A nonlinear model for optimizing the performance of a multi-product production line

This paper examines the measures of performance and in particular addresses the throughput of an automated production line processing multiple products. The line is composed of a sequence of workstations connected in series with finite buffers in between. We explore the effects of buffer size on attenuating the impact of line blocking and starvation that can cause a reduction in the output. Such effects are analyzed through a nonlinear mathematical programming model and the implications are examined. The aim of the model is to achieve the best performance subject to available workstation capacity without overexpenditure on buffer size. Single and multi-objective optimizations are carried out in the paper. A numerical example of a production line with a given configuration of workstations; workstation capacity; and job mix is presented to demonstrate the model and its application. A discussion of the impact of buffer size on maximum throughput is also provided. The paper is concluded with a discussion on the decision-making implications.