An Approximate Solution Method for Optimal Buffer Allocation in Serial n-stage Automatic Production Lines : Series C : Vibration, Control Engineering, Engineering for Industry

In this paper we consider the allocation of buffer capacities in a serial, synchronized, automatic production line with buffer storages between adjacent stages. It is assumed that every stage has a geometric distribution of up time. The measure of line efficiency is the maximum output rate from the last stage of the line in the steady state which is referred to as production rate. First, we develop in this paper a new efficient method of calculation of production rate which is suitable for applying dynamic programming approaches. Then, we propose an approximate solution method for optimal buffer allocation so as to maximize production rate applicable even to long lines with many buffer storages and a large total buffer capacity by applying dynamic programming techniques. We confirm the validity of the approach by comparing the solutions obtained by the present method with those obtained by computer simulation for many example problems.