Homogeneous, asymptotically reliable serial production lines: theory and case study

In this paper, a model of homogeneous, asymptotically reliable serial production lines is introduced, analyzed, and applied to performance evaluation of a modular paint shop at an automobile assembly plant. The results obtained indicate that the homogeneous, asymptotically reliable production lines are, on one hand, much simpler for analysis than the traditional models discussed in the literature for the last 25 years and, on the other hand, are sufficiently rich to reflect the behavior of real manufacturing systems. The asymptotic theory developed here gives analytical formulae for production rates as a function of system parameters and, therefore, can be used as an inexpensive tool for analysis and design of manufacturing processes in mass production systems eliminating, in certain cases, the necessity of complex and costly computer simulations.