10(9), pages 1-24, September.

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