PERFORMANCE MODELING OF AUTOMATED MANUFACTURING SYSTEMS

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1 PERFORMANCE MODELING OF AUTOMATED MANUFACTURING SYSTEMS N. VISWANADHAM Department of Computer Science and Automation Indian Institute of Science Y NARAHARI Department of Computer Science and Automation Indian Institute of Science PRENTICE HALL, Englewood Cliffs, New Jersey 07632

2 PREFACE xiii Chapter 1 INTRODUCTION MODELING AUTOMATED MANUFACTURING SYSTEMS Role of Performance Modeling Performance Measures PERFORMANCE MODELING TOOLS Simulation Models Analytical Models ORGANIZATION OF THE BOOK BIBLIOGRAPHIC NOTES AND BIBLIOGRAPHY 9 Chapter 2 AUTOMATED MANUFACTURING SYSTEMS INTRODUCTION History of Manufacturing The Product Cycle Manufacturing Automation Economies of Scale and Scope MANUFACTURING SYSTEMS Input-Output Model Plant Configurations PERFORMANCE MEASURES Manufacturing Lead Time Work-in-Process 45

3 2.3.3 Machine Utilization Throughput Capacity Flexibility Performability Quality COMPUTER-CONTROLLED MACHINES Numerically Controlled Machines Pallets and Fixtures Machine Centers Automated Inspection Systems MATERIAL HANDLING SYSTEMS Introduction Conveyors Industrial Robots Automated Guided Vehicles PLANT LAYOUT Group Technology Some Typical Layouts FLEXIBLE MANUFACTURING SYSTEMS Architecture of FMS Automated Workpiece Flow Automated Assembly Systems Deadlocks in Automated Manufacturing Systems Performance Measures COMPUTER CONTROL SYSTEMS Control System Architecture Factory Communications Local Area Networks Factory Networks Open Systems Interconnection Model.. 142

4 vii Network to Network Interconnections Manufacturing Automation Protocol Database Management System BIBLIOGRAPHIC NOTES AND BIBLIOGRAPHY 155 Chapter 3 MARKOV CHAIN MODELS MEMORYLESS RANDOM VARIABLES Geometrie Random Variable Exponential Random Variable STOCHASTIC PROCESSES IN MANUFACTURING Examples of Stochastic Processes Poisson Process DISCRETE TIME MARKOV CHAIN MODELS Definitions and Notation Sojourn Times in States Examples of DTMCs in Manufacturing Chapman-Kolmogorov Equation Steady-State Analysis CONTINUOUS TIME MARKOV CHAIN MODELS Definitions and Notation Sojourn Times in States Examples of CTMCs in Manufacturing Equations for CTMC Evolution Analysis of Homogeneous CTMCs Embedded Markov Chain in CTMCs AN EXAMPLE: MARKOV MODEL OF A TRANSFER LINE Rate Balance Equations 240

5 viii CONTENTS Steady-State Analysis Performance Evaluation BIRTH AND DEATH PROCESSES IN MANUFACTURING Steady-State Analysis of BD Processes Typical BD Processes in Manufacturing TIME REVERSIBLE MARKOV CHAINS IN MANUFACTURING Time Reversible DTMCs Time Reversible CTMCs ABSORBING STATES AND MODELING OF DEADLOCKS Examples of Absorbing States Analysis of Markov Chains with Absorbing States Application to Examples SEMI-MARKOV PROCESSES IN MANUFACTURING Definition and Examples Analysis of Semi-Markov Processes Application to Examples TRANSIENT ANALYSIS OF MANUFACTURING SYSTEMS Solution of Forward and Backward Equations Distribution of Time to Deadlock COMPUTATIONAL ISSUES IN MARKOV ANALYSIS Computational Issues in Steady-State Analysis Solution Methods for Steady-State Analysis Time Scale Analysis Technique 297

6 ix Computational Issues in Transient Analysis Uniformization BIBLIOGRAPHIC NOTES AND BIBLIOGRAPHY 307 Chapter 4 QUEUING MODELS QUEUES: NOTATION AND EXAMPLES Notation for Queues Examples of Queues in Manufacturing Systems Performance Measures Little's Result THE M/M/1 QUEUE Steady-State Analysis of the M/M/1 Queue Waiting-Time Distributions The M/M/l/N Queue THE M/M/m QUEUE Steady-State Analysis Departure Process of M/M/m Queue BATCH ARRIVAL QUEUING SYSTEMS QUEUES WITH GENERAL DISTRIBUTIONS The M/G/l Queue The GI/M/1 Queue The GI/G/1 Queue QUEUES WITH BREAKDOWNS Problem Formulation Steady-State Analysis 360

7 X CONTENTS 4.7 ANALYSIS OF A FLEXIBLE MACHINE CENTER Problem Formulation Performance Measures Analysis for Exhaustive Service and Gated Service QUEUING NETWORKS Examples of QN Models in Manufacturing Little's Law in Queuing Networks OPEN QUEUING NETWORKS The Tandem Queue An Open Queuing Network with Feedback An Open Central Server Model for FMS Jackson's Network CLOSED QUEUING NETWORKS A Closed Transfer Line The Closed Central Server Model Gordon-Newell Networks Computation of Normalization Constant Computation of Performance Measures Mean Value Analysis PRODUCT FORM QUEUING NETWORKS Types of Service Centers Closed Networks with Multiple Job Classes QUEUING NETWORKS WITH BLOCKING Types of Blocking Mechanisms Two-Node Open Network with В AS Blocking 423

8 xi Two-Node Closed Network with BAS Blocking Central Server Model with Blocking APPROXIMATE ANALYSIS OF QUEUING SYSTEMS Non-Product Form Features in AMSs Approximate Analysis Through Aggregation Approximations Employed in the AMS Context PERFORMABILITY ANALYSIS Reliability and Availability Measures Performability Measures Machine Center with Infinite Waiting Space Central Server FMS Without Repair BIBLIOGRAPHIC NOTES AND BIBLIOGRAPHY 462 Chapter 5 PETRI NET MODELS CLASSICAL PETRI NETS Preliminary Definitions Transition Firing and Reachability Representational Power Properties of Petri Nets STOCHASTIC PETRI NETS Exponential Timed Petri Nets GENERALIZED STOCHASTIC PETRI NETS Definition and Firing Rules Analysis of GSPNs Computation of Performance Measures. 506

9 xii CONTENTS Representational Power of GSPN Models GSPN MODELING OF KANBAN SYSTEMS Description of the System GSPN Model Numerical Results DEADLOCK ANALYSIS USING PETRI NETS Deadlock Prevention Deadlock Avoidance Performance Evaluation in the Presence of Deadlocks EXTENDED CLASSES OF TIMED PETRI NETS Colored Stochastic Petri Nets Extended Stochastic Petri Nets Petri Nets with Deterministic and Exponential Firing Times Space of Timed Petri Nets INTEGRATED PFQN-GSPN MODELS BIBLIOGRAPHIC NOTES AND BIBLIOGRAPHY 571 Chapter 6 EPILOGUE 581 INDEX 585

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