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PROCESS U N R E L I A E I L I ~ Y
Menberu Lulu
University of South Florida
ABSTRACT.
T h e effects of process unreliab{,l,~ty on the p e r f o r m a n c e of a simulation m o d e ~ of a Just-in-Time Production and M a n u f a c t u r i n g System (J!TMPS) is investigated.
In a m u l t i - c o m p o n e n t - f a b r i c a t i o n and product-assembly environment,
a relatively lowe~ ]~e~e~ of fabrication process unreliability results in a pronou~ced level of lowered s y ~ e ~ utilization.
Work-in-Process inventory-induced
gains in p~o.d~tion rates in ~he: J I ~ P S a~re ~ t a s
si~mi~_~a~ a~ ma~ee~~.is-io~ed~ i~ ~r~dit/uD~al p r o d ~ c t i ~ s y s t e m s that e s ~ e m ~ - ~ e ~ r a ~ e ~ d e r
"~as~
INTRODUCTION
The o~erational objective of the Just-in-Time M ~ a c ~ [ i ~
System
Pr~l~ction
a~
Denning - USA)
and in systems-based
prod~ction--cellular manufacturing
(Group TechnoIogy)
(most notably:
[i.e.
and
rat~o.al~zation of batch
~mporta~
manufacturing system.
Quality control,
The p n e d ~ t ~
these are
a~
c~erol.
The
JITMPS management approach and the cellular structure of ~ts manufacturing systems haue generated new forms of worker organization,
[5].
AnnualSimulation Symposinm/~
2'3T
q~sality im-
238
LULU
In the "Pull System" of production control,
these parts,
for a
(i.e.,
the preceding process obtains the necessary parts from the process
further preceding
it.
(nonautomated)
implementa-
(cart).
ing process, and the "Production Kanban" that is utilized to order production of
the portion withdrawn by the succeeding process.
detailed explanation of the Kanban system.
See references
[3,5,7]
for
processes links the activities of the final process to the remaining preceding
processes.
This chain-linking
fluctuation at
the preceding n-i production stages equals that of the last stage.
in each of
Kim
[i]
analyzed an operating policy for JIT production called Periodic Pull System
(PPS).
intervals.
Consequently,
flow at all
that has been consumed at a succeeding stage since the last review time
is allowed to be Withdrawn.
processing of information
information processing.
PROBLEM DESCRIPTION
In a Kanban-linked JITMPS, when a breakdown occurs at a preceding cell
(process),
cell
As a consequence,
Furthermore,
Similarly,
a breakdown at a succeed-
ing stage delays movement of conveyance Kanbans to the output stock point of a
preceding cell.
ing cell.
This,
in the preced-
JUST-IN-TIME
production
due to blocking
conveyance
Kanban movements
responding
absence
processes
production
higher
stages
production
Instead
[6].
of adding
deliberately
irregularity.
managers
continually
perfecting
is that WIP
inventory
This paper
utilization
buffer
their
stocks
correct
guo;
problems
stage)
absence
induce a cor-
buffer
in higher
the causes
or rather,
WIP
thesis
of
JIT production
of production
irregularity,
to settle
becomes
the
into a
one of
is caused by
inventory.
allowed
the pattern
The
between
the maintenance
of a recent
are never
stocks
that
of irregularity,
process.
cycle
of
guarantees
results
The workers
Hence,
irregularity
approach
on investigating
(production
will
the production
hides
processes
239
production.
at points
the work
of the status
focuses
The eventual
production
it nevertheless
inventory.
pattern
single process
While
comfortable
cell.
against
expose
remove more
UNRELIABILITY
Kanban movements.
managers
rates,
PROCESS
the upstream
from further
to protect
unreliability
managers
between
of production
production
AND
by the succeeding
will be prevented
Western
process
PRODUCTION
irregularity.
unreliability
performance.
of a
System
as measures
of system
JITMPS model
(see Figure
i) constitutes
performance.
SIMULATION
MODEL DESCRIPTION
Structure
The structure
microcosm
assembly
of the hypothetical
of a manufacturing
cell.
Within
Stock
ing to be processed
are waiting
control
cell.
Point
to be conveyed
process.
inventories
(OSP).
Kanbans
(CKs)
stages
that
link all
correspondence
are directly
part
Production
control
cell
cells
Stock
and an
Point
(ISP)
inventories
Kanbans
that
(PKs)
and
facilitate
the m o v e m e n t
processes
is isomorphic;
Input
inventories
inventories
part
cell.
of part
of the fabrication
more
is one
representation
of two fabriction
there
the movement
Conveyance
cell
to the succeeding
The model
It consists
fabrication
in the cell.
and facilitate
responding
of part
each
system.
is homomorphic;
each
the modeling
the three-stage
linked.
i.e.,
(Si,
$2, $3)
JITMPS.
Note
240
LULU
RMSP
ISPI
OSPI
~fiP2'
FABRICATION CELL
OSP2
FABRICATION CELL
...............................
PRODUCTION, SCHEDULE
:'............................................i
,~.....
A~'A
-L-
PRODUCT
'
Ii
I
ISP
.I
ASSE~BLY CELL
-I
{....................................................
sl, $2, $3
~-~-~4h.
~ : ~
__ . ~
~
ItMSP
ISP
OS9
The
system
component
2.
A product
and four
%
at S3.
CONVEYANCE KANBANS
PRODUCTION KANBANS
WORKPIECE FLOW
SUBASSEMBLY FLOW
RAW MATERIAL STOCK POINT
I~IPUT ZTQCK POINT
OUTP.U~STOCK ~OINT
produces
types,
identified
Component
Figure i.
product
that
one
is a s s e m b l e d
of
ASSEMBLY ST/LC~ES
as
A,
from
Type
one
C.
and
of
is
is a s s e m b l e d
C,
that
are
Component
added
at
three
fabricated
Type
SI~ ~
from
A,
is
different
in C e l l
i and
two
of
Component
added
at
$2,
and
Cell
Type
C
:B,
is a d d e d
Operation
As
is
the
facility
that
schedule
is
unctiom
for
For
tions
When
is
with
the
at
is
S3,
entire
assembly
be
"pull
scheduled
received
an
must
case
the
the
production
last
assembly
Kanhas
system
control,
state
ca{xies
the
(S3).
out
only
Once
the
prod~uction
a production
production
control
system.
operation
to c o m m e n c e
at
any
stage,
the
following
two
condi-
met.
I)
A finished
subassembly
2)
Parts
must
be
added
on
these
system"
two
must
available,
a preceding
in a s s e m b l y
to a s u b a s s e m b l y
conditions
be at
from
are met,
assembly
requirement
a precedi,g
assembly
stage.
quantity~
ready
to
be
stage.
operation
commences
at
a succeedLng
stage.
Since
tially,
aa
a product
assembly
a fabrication
rate
unit t i m e .
The
fabriction
times
units
of
requires
rate
of
one
of
one
unit
corresponding
Component
for
C.
one
In
the
unit
this
three
unit
of
A,
assembly
of
part
of
product
two
units
cycle
Component
study,
types
A,
that
per
are
fabricated
unit
time
mnst
units
of
B,
and
four
time
is
set
to b e
two
units
Work-in-Process
the
correspond
of
C,
per
sum
of
the
of Component
(WIP)
inventory
sequen-
B~
&o
ar~/] ~ a u r
is m e a s u r e d
JUST-IN-TIME
i~ A s s e m b l y
unit
Units
of p r ~ . u c t ;
(AU) .
PRODUCTION
One
a Kanban-linked
JITMPS
of p r o d u c t
will
not f u n c t i o n
of p r o d u c t
at each
each
inventory
Failure
(Figure
model,
part
WIP
inventory
of a m i n i m u m
corresponding
level.
statement
level W I P
to a s i n g l e
The K a n b a n
system
This minimum
U I T M P S ~structure.
inventories
is p u l l e d
To b e o p e r a t i o n a l ,
at e a c h s t o c k p o i n t .
component
stock point
inventory
inventory.
inventories
the f o l l o w i n g
with
model,
of A,
Hence,
inven-
with
is a p p r o p r i a t e .
corresponding
is a ~ z e r o - i n v e n t o r y Dr m i n i m u m
stock
zero
Types
two u n i t s
point.
"Zero
to one
(I)
inventory
inventory
corresponds to
A, B and C, w i t h
of B and
four
inventory"
units
probability
i) are set
is 36 m i n u t e s
parameters
to zero.
of C,
of part
with
of
inven-
respectively,
at
"lotless
(one p r o d u c t
~he
cycle
Process
2, f a i l u r e
c:ell d o w n t i m e
time).
1 and a s s e m b l y ~ t a g e s
(Td)
of a c o m p o n e n t .
per
assembly
Td
= 36 min.
per
failure,
WIP
inventory
failures
and WIP
conEigur~tio~
representing
inventory
was run
2 render
were
15,
yielded
an a v e r a g e
constitutes
a two-factor
failure
fa:~lure o c c u r s
unit
15,
30)
AU
mode'l ~toch~s~kc~.
combinations
~n~
of levels
replicated ~
of 7 2 <Observations.
factorial
each
~A t ~ t a l
design.
Thus
Each m o d e l
t~ime~..
~adh
the e x p e r i m e n t a l
The ~WIP i n v e n t o r y
factor
of
of process
in the simulat~ion e x p e r i m e n t .
500Z simulated, m i n u t e s
replication
10,
the J I T M P S
specific
used
dbat ~ r o c e s
(p) of ~.i,
0.3)
:= (0, 5, 10,
of P r o c e s s
configurations
0.2,
with
S2 and
Specifically,
= 36 min.
(0.1,
Si,
probabilities
associated
It is a s s u m e d
P r o c e s s :cycle t i m e
reliability
a capacity
is s y n o n y m o u s
for P r o c e s s
For
Random
the al~location
of M o d e l ~a~ramete~s
27 m o d e l
upstream
[5].
Specification
0.2
line,
inventory
for c o m p o n e n t
of one unit
production"
~3
(i)
system.
three c a r t s
each
control,
by d o w n s t r e a m
the m i n i m u m
JITMPS
In the h y p o t h e t i c a l
tories
'for one
of p r o d u c t .
of the K a n b a n - L i ~ k e d
te the h y p o t h e t i c a l
production
requirements
a sys~tem-wide a l l o c a t i o n
product
without WIP
A Kanhan-linked
unit
processes
constitute
is an e l e m e n t
.one unit
of p r o d u c t i o n
requires
In a s i n g l e
unit
regard
system
the m a n u f a c t u r i n g
tory level
to p a r t
241
i.e.,
In the K a n b a n
inventory.
PROOE~iUNREL~A~ILIT~
(i) AU c o r r e p o n d s
1 AU E iA + 2B + ~C~E
through
AND
design
is at s e v e n
242
LULU
levels
levels
(0.9,
0.8,
0.7)
per 36-minute
1 utilization
(pl),
b)
Cell
3 utilization
(p3),
c)
Product
cycle
EXPERIMENTAL
EFFECT OF WIP
INVENTORY
1 reveals
When
inventory
For WIP
unchanged
tests)
on the analysis
Model
showed
used are:
adequacy
of variance
checks
(fixed ef-
(normal p r o b a b i l i t y
variance.
LEVEL ON AVERAGE
that,
of WIP
the WIP
Performance measures
AND ANALYSES
ing function
remains
are based
RESULTS
is at three
(Tc).
- two-way classification).
with mean
minutes.
time
analyses
and h o m o s c e d a s t i c i t y
Table
cycle.
Cell
fects model
tributed
a)
The statistical
plots
30 AOs)
for a given
inventory.
level
inventory
is lowered
the curve
of WIP
problems
15 AU
The jumps
can be equated
hidden
(20,
25,
Table
(see Figure
from 72.65
30),
2).
to 78.95
the value of T
to the exposing
by WIP
T c is a nonincreas-
for R = 0.8
to 15 AU, T c jumps
levels beyond
lowering
TIME
level of reliability,
Consider
at 72.65 minutes.
inventory
PRODUCT CYCLE
of process
with
reliability
inventory.
stochastic
justified
30
36
36
36
60.94
57.14
57.14
57.14
57.14
57.14 57.14
84.70
78.95
78.95
72.65
72.65
72.65 72.65
I[05.59 I00.~i
93.46
93.46
87.48
87.48 87.48
R = 0.9
R = 0.8
in T c from 36 minutes
of the component
processes
25
36
20
15
36
36
increase
i0
Inventory
36
R = 1.0
R = 0.7
The large
the reader.
requirement
that result
the corresponding
large
to 84.70 minutes
However,
for assembly
from failure
increase
as discussed
as R is lowered
below,
in conjunction
probability
in product
with
an exthe
cycle
time,
the
T c.
2,
JUST-IN-TIME
PRODUCTION
AND PROCESS
UNRELIABILITY
105.59
I00.01
93.46
I R = 0.7
87.48
85.56
84.70
%
78.95
E
Rffi0.8
72.65
60.94 -.
R = 0.9
57.14
Ideal T
R=
1.0
36.0
O. 0---[0
2 .
243
244
LULU
To a s s e m b l e
fabricate
and 4 units
during
one-.uni~t of "product
of C o m p o n e n t
component
C,
in:.exac~l~y 36 minutes..
fab~rica~i~n;, ~the a c ~ u a ~
components
tion
cyc'le ~t~mes
process
w o u l d .result
x process~ failures
components
and
the
fabricat'ion
(7-x)
process
can be cacula~ed,
Table
of
lerrg~hening
Basedi on t h e
off a component~,
~fai'lures
and
correspo'nding
of a c t u a l
assumption
-fabrica-
of o n e
:fabribs~ti~)n o f
distribut.ibn,
the- sev.en~
i.e.,
fa~ilu~es)
act~a-l" f~br!i~e~tion
Table
Eail.uKe D i s t r i b u t i o n
is len~the%ne~ ,13,y.
t h e :pr.o'b~ab~:li1~y o f . e a a c t l y
~ne'nfailures d u r i n g
pzocess
2_ 9aiil,s o n c e
cy~clie~ t i m e
P ,(off e.xaCtly~ x m a c h i n e
f_ai,lu~..u~during '~.ro-d,uc.cri~n,o ~ - t h e s e
in a co~Tre.sponding
failu.r~e~dhring
.If R r o c e s ~
f~l~i~a~tion
must
cycle
times
in
Cell
2.
and Corresponding
-4
!5
-6
P'(N = x)
I
__
36 1
TF
The
resul~ting avemage
E [ T F]
Note
and
0).,
the
256 I, 292
= 88.84.
the c l o s e n e s s : of t h e
88.84-minu,d~
average
theoretical
fabr:i~ation
,t;/Tme (:see T a b l e
seeming~l,~ , ~n~Idina~ce
_Z,~ ~R =
cycle
time
0.8, W I P
failure
free,
can
Cell
dictated
Two
by
(fabrication
under
the
.s~st.~m i m p o s e s
cell)
and
theoretical
Cell
cycle
(assembly
,time o ~
ce'll)~, b e i n s
3~ m i n u t e s
t h e .slowes~t J~ITMP.S c e l l .
aspects
JITMPS
operate
However,. t h e K a n D a n
the
fabriica%i~owcye%/e-.t~ime, l.s.:.
Besi~]es_ verii~yi!~ ~ h e
system
76
o~ the p r a c t i c a T
limit
of WIP-ir~%aced
T c reducti;ons
are:
in
per
w~de,
AU.
as
3UST-IN-TIME
1.
For a given
beyond
in T
2.
!eve1 of reliability,
a certain
level does
R, i n c r e a s i n g
not result
245
UNRELIABILITY
the W I P
inventory
in c o r r e s p o n d i n g
decreases
These observed
levels
average
tion control.
AND P R O C E S S
PRODUCTION
product
inventory
cycle
RELIABILITY
The utilization
factors
induced by various
inventory.
Figure
3 is
the g a p b e t w e e n
times
be c l o s e d
cannot
by in-
a r e d u e to " p u l l s y s t e m "
is f u r t h e r a n a l y z e d
AND WIP
in T a b l e
utilization
reliability,
i n t o the s y s t e m .
system characteristics
This phenomenon
EFFECTS OF PROCESS
of process
INVENTORY
3 reflect
l e v e l s of p r o c e s s
corresponding
produc-
in t h e n e x t s e c t i o n .
ON S Y S T E M U T I L I Z A T I O N
actual
differences
reliability
i.
p l o t of the d a t a
in cell
(Process
Table
3.
2) and W I P
Table 3
Cell Utilization Factors
10
15
20
25
30
Cell 1
1.0
1.0
1.0
1.0
1.0
1.0
1.0
I.Q
1.0
1.0
1.0
1.0
i.0
1.0
Cell 1
.60
.60
.60
.60
.60
.60
.60
.60
.62
.62
.62
.62
.62
.62
Cell 1
.42
.42
.42
.42
.42
.42
.42
Cell 3
.42
.45
.45
.47
.50
.50
.50
Cell
.34
.34
.34
34
.34
34
.34
Cell
.34
.35
.38
40
.42
WIP Inventory +
R=
1.0
Cell
R=0.9
Cell
R=0.8
R=
The
following
I.
Cell
utilization
A 10% d e c r e a s e
decreases
in R c a u s e s
Utilization
.40
.40
are r e v e a l e d :
rapidly
as the r e l i a b i l i t y
a 40% d e c r e a s e
'
0.7
level d e c r e a s e s .
in u t i l i z a t i o n
-- r e f e r
to
(Table 3).
of C e l l
I is i n d e p e n d e n t
factors
for C e l l
of the W I F
inventory
level
in the
system.
3.
Utilization
increases.
A 23.5%
increasing
WIP
increase
inventory
3 improve
somewhat
in u t i l i z a t i o n
by 600%
(0 to 30)
as W I P
{34 to 42)
-- r e f e r
(Table 3).
oi~:
inventory
is o b t a i n e d
to R = 0.7,
by
Cell
246
LULU
R=I.0
1.0
Cell 3
KEY:
Cell I
o
Iq
-4
-,~
R=0.9
R_ = 0_.9_
0;60
0.50
0.47
0.45
R = 0.8~
R=0.8
----_
0.42
0.40
R=0.71
0.38
[
0.34
R=
0.7
0.0
Figure
3.
1"0
15
20
2'5
30
J U S T - I N - T I M E P R O D U C T I O N AND P R O C E S S U N R E L I A B I L I T Y
247
total cell
Cell
1 utilization factors
Cell 2 (OSP2), components are moved to the input stock point of the assembly cell
(ISPA). Simultaneously, a corresponding production Kanban is dispatched
Process 2.
to
Therefore,
inference is
presented.
Given a process subject to random failures, WIP inventory does not effect
production rate increases in preceding cells.
does effect production rate increases
in succeeding cells.
A 0.2 unreliability value for Process 2 (see Figure 2, R = 0.8, WIP = 0 AU)
results in a 0.42 system utilization.
unreliability
operation
T d increases
(decreases).
increase
(decrease)
in a multicomponent
environment.
Hence, a 0.2
as
248
LULU
Also,
clusively
the research
findings
reported
improvements.
This
leaves
(preventive maintenance)
in assuring
higher
and analyzed
has minimal
the m i n i m i z a t i o n
and process
in this chapter
impact on system
of the likelihood
downtime
as decisive
con-
utilization
of process
failures
andsignificant
factors
system utilization.
CONCLUSION
If an individual
inventory
process
effect
process
increases
unreliability,
that essentially
system
process
tion
operate
processes,
in the system's
the d o w n s t r e a m
lower
level
level of lowered
production
for a given
beyond
which
rates
(decreases
as may be envisioned
production
in upstream
if these processes
in WIP
level
increases
in production
of
in WIP
rates.
in product
cycle
in traditional
control.
processes
production
fabrication
of fabrication
system
MPS
The Kanban
preceding
produc-
Observed
of WIP
and product
process
utilization.
the injection
exists
increases
inventory
in
processes.
In a m u l t i c o m p o n e n t
tively
failure,
However,
increases
system"
production
is idled by failure.
in downstream
increases
under "push
prevents
rates.
in production
ar not as significant
automatically
that
gains
to random
threshold
in corresponding
WIP inventory-induced
in the JITMPS
in production
a practical
time)
is subject
assembly
unreliability
The principal
process downtime
environment,
results
factors
in a pronounced
enhancing
and preventive
inventory.
a rela-
the JITMPS
maintenance,
not
249
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553-562.
2.
Kimora, O., and Terada, H., "Design and Analysis of Pull System,"
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PA, 1982.
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