Dynamic production control and deadlock prevention in conveyor equipped manufacturing systems

Abstract: Flexible CONWIP approaches enable the dynamic production control to align production performance with production targets in the presence of high-fluctuating demand and system variability. However, frequently changing the WIP level might generate nervousness and, thus, can be practically infeasible. This paper investigates the combined use of job sequencing and routing to enable dynamic control in a CONWIP system comprising six unreliable workstations interconnected by conveyor carousels. Job sequencing and routing have been investigated using scenario analysis and discrete-event simulation. The results shed light on the effectiveness of the proposed approach, which improves throughput and enables dynamic production control without changing the WIP level. The results also provide managerial insights for system design, considering the impacts of the job-handling system (transport) and the minimum digital and technological requirements from Industry 4.0 for implementing the proposed approach.