A simulation optimization based control policy for failure prone one-machine, two-product manufacturing systems

  • Authors:
  • J. P. Kenne;A. Gharbi

  • Affiliations:
  • Department of Mechanical Engineering, Ecole de Technologie Superieure, University of Quebec, 1100 Notre Dame Ouest, Montreal, Que., Canada H3C 1K3;Department of Automated Production Engineering, Production Systems Design and Control Laboratory, Ecole de Technologie Superieure, University of Quebec, 1100 Notre Dame Ouest, Montreal, Que., Cana ...

  • Venue:
  • Computers and Industrial Engineering - Special issue: Selected papers from the 27th international conference on computers & industrial engineering
  • Year:
  • 2004

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Abstract

This paper presents the optimal flow control for a one-machine, two-product manufacturing system subject to random failures and repairs. The machine capacity process is assumed to be a finite state Markov chain. The problem is to choose the production rates so as to minimize the expected discounted cost of inventory/backlog over an infinite horizon. We first show that for constant demand rates and exponential failure and repair time distributions of the machine, the hedging point policy is optimal. Next, the hedging point policy is extended to nonexponential failure and repair time distributions models. The structure of the hedging point policy is parameterized by two factors representing the thresholds of involved products. With such a policy, simulation experiments are coupled with experimental design and response surface methodology to estimate the optimal control policy. Our results reveal that the hedging point policy is also applicable to a wide variety of complex problems (i.e. nonexponential failure and repair time distributions) where analytical solutions may not be easily obtained.