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Recent advances in manufacturing system, such as advanced embedded sensing, big data analytics and IoT and robotics, are promising a paradigm shift in the manufacturing industry towards smart manufacturing systems. Typically, real-time data is available in many industries, such as automotive, semiconductor, and food production, which can reflect the machine

Recent advances in manufacturing system, such as advanced embedded sensing, big data analytics and IoT and robotics, are promising a paradigm shift in the manufacturing industry towards smart manufacturing systems. Typically, real-time data is available in many industries, such as automotive, semiconductor, and food production, which can reflect the machine conditions and production system’s operation performance. However, a major research gap still exists in terms of how to utilize these real-time data information to evaluate and predict production system performance and to further facilitate timely decision making and production control on the factory floor. To tackle these challenges, this dissertation takes on an integrated analytical approach by hybridizing data analytics, stochastic modeling and decision making under uncertainty methodology to solve practical manufacturing problems.

Specifically, in this research, the machine degradation process is considered. It has been shown that machines working at different operating states may break down in different probabilistic manners. In addition, machines working in worse operating stage are more likely to fail, thus causing more frequent down period and reducing the system throughput. However, there is still a lack of analytical methods to quantify the potential impact of machine condition degradation on the overall system performance to facilitate operation decision making on the factory floor. To address these issues, this dissertation considers a serial production line with finite buffers and multiple machines following Markovian degradation process. An integrated model based on the aggregation method is built to quantify the overall system performance and its interactions with machine condition process. Moreover, system properties are investigated to analyze the influence of system parameters on system performance. In addition, three types of bottlenecks are defined and their corresponding indicators are derived to provide guidelines on improving system performance. These methods provide quantitative tools for modeling, analyzing, and improving manufacturing systems with the coupling between machine condition degradation and productivity given the real-time signals.
ContributorsKang, Yunyi (Author) / Ju, Feng (Thesis advisor) / Pedrielli, Giulia (Committee member) / Wu, Teresa (Committee member) / Yan, Hao (Committee member) / Arizona State University (Publisher)
Created2020
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Description
Modern manufacturing systems are part of a complex supply chain where customer preferences are constantly evolving. The rapidly evolving market demands manufacturing organizations to be increasingly agile and flexible. Medium term capacity planning for manufacturing systems employ queueing network models based on stationary demand assumptions. However, these stationary demand assumptions

Modern manufacturing systems are part of a complex supply chain where customer preferences are constantly evolving. The rapidly evolving market demands manufacturing organizations to be increasingly agile and flexible. Medium term capacity planning for manufacturing systems employ queueing network models based on stationary demand assumptions. However, these stationary demand assumptions are not very practical for rapidly evolving supply chains. Nonstationary demand processes provide a reasonable framework to capture the time-varying nature of modern markets. The analysis of queues and queueing networks with time-varying parameters is mathematically intractable. In this dissertation, heuristics which draw upon existing steady state queueing results are proposed to provide computationally efficient approximations for dynamic multi-product manufacturing systems modeled as time-varying queueing networks with multiple customer classes (product types). This dissertation addresses the problem of performance evaluation of such manufacturing systems.

This dissertation considers the two key aspects of dynamic multi-product manufacturing systems - namely, performance evaluation and optimal server resource allocation. First, the performance evaluation of systems with infinite queueing room and a first-come first-serve service paradigm is considered. Second, systems with finite queueing room and priorities between product types are considered. Finally, the optimal server allocation problem is addressed in the context of dynamic multi-product manufacturing systems. The performance estimates developed in the earlier part of the dissertation are leveraged in a simulated annealing algorithm framework to obtain server resource allocations.
ContributorsJampani Hanumantha, Girish (Author) / Askin, Ronald (Thesis advisor) / Ju, Feng (Committee member) / Yan, Hao (Committee member) / Mirchandani, Pitu (Committee member) / Arizona State University (Publisher)
Created2020