Optimal utilization of a finite capacity integrated assembly system

In this paper, a heuristic optimization methodology is provided to maximize the throughput rate from a finite capacity integrated assembly system consisting of a set of tandem workstations, a set of inspection stations, a loading station and an unloading station, linked by a set of transporter stations, while controlling the blocking of the system. For this purpose, given that the fractions of: (1) the repairable defective; (2) the non-repairable defective; and (3) the non-defective workpieces at each inspection station, the local storage sizes and the processing rates of all the workstations and the transporter stations, and the acceptable probabilities of finding each workstation and each transporter station blocked are given, a simple closed form expression is derived for approximating the maximum throughput rate from the system such that the resulting probability of finding either a workstation or a transporter station blocked, e.g. full, will not exceed its corresponding acceptable blocking probability, e.g. a value sufficiently close to zero.