Quantitative Analysis of FMS

CHAPTER 4
QUANTITATIVE ANALYSIS OF
FMS
HASANI BIN ZAID, KKTM KUANTAN, DAR 5093

Analysis Method
FMSs can be analyzed under four different approaches; these are :
Method Description
1. Deterministic models models that are used to gain starting estimations
of system performance, but not for complex phenomena,
such as the build-up of queues and other dynamics that
can impair system performance.
2. Queuing models these attend to issues of queuing not examined in
deterministic models, and they examine various simple
system configurations.
3. Discrete event often used in the latter parts of system design to
simulation determine the most accurate methods for modeling
specific attributes of the FMS.
Characteristics handled here include layout configuration,
number of pallets in the system, and production
scheduling rules.
4. Other techniques this is a hold-all title that includes various approaches,
from mathematical programming, heuristic approaches,
and a number of operational research techniques.
Deterministic model
We focus upon the most important approach in the sub-sections below,
the deterministic modeling approach.
Bottleneck model
✔
Here we focus upon the deterministic model known as the bottleneck
model.
✔
The bottleneck model is simple and intuitive in approach, and can be
used to determine a number of FMS starting parameters.

The term bottleneck refers to the fact that the output of the
production system has an upper limit, given that the product mix
flowing through the FMS is fixed.

KEYPOINT
For deterministic modeling, we examine the bottleneck model, which
is a model that examines the production system’s upper limit, given
that the product mix flowing through the FMS is fixed.
Bottleneck model
In the bottleneck model the following terminology and symbols are
relevant.
Part mix, or the mix of the various parts or product styles produced by
the FMS, is defined as:
pj : fraction of the total system output that is of style j;

P : total number of different part styles made in the FMS.
n : the number of workstations in the system.
in the bottleneck model, each workstation may have more than one
server (two or more machines capable of performing the same
operation) .
Let s i be the number of servers at workstation i, where i = 1,2, ..., n.
Bottleneck model
In bottleneck modeling, process routing defines the sequence of
operations, the workstations where operations are performed, and
associated process times.
We can let tijk be the processing time (the total time that a production
unit occupies a given workstation server, not counting waiting time);
where
i : station,
j : part/product style
k : sequence of operations in the process routing.
For work handling, the material handling system is considered as a

special-case workstation in the bottleneck model.
It is designated as n + 1, with the number of carriers in the system being

equated to the number of servers in a workstation.
Bottleneck model
Thus Sn+1 can become the number of carriers in the FMS handling system.
For transport, we can let tn+1 be the mean transport time required to
move a part from one workstation to the next station in process routing;
where t is transport time.
Finally, operation frequency is defined as the expected number of times

a given operation in the process routing is performed for each work unit.
We can let fijk be the operation frequency for operation k in process plan
j, at station i, and where f is represents operation frequency.
Using these terms we can represent FMS operational parameters in the

context of the bottleneck model. Average workload is calculated as:
Bottleneck model
The work handling system is a special case and is treated as an extra
station.
The average number of transports is:
Thus, the workload of the handling system is:
KEYPOINT
The bottleneck model allows us to determine initial values for the
average workload of individual stations in the FMS,
the average number of transports in the system, and
the average workload of the material handling system.
Bottleneck model
Other important performance measures used in the bottleneck model
can also be calculated. The workload per server is given as:
If we let WL* and s* be the workload and number of servers respectively,

for the bottleneck station,
then the maximum production rate (R p *) of all parts of the FMS can be
determined as the ratio of these two entities; that is:
The value of R p * includes parts of all styles produced in the system.

Individual part production rates are obtained by R p * by the respective
part mix ratios; that is:
Bottleneck model
Utilization at each workstation is:
Based on this, average station utilization is:
Overall FMS utilization is calculated as:
Finally, the number of busy servers at each station is given as:
where BS i is the number of busy servers on average at station i.

Bottleneck model
KEYPOINT
Additional performance measures that can be computed for the
bottleneck model include:
the workload per server; the maximum production rate;
individual part production rates; and the utilization of individual
workstations, and the overall FMS utilization.
EXAMPLE 1
A flexible manufacturing cell has just been created. After considering a number of designs, the
system engineer chose a layout that consists of two machining workstations plus a load/unload
station. In detail, the layout consists of:
Station 1 : The load/unload station.

Station 2 : performs milling operations and consists of one server (one CNC milling machine)
Station 3 : has one server that performs drilling (one CNC drill press).
The three stations are connected by a part handling system that has one work carrier.
The mean transport time in the system is 2.5 min. The FMC produces three parts, A, B, and C.
The part mix fractions and process routings for the three parts are presented in the table below.
The operation frequency f ijk = 1.0 for all operations. Determine ;
(a) maximum production rate of the FMC,
(b) corresponding production rates of each product,
(c) utilization of each machine in the system, and
(d) number of busy servers at each station.
Bottleneck model
Solution:
(a) Use formula to calculate average workload at each station:
Bottleneck model
WL 1 = (3+2)(0.2)(1.0) + (3+2)(0.3)(1.0) + (3+2)(0.5)(1.0) = 5.0 min
WL 2 = 20(0.2)(1.0) + 15(0.3)(1.0) + 22(0.5)(1.0) = 19.5 min
WL 3 = 12(0.2)(1.0) + 30(0.3)(1.0) + 14(0.5)(1.0) = 18.4 min
nt = 3(0.2)(1.0) + 3(0.3)(1.0) + 3(0.5)(1.0) = 3, WL 4 = 3(2.5) = 7.5 min
Bottleneck station is determined by formula:
The station with the largest WLi /si ratio is the bottleneck station.
Bottleneck is station 2: Apply formula:
R p * = 1/19.5 = 0.05128 pc/min = 3.077 pc/hr

Bottleneck model
(b) Production rates for each product; apply formula for each:
R pA = 0.05128(0.2) = 0.01026 pc/min = 0.6154 pc/hr

R pB = 0.05128(0.3) = 0.01538 pc/min = 0.9231 pc/hr
R pC = 0.05128(0.5) = 0.02564 pc/min = 1.5385 pc/hr
(c) Utilization of each machine in the system; apply formula:
U 1 = (5.0/1)(0.05128) = 0.256 = 25.6%

U 2 = (19.5/1)(0.05128) = 1.0 = 100%
U 3 = (18.4/1)(0.05128) = 0.944 = 94.4%
U 4 = (7.5/1)(0.05128) = 0.385 = 38.5%
(d) Number of busy servers at each station; apply formula:
BS 1 = (5.0)(0.05128) = 0.256 servers

BS 2 = (19.5)(0.05128) = 1.0 servers
BS 3 = (18.4)(0.05128) = 0.944 servers
BS 4 = (7.5)(0.05128) = 0.385 servers

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CHAPTER 4

HASANI BIN ZAID, KKTM KUANTAN, DAR 5093

pj : fraction of the total system output that is of style j;

For work handling, the material handling system is considered as a

It is designated as n + 1, with the number of carriers in the system being

Finally, operation frequency is defined as the expected number of times

Using these terms we can represent FMS operational parameters in the

Thus, the workload of the handling system is:

If we let WL* and s* be the workload and number of servers respectively,

The value of R p * includes parts of all styles produced in the system.

Based on this, average station utilization is:

Overall FMS utilization is calculated as:

Finally, the number of busy servers at each station is given as:

where BS i is the number of busy servers on average at station i.

Station 1 : The load/unload station.

Bottleneck is station 2: Apply formula:

R p * = 1/19.5 = 0.05128 pc/min = 3.077 pc/hr

R pA = 0.05128(0.2) = 0.01026 pc/min = 0.6154 pc/hr

U 1 = (5.0/1)(0.05128) = 0.256 = 25.6%

BS 1 = (5.0)(0.05128) = 0.256 servers

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