The paper presents different periodical capacity setting methods for make-to-order, multi-machine production systems with stochastic customer required lead times and stochastic processing times to improve service level and tardiness. These methods are developed as decision support when capacity flexibility exists, such as, a certain range of possible working hours a week for example. The methods differ in the amount of information used whereby all are based on the cumulated capacity demand at each machine. In a simulation study the methods' impact on service level and tardiness is compared to a constant provided capacity for a single and a multi-machine setting. It is shown that the tested capacity setting methods can lead to an increase in service level and a decrease in average tardiness in comparison to a constant provided capacity. The methods using information on processing time and customer required lead time distribution perform best. The results found in this paper can help practitioners to make efficient use of their flexible capacity.

Key performance indicators (KPIs) are critical for manufacturing operation management and continuous improvement (CI). In modern manufacturing systems, KPIs are defined as a set of metrics to reflect operation performance, such as efficiency, throughput, availability, from productivity, quality and maintenance perspectives. Through continuous monitoring and measurement of KPIs, meaningful quantification and identification of different aspects of operation activities can be obtained, which enable and direct CI efforts. A set of 34 KPIs has been introduced in ISO 22400. However, the KPIs in a manufacturing system are not independent, and they may have intrinsic mutual relationships. The goal of this paper is to introduce a multi-level structure for identification and analysis of KPIs and their intrinsic relationships in production systems. Specifically, through such a hierarchical structure, we define and layer KPIs into levels of basic KPIs, comprehensive KPIs and their supporting metrics, and use it to investigate the relationships and dependencies between KPIs. Such a study can provide a useful tool for manufacturing engineers and managers to measure and utilize KPIs for CI.

In this paper, an integrated model to minimize energy consumption while maintaining desired productivity in Bernoulli serial lines is introduced. Exact analysis of optimal allocation of production capacity is carried out for small systems, such as three- and four-machine lines with small buffers. For medium size systems (e.g., three- and four-machine lines with larger buffers, or five-machine lines with small buffers), an aggregation procedure is introduced to evaluate line production rate, and then use it to search optimal allocation of machine efficiency to minimize energy usage. Insights and allocation principles are obtained through the analyses. Finally, for larger systems, a heuristic algorithm is proposed and validated through extensive numerical experiments.

Design for Manufacturing (DFM), especially the use of manufacturing knowledge to support design decisions, has received attention in the academic domain. However, industry practice has not been studied enough to provide solutions that are mature for industry. The current state of the art for DFM is often rule-based functionality within Computer-Aided Design (CAD) systems that enforce specific design requirements. That rule-based functionality may or may not dynamically affect geometry definition. And, if rule-based functionality exists in the CAD system, it is typically a customization on a case-by-case basis. Manufacturing knowledge is a phrase with vast meanings, which may include knowledge on the effects of material properties decisions, machine and process capabilities, or understanding the unintended consequences of design decisions on manufacturing. One of the DFM questions to answer is how can manufacturing knowledge, depending on its definition, be used earlier in the product lifecycle to enable a more collaborative development environment? This paper will discuss the results of a workshop on manufacturing knowledge that highlights several research questions needing more study. This paper proposes recommendations for investigating the relationship of manufacturing knowledge with shape, behavior, and context characteristics of product to produce a better understanding of what knowledge is most important. In addition, the proposal includes recommendations for investigating the system-level barriers to reusing manufacturing knowledge and how model-based manufacturing may ease the burden of knowledge sharing. Lastly, the proposal addresses the direction of future research for holistic solutions of using manufacturing knowledge earlier in the product lifecycle.

This paper reviews and classifies literature on operational control of discrete event logistics systems (DELS). Operational control manipulates the flow of items through a DELS. Each control problem addressed in the surveyed literature is classified based on the control decision that the analysis model is formulated to support. These control decisions are defined by abstract functional definitions focusing on analysis model inputs, outputs, and variables. This classification of control problems shows that five kinds of atomic control decisions are needed to cover the literature, either by themselves or in combination. Standard functional definitions of operational control decisions enable discovery and interoperability of decision-support analysis models.

This paper pursues two goals: (a) Define a class of widely used in practice flexible manufacturing systems, referred to as Multi-Job Production (MJP) and formulate industrially motivated problems related to their performance. (b) Provide initial results concerning some of these problems pertaining to analysis of the throughput and bottlenecks of MJP serial lines as functions of the product-mix. In MJP systems, all job-types are processed by the same sequence of manufacturing operations, but with different processing time at some or all machines. To analyze MJP with unreliable machines, we introduce the work-based model of production systems, which is insensitive to whether single- or multi-job manufacturing takes place. Based on this model, we investigate the performance of MJP lines as a function of the product-mix. We show, in particular, that for the so-called conflicting jobs there exists a range of product-mixes, wherein the throughput of MJP is larger than that of any constituent job-type manufactured in a single-job regime. To characterize the global behavior of MJP lines, we introduce the Product-Mix Performance Portrait, which represents the system properties for all product-mixes and which can be used for operations management. Finally, we report the results of an application at an automotive assembly plant.

Collaborative operations planning is a key element of modern supply chains. We introduce the collaborative multi-level lot-sizing problem with cost synergies. This arises if producers can realise reductions of their costs by providing more than one product in a specific time horizon. Since producers are typically not willing to reveal critical information, we propose a decentralised mechanism, where producers do not have to reveal their individual items costs. Additionally, a Genetic Algorithms-based centralised approach is developed, which we use for benchmarking. Our study shows that this approach comes very close to the a central plan, while in the decentralised one no critical information has to be shared. We compare the results to a myopic upstream planning approach, and show that these results are almost 12% worse than the centralised ones. All solution approaches are assessed on available test instances for problems without cost synergies. For the biggest available instances, the proposed centralised mechanism improves the best known solutions on average by 10.8%. The proposed decentralised mechanism can be applied to other problem classes, where collaborative decision makers aim for good plans under incomplete information.

Today, data analytics plays an important role in Smart Manufacturing decision making. Domain knowledge is very important to support the development of analytics models. However, in today's data analytics projects, domain knowledge is only documented, but not properly captured and integrated with analytics models. This raises problems in interoperability and traceability of the relevant domain knowledge that is used to develop analytics models. To address these problems, this paper proposes a methodology to enrich analytics models with domain knowledge. To illustrate the proposed methodology, a case study is introduced to demonstrate the utilization of the enriched analytics model to support the development of a Bayesian Network model. The case study shows that the utilization of an enriched analytics model improves the efficiency in developing the Bayesian Network model.

Engineering change is a significant cost sink in many projects. While avoiding and mitigating the risk of change is the ideal approach, mistakes and improvements are recognized inevitably as more is learned over time about the quality of the decisions made in a product's design. This paper presents a feasibility and performance analysis of automating engineering change requests to demonstrate the promise for increasing speed, efficiency, and effectiveness of product-lifecycle-wide engineering-change-request processes. To explore this idea, a comparatively simple case study is examined both to mimic the reduced set of alterable aspects of a typical change request and to highlight the need of appropriate search algorithms as brute force methods quickly prohibitively resource intensive. Although such cases may seem trivial for human agents, with the volume of expected change requests in a typical facility, the potential opportunity gain by eliminating or reducing the amount of human effort in low level change requests accumulate into significant returns for industry on time and money. Within this work, the genetic algorithm is selected to demonstrate feasibility due to its broad scope of applicability and low barriers to deployment. Future refinement of this or other sophisticated algorithms leveraging the nature of the standard representations and qualities of alterable design features could produce tools with strong implications for process efficiency and industry competitiveness in the execution of its projects.

Industry desires a digital thread of information that aligns as-designed, as-planned, as-executed, and as-inspected viewpoints. An experiment was conducted to test selected open data standards' ability to integrate the lifecycle stages of engineering design, manufacturing, and quality assurance through a thorough implementation of a small scale model-based enterprise. The research team set out to answer: from design, through production, and final inspections, what are the hurdles that a manufacturer would face during the development of a fully linked and integrated information chain? The research team was not able to fully link all the required information, but value for industry was still identified. This paper presents the results of the experiment, provides guidance on how to overcome or mitigate identified challenges, and discusses the benefits or incentives to be gained from tracing or linking information through multiple stages a product lifecycle.

Simultaneous allocation of service times and buffer capacities in manufacturing systems in a random environment is a NP-hard combinatorial optimisation problem. This paper presents a sophisticated simulation-based optimisation approach for the design of unreliable production lines to maximise the production rate. The proposed method allows for a global search using a Genetic Algorithm (GA), which is coupled with Finite Perturbation Analysis (FPA) as a local search technique. Traditional techniques based on perturbation analysis optimise decision variables of the same nature (e.g. service time only, buffer capacity only), whereas the proposed technique simultaneously provides an allocation of service times and buffer capacities. One of the main focuses of this paper is the investigation of the persistence or absence of the buffer and service rate allocation patterns which are among the most essential insights that come from designing production lines. The results show the superiority of the combined GA-FPA approach regarding GA and FPA in terms of solution quality and convergence behaviour. Moreover, considering instances ranging from 3 to 100 machines, our numerical experiments are in line with the literature for small instances (as similar allocation patterns are identified in our work), but important differences are highlighted for medium/large instances.