Application of a novel approach of production system modelling, analysis and improvement for small and medium-sized manufacturers: a case study

References

• Alavian, P., P. Denno, and S. M. Meerkov. 2017. “Multi-Job Production Systems: Definition, Problems, and Product-Mix Performance Portrait of Serial Lines.” International Journal of Production Research 55 (24): 7276–7301.
   Web of Science ®Google Scholar
• Ambani, S., S. M. Meerkov, and L. Zhang. 2010. “Feasibility and Optimization of Preventive Maintenance in Exponential Machines and Serial Lines.” IIE Transactions 42 (10): 766–777.
   Web of Science ®Google Scholar
• Anish, R., and K. Shankar. 2020. “Identification of Nonlinear Structural Parameters Using Combined Power Flow and Acceleration Matching Approaches.” In Advances in Mechanical Engineering, 1139–1149. Singapore: Springer.
   Google Scholar
• Arinez, J., S. Biller, S. M. Meerkov, and L. Zhang. 2009. “Quality/Quantity Improvement in an Automotive Paint Shop: A Case Study.” IEEE Transactions on Automation Science and Engineering 7 (4): 755–761.
   Web of Science ®Google Scholar
• Bai, Y., J. Tu, M. Yang, L. Zhang, and P. Denno. 2021. “A New Aggregation Algorithm for Performance Metric Calculation in Serial Production Lines with Exponential Machines: Design, Accuracy and Robustness.” International Journal of Production Research 59 (13): 4072–4089.
   Web of Science ®Google Scholar
• Bertsekas, D. P. 2016. Nonlinear Programming. Belmont, MA: Athena Scientific.
   Google Scholar
• Biller, S., J. Li, S. P. Marin, S. M. Meerkov, and L. Zhang. 2009. “Bottlenecks in Bernoulli Serial Lines with Rework.” IEEE Transactions on Automation Science and Engineering 7 (2): 208–217.
   Web of Science ®Google Scholar
• Biller, S., S. P. Marin, S. M. Meerkov, and L. Zhang. 2008. “Closed Bernoulli Production Lines: Analysis, Continuous Improvement, and Leanness.” IEEE Transactions on Automation Science and Engineering 6 (1): 168–180.
   Web of Science ®Google Scholar
• Biller, S., S. M. Meerkov, and C.-B. Yan. 2013. “Raw Material Release Rates to Ensure Desired Production Lead Time in Bernoulli Serial Lines.” International Journal of Production Research 51 (14): 4349–4364.
   Web of Science ®Google Scholar
• Chen, G., L. Zhang, J. Arinez, and S. Biller. 2012. “Energy-Efficient Production Systems Through Schedule-Based Operations.” IEEE Transactions on Automation Science and Engineering 10 (1): 27–37.
   Web of Science ®Google Scholar
• Chiang, S.-Y., A. Hu, and S. M. Meerkov. 2008. “Lean Buffering in Serial Production Lines with Nonidentical Exponential Machines.” IEEE Transactions on Automation Science and Engineering 5 (2): 298–306.
   Web of Science ®Google Scholar
• Cox, M. G. 1990. “Mathematical Modelling in Manufacturing Metrology.” In Proceedings of the Twenty-Eighth International, 533–539. New York, NY: Springer.
   Google Scholar
• Du, S., R. Xu, and L. Li. 2016. “Modeling and Analysis of Multiproduct Multistage Manufacturing System for Quality Improvement.” IEEE Transactions on Systems, Man, and Cybernetics: Systems 48 (5): 801–820.
   Web of Science ®Google Scholar
• Feng, Y., X. Zhong, J. Li, and W. Fan. 2018. “Analysis of Closed-Loop Production Lines with Bernoulli Reliability Machines: Theory and Application.” IISE Transactions 50 (3): 143–160.
   Web of Science ®Google Scholar
• Gershwin, S. B. 1994. Manufacturing Systems Engineering. Englewood Cliff, NJ: Prentice Hall.
   Google Scholar
• Jia, Z., and L. Zhang. 2019. “Serial Production Lines with Geometric Machines and Finite Production Runs: Performance Analysis and System-theoretic Properties.” International Journal of Production Research 57 (8): 2247–2262.
   Web of Science ®Google Scholar
• Jia, Z., L. Zhang, J. Arinez, and G. Xiao. 2015. “Finite Production Run-Based Serial Lines with Bernoulli Machines: Performance Analysis, Bottleneck, and Case Study.” IEEE Transactions on Automation Science and Engineering 13 (1): 134–148.
   Web of Science ®Google Scholar
• Jia, Z., L. Zhang, J. Arinez, and G. 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 54 (21): 6285–6301.
   Web of Science ®Google Scholar
• Ju, F., J. Li, and W. Deng. 2016. “Selective Assembly System with Unreliable Bernoulli Machines and Finite Buffers.” IEEE Transactions on Automation Science and Engineering 14 (1): 171–184.
   Web of Science ®Google Scholar
• Kim, D., S. Sra, and I. S. Dhillon. 2010. “Tackling Box-Constrained Optimization Via a New Projected Quasi-Newton Approach.” SIAM Journal on Scientific Computing 32 (6): 3548–3563.
   Web of Science ®Google Scholar
• Li, J. 2013. “Continuous Improvement at Toyota Manufacturing Plant: Applications of Production Systems Engineering Methods.” International Journal of Production Research 51 (23–24): 7235–7249.
   Web of Science ®Google Scholar
• Li, J., and S. M. Meerkov. 2009. Production Systems Engineering. New York, NY: Springer Science Business Media.
   Google Scholar
• Liberopoulos, G., and P. Tsarouhas. 2005. “Reliability Analysis of an Automated Pizza Production Line.” Journal of Food Engineering 69 (1): 79–96.
   Web of Science ®Google Scholar
• Lima, A. N., C. B. Jacobina, and E. B. de Souza Filho. 1997. “Nonlinear Parameter Estimation of Steady-State Induction Machine Models.” IEEE Transactions on Industrial Electronics 44 (3): 390–397.
   Web of Science ®Google Scholar
• Liu, Y., J. Li, and S.-Y. Chiang. 2010. “Performance Approximation of Re-Entrant Lines with Unreliable Exponential Machines and Finite Buffers.” The International Journal of Advanced Manufacturing Technology 49 (9–12): 1151–1159.
   Web of Science ®Google Scholar
• Liu, X., W. Wang, and R. Peng. 2015. “An Integrated Production, Inventory and Preventive Maintenance Model for a Multi-product Production System.” Reliability Engineering & System Safety 137: 76–86.
   Web of Science ®Google Scholar
• Liu, Y., Q. Zhang, Z. Ouyang, and H.-Z. Huang. 2021. “Integrated Production Planning and Preventive Maintenance Scheduling for Synchronized Parallel Machines.” Reliability Engineering & System Safety 215: 107869.
   Web of Science ®Google Scholar
• Meerkov, S. M., and C.-B. Yan. 2014. “Production Lead Time in Serial Lines: Evaluation, Analysis, and Control.” IEEE Transactions on Automation Science and Engineering 13 (2): 663–675.
   Web of Science ®Google Scholar
• Nocedal, J., and S. Wright. 2006. Numerical Optimization. New York, NY: Springer Science & Business Media.
   Google Scholar
• Nwika, C. A., G. Umoh, and F. B. Amaewhule. 2017. “A Method of Reliability Estimation of Individual Section Machine (IS) of Glass Manufacturing Facility; a Systematic Approach with Exponential Model, Availability and Mean Time Between Failures.” International Journal of Emerging Technologies in Engineering Research 5: 126–131.
   Google Scholar
• Papadopoulos, H. T., C. Heavy, and J. Browne. 1993. Queueing Theory in Manufacturing Systems Analysis and Design. London, UK: Chapman & Hill.
   Google Scholar
• Park, K., and J. Li. 2019. “Improving Productivity of a Multi-Product Machining Line at a Motorcycle Manufacturing Plant.” International Journal of Production Research 57 (2): 470–487.
   Web of Science ®Google Scholar
• Peri, D., and F. Tinti. 2012. “A Multistart Gradient-Based Algorithm with Surrogate Model for Global Optimization.” Communications in Applied and Industrial Mathematics 3 (1): 1–22.
   Google Scholar
• Reddy, T. A., and K. K. Andersen. 2002. “An Evaluation of Classical Steady-State Off-Line Linear Parameter Estimation Methods Applied to Chiller Performance Data.” Hvac&R Research 8 (1): 101–124.
   Web of Science ®Google Scholar
• Schmidt, M., D. Kim, and S. Sra. 2012. “Projected Newton-Type Methods in Machine Learning.” In Optimization for Machine Learning. Vol. 1. Cambridge, MA: The MIT Press.
   Google Scholar
• Sun, Y., and L. Zhang. 2020. “Parameter Identification for Multiple-Machine Bernoulli Lines Using Statistical Learning Methods.” In 2020 IEEE 16th International Conference on Automation Science and Engineering (CASE). IEEE.
   Google Scholar
• Sun, Y., and L. Zhang. 2021. “Parameter Identification for Synchronous Two-Machine Exponential Production Line Model.” In 2021 IEEE 17th International Conference on Automation Science and Engineering (CASE), 1884–1889. IEEE.
   Google Scholar
• Sun, Y., T. Zhu, L. Zhang, and P. Denno. 2020. “Parameter Identification for Bernoulli Serial Production Line Model.” IEEE Transactions on Automation Science and Engineering 18 (4): 2115–2127.
   Web of Science ®Google Scholar
• Tu, J., Y. Bai, M. Yang, L. Zhang, and P. Denno. 2020. “Real-time Bottleneck in Serial Production Lines with Bernoulli Machines: Theory and Case Study.” IEEE Transactions on Automation Science and Engineering 18 (4): 1822–1834.
   Web of Science ®Google Scholar
• Tu, J., and L. Zhang. 2022. “Performance Analysis and Optimisation of Bernoulli Serial Production Lines with Dynamic Real-time Bottleneck Identification and Mitigation.” International Journal of Production Research 1–17. doi:10.1080/00207543.2021.2019343.
   Web of Science ®Google Scholar
• Tu, J., T. Zhu, Y. Bai, and L. Zhang. 2020. “Estimation of Machine Parameters in Exponential Serial Lines using Feedforward Neural Networks.” In 2020 IEEE 16th International Conference on Automation Science and Engineering (CASE). IEEE.
   Google Scholar
• Wang, F., and F. Ju. 2021. “Decomposition-Based Real-Time Control of Multi-Stage Transfer Lines with Residence Time Constraints.” IISE Transactions 53 (9): 943–959.
   Web of Science ®Google Scholar
• Weston, B. 2019. “How Small Manufacturing Businesses Drive the U.S. Economy.” https://www.score.org/blog/how-small-manufacturing-businesses-drive-us-economy.
   Google Scholar
• Xie, X., and J. Li. 2012. “Modeling, Analysis and Continuous Improvement of Food Production Systems: A Case Study at a Meat Shaving and Packaging Line.” Journal of Food Engineering 113 (2): 344–350.
   Web of Science ®Google Scholar
• Yan, C.-B., and Q. Zhao. 2013. “A Unified Effective Method for Aggregating Multi-Machine Stages in Production Systems.” IEEE Transactions on Automatic Control 58 (7): 1674–1687.
   Web of Science ®Google Scholar
• Yao, D. D. 1994. Stochastic Modeling and Analysis of Manufacturing Systems. New York, NY: Springer-Verlag.
   Google Scholar
• Zandieh, M., M. Joreir-Ahmadi, and A. Fadaei-Rafsanjani. 2017. “Buffer Allocation Problem and Preventive Maintenance Planning in Non-Homogenous Unreliable Production Lines.” The International Journal of Advanced Manufacturing Technology 91 (5-8): 2581–2593.
   Web of Science ®Google Scholar
• Zhang, L., and X. Yue. 2011. “Operations Sequencing in Flexible Production Lines with Bernoulli Machines.” IEEE Transactions on Automation Science and Engineering 8 (3): 645–653.
   Web of Science ®Google Scholar
• Zhao, C., and J. Li. 2013. “Analysis of Multiproduct Manufacturing Systems with Homogeneous Exponential Machines.” IEEE Transactions on Automation Science and Engineering 11 (3): 828–838.
   Web of Science ®Google Scholar
• Zhao, C., and J. Li. 2015. “Analysis and Improvement of Multiproduct Bernoulli Serial Lines: Theory and Application.” IEEE Transactions on Systems, Man, and Cybernetics: Systems 45 (9): 1218–1230.
   Web of Science ®Google Scholar
• Zhao, C., J. Li, and N. Huang. 2014. “Performance Evaluation of Multi-Product Manufacturing Systems with Asynchronous Exponential Machines.” In 2014 IEEE International Conference on Automation Science and Engineering (CASE), 692–697. IEEE.
   Google Scholar