A I I E Transactions Volume 11 Issue 4 1979 [Doi 10.1080_05695557908974471] Muth, Eginhard J.;...

download A I I E Transactions Volume 11 Issue 4 1979 [Doi 10.1080_05695557908974471] Muth, Eginhard J.; White, John a. -- Conveyor Theory- A Survey

of 9

Transcript of A I I E Transactions Volume 11 Issue 4 1979 [Doi 10.1080_05695557908974471] Muth, Eginhard J.;...

  • 8/16/2019 A I I E Transactions Volume 11 Issue 4 1979 [Doi 10.1080_05695557908974471] Muth, Eginhard J.; White, John a. -…

    1/9

    This article was downloaded by: [York University Libraries]On: 03 March 2015, At: 23:23Publisher: Taylor & FrancisInforma Ltd Registered in England and Wales Registered Number: 1072954 Registered office: Mortimer Hous37-41 Mortimer Street, London W1T 3JH, UK

    A I I E TransactionsPublication details, including instructions for authors and subscription information:

    http://www.tandfonline.com/loi/uiie19

    Conveyor Theory: A SurveyEginhard J. Muth

    a & John A. White

    b

    a Department of Industrial and Systems Engineering , University of Florida , Gainesville,

    Florida, 32611b School of Industrial and Systems Engineering, Georgia Institute of Technology , Atlanta

    Georgia, 30332

    Published online: 09 Jul 2007.

    To cite this article: Eginhard J. Muth & John A. White (1979) Conveyor Theory: A Survey, A I I E Transactions, 11:4, 270-27DOI: 10.1080/05695557908974471

    To link to this article: http://dx.doi.org/10.1080/05695557908974471

    PLEASE SCROLL DOWN FOR ARTICLE

    Taylor & Francis makes every effort to ensure the accuracy of all the information (the “Content”) containedin the publications on our platform. However, Taylor & Francis, our agents, and our licensors make norepresentations or warranties whatsoever as to the accuracy, completeness, or suitability for any purpose of the Content. Any opinions and views expressed in this publication are the opinions and views of the authors,and are not the views of or endorsed by Taylor & Francis. The accuracy of the Content should not be reliedupon and should be independently verified with primary sources of information. Taylor and Francis shall not bliable for any losses, actions, claims, proceedings, demands, costs, expenses, damages, and other liabilitieswhatsoever or howsoever caused arising directly or indirectly in connection with, in relation to or arising out the use of the Content.

    This article may be used for research, teaching, and private study purposes. Any substantial or systematicreproduction, redistribution, reselling, loan, sub-licensing, systematic supply, or distribution in anyform to anyone is expressly forbidden. Terms & Conditions of access and use can be found at http://www.tandfonline.com/page/terms-and-conditions

    http://dx.doi.org/10.1080/05695557908974471http://www.tandfonline.com/action/showCitFormats?doi=10.1080/05695557908974471http://www.tandfonline.com/page/terms-and-conditionshttp://www.tandfonline.com/page/terms-and-conditionshttp://dx.doi.org/10.1080/05695557908974471http://www.tandfonline.com/action/showCitFormats?doi=10.1080/05695557908974471http://www.tandfonline.com/loi/uiie19

  • 8/16/2019 A I I E Transactions Volume 11 Issue 4 1979 [Doi 10.1080_05695557908974471] Muth, Eginhard J.; White, John a. -…

    2/9

    Conveyor Theory:

    A

    Survey

    EGINHARD

    J

    MUTH

    Department o f Industrial and Systems Engineering

    University of Florida

    Gainesville Florida 3261 1

    JOHN

    A.

    WHITE

    SENIORMEMBER,AIIE

    School of Industrial and Systems Engineering

    Georgia Institute of Tech nology

    Atlanta Georgia 30332

    Abstract This paper surveys the research which has been published in the area of conveyor theory.

    Deterministic and probabilistic approaches as well as descriptive and normative approaches to modeling

    conveyor systems are discussed. Areas for further study are suggested.

    The subject of m aterial handling is one of current interest

    in both the public and the private sectors. Whether the

    material to be handled is people, mail, solid waste, raw

    materials, finished good s, in-process goods, or in forma tion,

    some material handling equipment is normally used to

    facilitate the material transfer. Conveyor systems are very

    universally employed, perhaps more than any other type of

    material handling equipment.

    The mechanical design problems of conveyor systems

    have been well studied by m echan ical and electrical engineers.

    However, the operational problems of conveyor systems are

    not as well understo od. Th e study of the operational charac-

    teristics of conveyor systems has long been a concern of

    industrial engineers. In an operational sense, the conveyor is

    an element of a larger system, including loading and unload-

    ing stations, material supply and demand, operating disci-

    plines, and human components as well. Hence, system

    to classify conveyors, to give an overview of the literature,.

    to discuss several representative research contributions, and

    to point ou t areas for further study.

    onveyor lassification

    There are m any criteria by which one can classify conveyors.

    We wish t o classify m odels and m ethods used to describe

    and t o analyze the opera tion of conveyor systems. With this

    purpose in mind we list some common criteria for classifica-

    tion.

    1. Conveyor arrangement

    a. Feedforward

    b. Closed-loop recirculating)

    2.

    Conveyor use

    a. Deliverv

    parameters include no t only equipment parameters, but also

    b. Storage

    such considerations as waiting space allowances and t he

    3. Loading and unloading stations

    number, spacing, and sequencing of loading and unloading

    a. Single

    stations.

    b. Multiple

    This paper is directed at conveyor theory in terms of the

    operational setting. I ts purpose

    is

    to provide a bibliography,

    4

    Material flow in and ou t of stations

    a. Continuous in time

    b. Discrete in time.

    Received June 1977; revised July 1979. Paper was handled y

    Scheduling Planning and Control Departm ent.

    c. Deterministic

    d. Stochastic

    270

    0569-5554/79/1200-0270/ 02.00/0

    197 9 AIIE

    AIIE

    TRANSACTIONS

    Volume

    11

    NO.

    4

  • 8/16/2019 A I I E Transactions Volume 11 Issue 4 1979 [Doi 10.1080_05695557908974471] Muth, Eginhard J.; White, John a. -…

    3/9

    5. Placement of material on conveyors

    a. Continuous placement

    b. Discrete placement, uniformly spaced

    c. Discrete placement, randomly spaced

    6. Nature of material flows

    a. Bulk loads

    b. Discrete parts

    7. Method of modeling

    a. Analytical models

    b. Simulation models

    c. Deterministic models

    d. Queueing models

    e. Markovian models

    f. Other stochastic models.

    Overview o th

    iterature

    It appears that the earliest published work seeking to

    identify a body of knowledge called conveyor theory is

    that of Kwo [34]. His appeal for analytical approaches in

    the study of conveyors was followed by a surge of publica-

    tions in the early 1960's. Among the earliest publications

    were those of Kwo [34], [35], Mayer [37], Helgeson [29],

    Reis and Schneider [56] Reis, Dunlap, and Schneider [57]

    Reis and Hatcher [58], and Morris [39].

    It is interesting to note that the authors of the first four

    publications (Helgeson, Kwo, and Mayer) were employed as

    engineers in industry. Thus, conveyor theory developed

    from a concern within industry to develop analytical models

    of a real world problem, the design of conveyor systems.

    Also, it is worthwhile to observe that Helgeson and Kwo

    employed a deterministic modeling approach, whereas Mayer

    employed a probabilistic approach.

    Since the initial surge of interest in the 1960's, conveyor

    theory has attracted a steady following, as indicated by the

    following chronological listing of known research efforts:

    Disney [15] and Mednis [38] in 1962; Disney [16] Parker

    [50], and Schumacher [61] in 1963; Ghare, Ward, and

    Perry [20], Howell [32] Perry [51], and Ward [64] in

    1965; Gupta [26], Pritsker [54], and Vars [63] in 1966;

    Crisp

    [12] and Reis, Brennan, and Crisp [59] in 1967;

    Beightler and Crisp [4] and Phillips [52] in 1968; Crisp,

    Skeith, and Barnes [13] and Phillips and Skeith [53] in

    1969; Brady [5] and Burbridge [7] in 1970; Bussey and

    Terrell [8] and Heikes [28] in 1971 gee and Cullinane [I]

    and Muth [40] in 1972; Brady [6] and Bussey and Terrell

    [9] in 1973; Gourley and Terrell [21] [22] and Muth [43]

    in 1974; Gregory and Litton [24] [25], Gourley, Terrell,

    and Chen [23], Matsui and Fukuta [36] and Muth [44]

    [45] in 1975; Chen and Terrell lo]

    l

    11 Duraiswamy and

    Terrell [17], El Sayed, Proctor, and Elayat [18], Hedstrom

    [27], White [66] and White and Woodbury [67] in 1976;

    El Sayed and Proctor

    [19], Muth [47], and Proctor, El

    Sayed, and Elayat [55] in 1977.

    December 1979, AIIE TRANSACTIONS

    The majority of the conveyor research has concentrated

    on conveyor systems consisting of equally spaced hooks (or

    carriers) passing a number of work stations. Kwo [34] [35]

    developed a deterministic model of material flow on a

    conveyor having one loading station and one unloading

    station, and time-varying patterns of material flow. His

    concern was in developing feasibility conditions to insure

    that the input and output rates of material were compatible

    with the design of the conveyor. Muth [40] [43] provided

    a thorough mathematical analysis of the problem studied by

    Kwo and considered both continuous-time and discrete-

    time material flow. He employed methods of systems

    analysis and control theory to develop stability conditions

    for the conveyor system. Subsequently, Muth [44] extended

    his results to the case of multiple loading and unloading

    stations.

    Mayer [37] appears to have been the first to model a

    conveyor system probabilistically. He considered a closed

    loop conveyor having loading stations operating indepen-

    dently. His analysis allowed each discretely spaced carrier to

    have a capacity to handle multiple items. Morris [39] ex-

    tended the probabilistic approach of Mayer to include

    multiple loading and multiple unloading stations. conser-

    vation of flow approach was employed to develop perfor-

    mance measures for the system. White and Woodbury [67]

    used a simulation approach to test the validity of Morris'

    model. Their results indicate the conservation of flow ap-

    proach yields good approximations as long as the probability

    of

    self-blocking is small. White [66] developed normative

    models based on the descriptive models of Mayer [37] and

    Morris [39].

    number of researchers have studied an individual work

    station.

    Reis and Schneider [56], Reis, Dunlap, andschneider

    [57], and Reis and Hatcher [58] developed probabilistic

    models of an individual work station which performs load-

    ing andlor unloading operations. It was assumed that

    temporary storage areas or banks are available so that in

    the event of an unsuccessful loading attempt or unloading

    attempt the worker is not unnecessarily delayed. The re-

    search focused on determining the effect of various banking

    disciplines on the productivity of the work station. Reis,

    Brennan, and Crisp [59] modeled the individual work

    station as a Markov process. banking discipline referred to

    as the Sequential Range Policy was defined by Beightler

    and Crisp [4] , who also employed Markov processes in

    analyzing the in-process storage requirements of the individ-

    ual work station. stationary Bernoulli arrival distribution

    was assumed for each work station. In a later study, Crisp,

    Skeith, and Barnes [13] employed simulation to test the

    assumption that arrivals were Bernoulli distributed. It was

    found that such an assumption could not be supported.

    Schumacher [61] Ward [ a ] , Perry [50], and Vars [63]

    investigated conveyor systems involving variations of the

    banking disciplines studied by Reis et al. Ghare, Ward, and

    Perry [20] examined the effects of interaction for a number

    of loading and unloading stations. Heikes [28] developed

    approximations of the interaction effects and employed

    them in an economic model of the conveyor system.

  • 8/16/2019 A I I E Transactions Volume 11 Issue 4 1979 [Doi 10.1080_05695557908974471] Muth, Eginhard J.; White, John a. -…

    4/9

    Queueing theory has been employed by a number of

    researchers in analyzing conveyor systems. In particular, a

    power and free conveyor system having two unloading

    stations was studied by Disney [16] . The problem was for-

    mulated as a multichannel queueing problem with ordered

    entry. Gupta [26] extended the results of Disney's research

    to obtain the steady state distribution for material queued

    at each of the two w ork stations. Pritsker [54] generalized

    Disney's analysis to include m unloading stations with

    storage allowed only at the last station. Whereas Disney

    assumed an M/M/m queue, Pritsker considered the M/G/m

    and DIM lm queueing situations. Additionally, Pritsker con-

    sidered the effects of recirculation; this case was studied

    using simulation. Gregory and Litton [24] modeled a

    queueing system with m dissimilar service channels and

    ordered entry, where the interarrival times are random

    multiples of a fuced time interval. They showed tha t in order

    to minimize the number of units which are lost, the

    channels should be ordered by descending service rate, that

    is, the fastest server should com e first. R ecirculation of units

    is not allowed in their analysis. El Sayed, Procto r, and E layat

    [18 ], El Sayed and Proctor [19 ], and Procto r, El Sayed,

    and Elayat [55] used queueing models which include bulk

    arrivals, dual inputs with different service characteristics,

    and heterogeneous servers; they determined the steady-state

    probabilities of the system. I t should be observed that all of

    the work quoted in this paragraph addresses queueing sys-

    tems rather than conveyor systems since there are no

    conveyor parameters contained in the analyses. Also, the

    assumption is made that items which find all servers busy

    are lost to the system. This assumption is highly unrealistic.

    Agee and Cullinane

    [I ] studied a conveyor system which

    connected a single loading point with a single unloading

    point. Multiple loading (unloading) stations were allowed at

    the loading (unloading) point. A nonstationary Poisson

    process was assumed and blocking could occur when the

    conve yor was fu ll. A transient analysis was performed using

    numerical methods. n economic model was developed to

    determine the optimum number of loading and unloading

    stations and conveyor length.

    Hedstrom [27] appears to be the first t o study the

    problem of sequencing heterogeneous loading stations along

    a continuous space conveyor. Workers are assumed to be

    placing cartons of unequal length on a constant speed,

    powered belt conveyor; workers operate independently at

    different rates. n approximate analytical model and a

    simulation model are developed to assist in the determina-

    tion of the optimu m sequence of workers along the belt.

    Muth [47] analyzed a closed loop conveyor with one

    loading station, one unloading station, and random m aterial

    flow. The flow is modeled as signal plus noise and recircula-

    tion is taken into account. It is shown that with a suitable

    decision rule for unloading the conve yor acts as a smoothing

    device, that is, the variance of the output flow is smaller

    than the variance of the input flow.

    Phillips and S keith [53] performed a simulation analysis

    of the m unloading station case involving homogenous and

    heterogeneous service stations. Recirculation and storage at

    each station are allowed. The simulation model was used to

    validate the results obtained by Pritsker. Bussey and Terrell

    [8] [9] employed a simulation model to account for the

    discrete spacing of carriers on the conveyor, the storage of

    units at each station, and the recirculation of units on the

    conveyor. Their results indicate the importance of taking

    into consideration the amount of spacing between carriers.

    Gourley and

    Terrell[21 ] [22] developed a modular general-

    purpose simulation model to study performance aspects of

    constant-speed, discretely loaded, recirculating conveyors.

    The simulation model was extended by Gou rley, Terrell, and

    Chen [23], Chen and Terrell [lo], and Duraiswamy and

    Terrell [17] The mo dular general-purpose simulation model

    was extended by Chen and Terrell [ l l ] to include multiple

    loop co nveyor systems which service multiple floors.

    Conveyors frequently serve as the link that transports

    material to production lines. Therefore, a research area

    closely related to conveyor th eory is that involving produc-

    tion lines. Hillier and Boling [30] [3

    1

    Anderson and

    Moodie [2] , Sadowski and Moodie [60], K nott [33], and

    Muth 1411 [4 6], among others, have studied problems

    related to the output rates of production lines. Another

    productio n problem which relates to th e design of conveyor

    systems is the assembly line balancing problem. Over one

    hundred papers are available on this subject; Panwalker

    [49] provides a recent survey of assembly line balancing

    techniques.

    Representative Research Contributions and Results

    1. Deterministic Models

    Kwo [34] [35] develops a deterministic model of material

    flow o n a conveyor having one loading station, one unload-

    ing station, equally spaced carriers, and periodically time-

    varying patterns of m aterial flow. His objective is to deter-

    mine conveyor design parameters that

    will

    assure the

    compatibility of different input and output patterns. The

    problem development makes use of three intuitively derived

    principles. The principle of uniformity leads to some

    feasible solutions under very restrictive inpu t outpu t condi-

    tions, but it does not lead to a general solution procedure.

    Muth 1401 [43] provides a thoroug h math ema tical

    analysis of the problem studied by Kwo. He treats con-

    veyors for continuous bulk loads [40], and for discretely

    spaced loads [43] The material flow along the conveyor is

    described by a difference equation whose solution yields

    conditions under which stable conveyor operation is possible

    for general periodic input and output flow patterns. It is

    shown that a critical design parameter is the ratio SIP,

    where S

    =

    T mod

    P

    T is the conveyor revolution time, and

    P s the work-cycle period. In a good design SIP should be

    in the range (0.25, 0.75). In the contin uou s load case SIP

    should not be a rational number whose deno mina tor is a

    small integer. In th e discrete load case

    SIP

    =r/p , where r =

    k

    mod p, k is the number of carriers on the conveyor and p =

    kP/T

    In that case r/p should be a proper fraction and for

    AIIE

    IRANSACTIONS,

    Volume 1

    1

    No. 4

  • 8/16/2019 A I I E Transactions Volume 11 Issue 4 1979 [Doi 10.1080_05695557908974471] Muth, Eginhard J.; White, John a. -…

    5/9

    greatest operational flexibilityp should be a prime number.

    In

    [44]

    Muth extends the results of

    [43]

    to th e case of

    multiple loading and unloading stations, where each of the

    stations can perform either pure loading, or pure unloading,

    or alternating loading and unloading operations. Station

    inputs

    fi n)

    units of material to carrier n on the conveyor;

    the amou nt of material in carrier

    n

    after it leaves statio n is

    Hi n).

    The sequences

    Cfi n))

    re periodic with pe riod p. For

    given values of

    k

    and p the required carrying capacity of the

    carrier is the m aximum value in the sequence

    { H i @ ) )

    or all

    i and n . A recursive procedure for computing the sequence

    of values is given in [44].

    2. Stochastic Models

    Mayer

    [37]

    analyzes a conveyor with discretely spaced

    carriers which pass by

    n

    work stations. All carriers arrive

    empty at the first work station. The conveyor transports

    the unit produced from all work stations to the next stage

    of the produ ction process. Each work station produces one

    unit of product during one work cycle. The operator who

    finishes work on a unit of product will place that unit on

    the nearest carrier, or place it on the floor if the carrier is

    already filed to capacity. A figure of demerit is

    D ,

    the

    probability that a unit of production will be set aside on

    the floor. With the assumption that a loading attempt will

    be made with probability p as a carrier passes a sta t~ on ,he

    total number of loading attempts per carrier as it passes n

    work stations is binomially distributed. As a result Mayer

    shows that when the carriers have capacity for one unit of

    product, then

    where

    q

    p , and

    h l l p

    is the expected number of

    carriers passing a station during one work cycle. He further

    shows that

    for carriers with two-unit capacity.

    White [661 considers the general case of a carrier with

    capacity for

    x

    units. In that case

    Based on this formulation White develops a normative

    conveyor model. He notes that

    D

    is a function of two

    equipment design parameters: h and x. D can be decreased

    by either increasing th e conveyor speed, or decreasing the

    spacing between carriers, or increasing the number of load-

    ing positions per carrier. White's model for determining the

    optim um value of

    x ,

    given a value of

    h ,

    is:

    Minimize

    TC x ) C1Rn D x ) D2Kx

    Subject to

    x =

    1 . n

    where

    TC x) total expected cost per shift as a function of x

    C 1

    cost per unit set aside on the floor

    z

    cost per shift per loading position o n a carrier

    D x)

    fraction of loading attempts which are unsuccess-

    ful as a function of

    x

    n

    number of loading stations

    R

    expected num ber of work cycles per shift

    K number of carriers on the conv eyor.

    Employing difference calculus methods White shows that

    the optim um value of is the smallest value satisfying the

    relation

    .-

    where

    F x t 1 )

    s the complementary cumulative distribution

    function of a binomial distribution with parameters n andp

    evaluated at

    x t l .

    In

    [66]

    additional no rmative models arc

    constructed for the case where h is the decision variable,

    and for the case where both h and x are d ecision variables.

    D

    is shown to be a strictly convex function of

    h .

    Morris

    [39]

    extends the probabilistic model of Mayer

    using a conservation of flow approach. His model includes

    multiple unloading stations, and not all product placed on

    the conveyor is guaranteed to be removed during one cycle.

    The operating discipline is that assumed by Mayer, namely,

    if a loading attem pt is unsuccessful, then the unit of product

    is set aside on the floor. In addition, if an attempt to

    unload a carrier is unsuccessful (due to an empty carrier

    arriving next) then a unit of product is removed from the

    reserve inventory located at the station. Each carrier is

    assumed to have the capacity for carrying only one unit of

    product. The following notation is used:

    j

    rate at which loading attempts are made by loading

    station

    j

    pi

    rate at which unloading attemp ts are made by unload-

    ing station

    rate at which carriers pass a station

    fraction of carriers arriving at loading station which

    are full

    n

    number of loading stations

    --

    December

    1979

    AIIE

    TR NS CTIONS

  • 8/16/2019 A I I E Transactions Volume 11 Issue 4 1979 [Doi 10.1080_05695557908974471] Muth, Eginhard J.; White, John a. -…

    6/9

    pi

    = fraction of carriers arriving at unloading station i

    A n

    which are fidl

    C ; = m p - s

    f i

    m h

    m

    = number of unloading stations

    1 - ( I - ( I - ; )

    j = rate at which units are set aside on the floor at

    loading station

    wi

    =

    rate at which units are removed from the reserve at

    unloading station i.

    Assuming that loading stations are followed by unloading

    stations, and that flow rate in equals flow rate out, Morris

    provides the following relations

    Assuming further that loading attempts and unloading

    attempts are completely random, such that

    j

    =

    ajAj

    and

    wi

    =

    pi(l

    -

    Pi), the following balance equations app ly

    Pi+1s = Pi(s - Pi) i = l , . . . , m

    S i n ~ e a ~ ~ s = ~ , s a n d P ~ ~ s = a ~ s , i f h ~ = h V jn d p i = P

    Vi , the following solution to the balance equations is obtained

    The rate at which unsuccessful loading attempts occur

    for the system is given by

    @ A ' Y j

    j=

    Normative models are constructed by White [66] for the

    multiple loading and unloading station conveyor system

    studied by Mom s. White treats th e speed of the conveyor,

    as a decision variable and determines the value of s which

    yields an economic balance between the cost of unsuccess-

    ful loading or unloading attem pts and the.cost of increasing

    the speed of th e conveyor. It is noted for th e case of m = n =

    1 that J and t are strictly increasing functions of s; hence

    in that case s should be decreased rather than increased. For

    other values of m and

    n it appears that

    @

    and re strictly

    convex functions of s and achieve a minimum value for

    s > max (A, p).

    An alternative to the models of Mayer [37] and Morris

    [ 9]

    for a conveyor system consisting only of unloading

    stations is proposed by Gregory and Litton [24]. They

    assume that the time betw een successive unloading attempts

    is

    expon entially distributed and that all carriers approaching

    the first unloading station are loaded. If an unloading at-

    tempt is unsuccessful due to a carrier being empty, the

    operator waits for the next loaded carrier to arrive. Hence,

    reserve accumulation is not provided at any station. Any

    carriers which pass

    a l l

    m unloading stations are autom atically

    diverted to an accumulation line and processed at a later

    time. The conveyor speed is such that the equally spaced

    carriers pass a given point at intervals o f t time units and

    the operator's service time is exponentially distributed with

    (@)-I Hence, given that an operator is busy when carrier

    i

    passes, the probability that he

    will

    still be busy when

    carrier

    i

    1) passes is

    e Pt.

    Consequently, if an operator

    unloads carrier k then the probability that the next carrier

    he

    will

    unload is carrier k y is given by

    Gregory and Litton employ Palm's recurrence formula for

    overflows in queue s [4 8] in comb ination with a result given

    by

    T a k h

    [62] to obtain a recurrence relation which is

    used to analyze the individual work stations. Let A(')(z,

    @

    denote the probability generating function of the input to

    the ith work s tation. The following result is used:

    where

    and

    Likewise, the rate at which unsuccessful unloading attemp ts

    occur fo r the system is given bv

    hk(z, @ = A ( ~ ) ( @ ~ z ) ] 1

    t = P

    (1 - Pi)

    or i=1

    with D(')(z, @ = 1. Given the A(')(z, @) it is noted that

    the input to the ith station is the output from the (i-1)st

    74

    AIIE

    lkANSACTIONS

    Volume 1 , No.

    4

  • 8/16/2019 A I I E Transactions Volume 11 Issue 4 1979 [Doi 10.1080_05695557908974471] Muth, Eginhard J.; White, John a. -…

    7/9

    station. Gregory and Litton show that the proportion of

    parts which are not unloaded by any of the unloading

    stations is minimized by sequencing the servers using a

    fastest-first rule.

    Muth [47] introduces a model of a closed-loop conveyor

    with a single loading station and a single unloading station

    and with random material flow. The amount of material to

    be loaded into bucket n as it passes the loading statio n isX, .

    The sequence { X , is assumed t o be a wide sense stationary

    process.This implies that th e m ean value fu nction is constant

    and that the covariance of

    Xn

    and

    ,f,,+i

    is a function of the

    difference j only. The amount of material unloaded from

    bucket n at the unloading station is Y , . Not

    ll

    of the

    material in the bucket will be un loaded. T he idea is to use

    the storage feature of the return loop to cause { Y , t o

    have less random fluctuation than { X ,

    1 .

    In particular,it

    is assumed that the fraction

    a

    of the amount G , arriving is

    unloaded, leaving the amo unt

    H ,

    = (1 a)G, in the bucke t.

    The sequence

    Y ,

    is thus governed by th e difference equation

    where k is the number of buckets on the conveyor. Based

    on this difference equation the stsady-state probability

    properties of

    { Y ,

    are derived.

    A

    measure of the reduction

    in random fluctuation is the ratio of the variance of Y , to

    the variance of

    X, .

    This variance reduction factor is found

    to be equal to 4 ( 2 - a).It can be made arbitrarily small by

    making

    u

    small. However, the conveyor bucket capacity

    required to accommodate the greatest possible load G , on

    the forward leg grows in proportion to l/ a. Thus the price

    for decreased output variance has to be paid by providing

    increased conveyor capacity.

    reas for Further

    Study

    Further work in conveyo r modeling is likely to con tinue in

    two directions. On one han d, there

    is

    a place for large-scale,

    general-purpose simulation models th at can cope with the

    complexity of actual conveyor systems and that allow

    tradeoff studies in the design stage as well as the analysis of

    operational problems of existing conveyors. Analytical

    models, on the o ther hand, are inherently limited to a low

    level of complexity but are designed to shed light on the

    fundamental relationships among im portant conveyor para-

    meters such as conveyor speed, length of forward and return

    paths, spacing of carriers, number and spacing of work

    stations, amounts of in process storage, service disciplines,

    and material flow rates. Existing analytical models should

    evolve towards greater complexity by including a greater

    number of these parameters. In addition, considerable re-

    search opportunities exist fo r the formulation and solution

    of o ptimization problems. Several examples of specific areas

    for fu rther work follow.

    The descriptive model of Gregory and Litton [ 5] may

    be extended to provide performance measures leading to

    determination of the optimum number of servers, the opti-

    mum combination of the conveyor speed and carrier spa.

    ing, and the optimum carrier capacity.

    The deterministic model of Muth [44]

    suggests several

    optimization problems. 1) Given the seq uences Cfi(n)) of

    material flow, how many carriers of what capacity

    will

    minimize the cost of the conveyor system? 2 Given the

    total loading and unloading requirements, what sequences

    &(n) will minimize the cost of the conveyo r system? Here

    it is assum ed th at in process storage is available at th e load-

    ing points and that delayed loading is permitted. This case

    can be formulated as an integer programming problem.

    3 Consider a single loading station having input sequence

    X

    =

    {xi: = 1, . and a single unloading station having

    output sequence

    Y

    =

    bj

    =

    1

    . where

    xi

    and

    y

    are

    nonnegative integers. The following optimization problem

    is posed:

    Minimize

    Ak

    X,

    Y

    P

    Subject to

    C

    xi = yj =K

    j = l

    j=l

    k m o d p O

    k x i, y j

    nonnegative integers.

    The objective function will be a nonlinear function of k and

    the sequences X and Y . Differences in the actual loading

    and unloading sequences

    X

    and

    Y

    and the natural loading

    and unloading sequences fi@ and

    Cf 69)

    will resu lt in

    added costs, perhaps of the form

    [xi

    -

    fI j)l2

    and lyj

    f26]I2

    The value of

    k

    selected yields an associated value o f

    r

    from the relation

    r =

    k mod

    p,

    and the relative convey or

    loading can be d etermined fro m th e recursive relation

    where Hi 0.

    Letting

    c

    =

    minHi*

    then th e actual conveyor

    i

    loading is given by Hi = Hi* - c . The maximum carrying

    capacity of carriers on the conve yor is given by

    Knowing

    B

    and

    k

    the equipment cost component of the

    objective function can be computed.

    The stochastic model of M uth [47] offers the following

    extensions. 1) Given the conve yor cost as a function of

    conveyor capacity, and given the penalty one has to p ay fo r

    the randomness in the conveyor outpu t flow, determine the

    conveyor capacity that minimizes cost. 2) For a fmed

    probability distribution of the inp ut sequence { Xn } and for

    fmed conveyor capacity, determine if there are nonlinear

    decision rules for unloading that achieve a greater variance

    reduction tha n th e linear decision rule.

    3

    Extend this model

    to the case of multiple loading and unloading stations, and

    December 1979, AlIE

    TRANSACTIONS

  • 8/16/2019 A I I E Transactions Volume 11 Issue 4 1979 [Doi 10.1080_05695557908974471] Muth, Eginhard J.; White, John a. -…

    8/9

    seek to reduce this to an equivalent two-station conveyor

    model. One of the interesting aspects of this problem will

    be the allocation of decision rules to the various unloading

    stations, depending upon some predetermined expected

    output rate at each station.

    References

    [ I ]

    Agee, M. H. and Cullinane, T. P., Analyzin g Tw o Link

    Materials Handling Systems for Short Run Production Jobs.

    presented at the 41st National Meeting of ORSA,

    Neu

    Orleans, La. (1972).

    [ 2 ]

    Anderson, D. R. and Moodie, C. L., Optimal Buffer Storage

    Capacity in Production Line Systems,

    International Journal

    of P roduction Research

    7, 3, 233-240 (1969).

    [ 3 ]

    Backart, L. G., Equ ipm ent Se lection Criteria-Conve yors.

    ASTME Publication 73-M H-14, Materials Handling Engineering

    Division, presented a t the Joint Materials Handling Con ference,

    Pittsburgh, Pa., (September 1973).

    [ 4 ]

    Beightler, C. S. and Crisp, R. M., A Discrete-Tim e Quey elng

    Analysis of Conveyor-Serviced Production Stations,

    Opera-

    tions Research

    16,5,986-1001 (1968).

    [ 5 ]

    Brady, W., The Closed Free-Transfer Conv eyor, Unp ublis hed

    B. Sci Thesis, Department of Engineering Production, Uni-

    versity of Birmingham, England (1970).

    (61

    Brady, W., A Comp arison of the Effect of Work-Time Varia-

    tion in Tw o Types of C onveyor System, International Jouv.

    nalofA.oduction Research

    l l , 2 , 171-182 (1973) .

    [ 7 ]

    Burbridge, J. J., An Approa ch to the Analysis of a Conveyor

    System, 38t h National Meeting of ORSA, Detr oit, Michigan,

    (1970).

    [ 8 ]

    Bussey, L. E. and Terrell, M. P., Some Operational Charac-

    teristics of Constant-Speed Recirculating Conveyors with

    Markovian Loadings and Services, presented at the 39th

    National Meeting of ORSA, Dallas, Texas (1971).

    [ 9 ]

    Bussey, L. E. and T errell, M. P., A M odel for Analyzing

    Closed-Loop Conveyor Systems with Multiple Work Stations,

    presented at the 197 3 Winter Simulation Conference. San

    Francisco, California.

    [ l o ] Chen, T. C. and Terrell, M. P., The Stu dy and Developrnent

    of a Utility Simulation Model for Conveyor System Ana lys~s

    Using SIMSCRIPT 11.5, presented a t the Joint ORSA ITIMS

    National Meeting, Philadelphia, Pennsylvania (1976 ).

    1111 Chen, T. C. an d Terre ll, M. P., A Modu lar G enera l Purpose

    Approach to the Simulation of Complex Multi-Loop, Multi-

    Floo r Convey or System, presented at the 1st National Con>-

    puters and Industrial Engineering Conference, Tulsa, Okla-

    homa (1976).

    [1 2] Crisp, R. M., An Analysis of Conve yor Serviced Pro du ctit~ n

    Stations, Unpublished PhD dissertation, University of

    Texas.

    Austin (1976).

    [13]

    Crisp, R. M., Skeith, R. W., and Barnes, J. W., A Simulated

    Study of Conveyor-Serviced Production Stations,

    Interna-

    tional Journal of Production Research

    7,4, 301-309 (1 969).

    [14 ] Cullinane, T. P., A Transient A nalysis of Two. Link Fixed

    Conveyor Systems, Unpub lished PhD dissertation, Virginia

    Polytechnic In stitute an d State University, Blacksburg 197 . .

    1151 Disney, R. L., Some M ultichannel Queue ing Problems wliir

    Ordered Entry,

    Journal o f Industrial Engineering

    13.1,

    46-

    48 (1962).

    [1 6] Disney, R. L., Some Multichann el Queueing Problems with

    Ordered Entry An Application to Conveyor Theory,

    Journal o f Industrial Engineering

    14,2, 105-108 (1963).

    [17]

    Duraiswamy, N. G. and Terrell, M. P., Simulation el ('on-

    stant Speed, Discretely Spaced Recirculating Convey l r ) \

    tems Using GASP IV, presented at the Joint ORS A'I MS

    National Meeting, Philadelphia, Pa., (1976).

    [1 8] El Sayed, A. R., Proct or, C. L., and Elayat, H. A., An dl c\~ \

    of Closed-Loop Conveyor Systems with Multiple Po~\\on

    Inputs and Outputs, International Journal of

    Protluc

    / / ON

    Research

    14, 1,99-109 (1976).

    1191

    El Say ed, E. A., and Proctor, C. L., Ord ered E ntry dnd Kdn

    dom Choice Conveyors with Multiple Inputs, Internatronal

    Journal o f Production Research

    1 5 , 5 , 4 3 9 4 5 1 (1977).

    [2 0] Ghare, P. M., Ward, J. L., and Perry, C. R., Develop ment of

    Conv eyor Unloading Theory, Technical Repo rt of the De-

    partment of Industrial Engineering, Texas Technological

    College, Lubbock (1964).

    [2 1] Go urley , R. L. and Terrell, M. P., A Modu lar Utility Simula-

    tion Model Used to Test and Analyze Proposed Conveyor

    Layouts, Join t ORSA/TIMS National Meeting, San Juan ,

    Puerto Rico (1974).

    1221 Gourley, R. L. and Terrell, M. P., A M odul ar Gen eral Pur-

    pose Approach t o the Simulation of Con stant Speed Discreetly

    Spaced Recirculating Conveyor Systems, 197 4 Systems

    Engineering Conference, American Institute of Industrial

    Engineers, Minneapolis, Minnesota.

    [23] Gourley, R.

    L.,

    Terrell, M. P., and Che n, T. C., The Develop -

    ment of A General Purpose Conveyor Systems Simulation

    Model Utilizing a Modular Format, presented at the 19 75

    Summer Simulation Conference, San Francisco, California.

    Gregory, G. and Lit ton, C. D., A Conve yor Model with

    Exponential Service Times,

    International Journal of Produc-

    tion Research

    13 , 1, 1-7 (1975).

    Gregory, G. and Litto n, C. D., A M arkovian Analysis of a

    Single Conveyor System,

    Management Science

    22, 3, 371-

    375 (1975).

    Gu pta, S. K., Analysis of a Two-Channel Queu eing Problem

    with Ord ered Entry:' Journal of Industrial Engineering 17, 1,

    54-55 (1966).

    Hedstrom , J. C., Ordering L oading Stations Along a Delivery

    Conveyor, Unpub lished MS Thesis, Georgia Ins titut e of

    Technology, A tlanta, Georgia (1976).

    Heikes,

    R.

    G., A Markov Chain Model of a Closed Loo p

    Conve yor System, Unpu blished PhD Dissertation, Tex as

    Tech University, Lub bock (1971).

    Helgeson, W. R., Planning for the Use of Overhead Mono-

    rail Non-Reversing Loo p T ype C onveyor Systems for Storage

    and Delivery,

    The Journal o f Industrial Engineering

    1 1, 6,

    480-492 (1960).

    Hillier,

    I:

    S. and Boling, R. W., The Effect of Some Design

    Factors on the Efficiency of Production Lines with Variable

    Operation Times, Journal o f Industrial Engineering

    7

    12,

    651-658 (1966).

    Hillier, F S. and Boling, R. W., Finite Queues in Series with

    Exponential or Erlang Service Times: 4 Numerical Approach,

    Operations Research

    15 2, 286-303 (1967).

    Howell, W. S., The Analysis of Powered Monorail Conve yor

    Systems, Unpu blished MS Thesis, College of Engineering

    Sciences, Arizona State University (1965).

    *K nott, A. D., The Inefficiency of a Series of Work Stations-

    A Simple Formula,

    International Journal of Production

    Research

    8 2 109-119 (1970).

    Kw o, T. T., A T heory of Conveyors,

    Management Science

    5

    1,51-71 (1958).

    Kwo, T. T., A Method for Designing Irreversible Overhea d

    Loop Conveyors,

    The Journal o f Industrial Engineering

    11

    6 , 4 5 9 4 6 6 ( 19 60 ).

    Matsui, M. and Fuk uta , J., A Queu eing Analysis of Conveyor-

    Serviced Production Station with General Unit-Arrival,

    Jour-

    nal o f the Operations Research Society of Japan

    18 3, 21 1

    227 (1975).

    AIIE

    TRANSACTIONS,

    Volume 1 1, No.

    4

  • 8/16/2019 A I I E Transactions Volume 11 Issue 4 1979 [Doi 10.1080_05695557908974471] Muth, Eginhard J.; White, John a. -…

    9/9

    [37] Mayer, H. Introduction to Conveyor Theory,

    Western

    Electric Engineer 4,1,43-47 1960).

    [38] Mednis, O., Conveyor Theory, talk delivered to the Contri-

    buted Papers Session of the 13th Annual Conference and

    Convention of the American Institute of Industrial Engineers,

    Atlantic City, New Jersey 1962).

    [39] Morris,

    W.

    T.,

    Analysis for Materials Handling Manag~ment

    Richard D. Irwin, Inc., 1962).

    [40] Muth, E.

    J.,

    Analysis of Closed-Loop Conveyor Systems,

    AIIE Transactions

    4

    2,134-143 1972).

    141)

    Muth, E. J., The Production Rate of a Series of Work

    Stations with Variable Service Times,

    International Journal

    of Production Research 11, 2,155-169 1973).

    1421 Muth, E. J., Modeling and System Analysis of Closed-Loop

    Conveyors, presented at the Joint ORSA/TIMS National

    Meeting, San Juan, Puerto Rico (October

    1974).

    [43] Muth, E. J., Analysis of Closed-Loop Conveyor Systems; the

    Discrete Flow Case, AIIE Transactions 6 1,73-83 1974).

    1441 Muth, E. J., Modeling and System Analysis of Multistation

    Closed-Loop Conveyors:'

    International Journal o f Production

    Research 13 6,559-566 1975).

    [45]

    Muth, E. J., A Model of a Closed-Loop Conveyor with Dis

    Crete Flow and Stochastic Input:' Joint ORSA/TIMS National

    Meeting, Las Vegas, Nevada 1975).

    [46] Muth, E. J., Numerical Methods Applicable to a Production

    Line with Stochastic Servers, in Algorithmic Methods in

    Probability, M. F. Neuts, Editor,

    T M S Studies in the Man-

    agement Sciences

    7

    143-159 1977).

    [47]

    Muth, E.

    J.

    A Model of a Closed-Loop Conveyor with

    Random Material Flow,

    AIIE Transactions

    9 4, 345-351

    (December 1977).

    [48] Palm, C., Intensity Fluctuations in Telephone Traffic,

    Ericcson Tech.

    1, 44, 1-18s 1943).

    [49] Panwalker, S. S., A Survey of Assembly Line Balancing

    Techniques, Proceedings American Institute of Industrial

    Engineers,

    27th

    Annual Conference and Convention, St. Louis,

    Mo., 259-263 1976).

    [50] Parker, M W., Aspects of Clump Formation on Conveyors,

    unpublished MS thesis, University of Arkansas, Fayetteville,

    1963).

    [51]

    Perry, C. R., Simulation of a Closed-Loop Conveyor System

    to Develop Relationships between Parameters, unpublished

    MS thesis, Texas Technological College, Lubbock 1965).

    [52] Phillips, D. T., A Markovian Analysis of the Conveyor-

    Serviced Ordered Entry Queueing System with Multiple

    Servers and Multiple Queues, unpublished PhD dissertation,

    University of Arkansas, Fayetteville 1968).

    [53] Phillips, D. T. and Skeith, R. W., Ordered Entry Queueing

    Networks with Multiple Servers and Multiple Queues,

    AIIE

    Transactions 1,4, 333-342 1969).

    [54] Pritsker, A.A.B., Application of Multichannel Queueing

    Results to the Analysis of Conveyor Systems,

    Journal of

    Industrial Engineering

    17,7,14-21 1966).

    [55]

    Proctor, C. L., El Sayed, E. A., and Elayat, H. A., A

    Conveyor System with Homogeneous and Heterogeneous

    Servers with Dual Input, International Journal of Produc-

    tion Research 15, 1, 73-85 1977).

    [56] Reis, I.

    L

    and Schneider, M

    H.

    Probabilistic Conveyor

    Decisions, Kansas State University Experiment Station S p s

    ci l Bulletin No. 19 1962).

    [57] Reis,

    I

    L., Dunlap,

    L.

    L. and Schneider, M H. Conveyor

    Theory: The Individual Station,

    The Journal of Industrial

    Engineering 14,4,212-217 1963).

    [58] Reis, I. L., and Hatcher, J. M., Probabilistic Conveyor

    Analysis,

    International Journal o f Production Research 2

    3,

    186-194 1963).

    Reis, I. L., Brennan, J. J., and Crisp, R. M., A Markovian

    Analysis for Delay at Conveyor-serviced Production Stations,

    International Journal o f Production Research 5,3,201-211,

    1967).

    Sadowski, R. P. and Moodie, C.

    L.

    A Quantitative Method-

    ology for Designing Handling Facilities for Continuous Pro-

    duction Processes with No In-Process Inventory, International

    Journal o f Production Research 11,3, 263-276 1972).

    Schumacher, F. W., A Probabilistic Economic Model of an

    Irreversible Loop Conveyor, unpublished MS thesis, Texas

    Technological College, Lubbock,

    1963).

    Takdcs,

    L.

    On the Limiting Distribution of the Number of

    CoincidencesConcerning Telephone Traffic, Annals o f Mathe-

    matical Statistics 30

    134-142 1959).

    Vars, J. J., An Investigation of Parameter Relationships of

    Closed Loop Conveyor System Models, unpublished MS

    thesis, Texas TechnologicalCollege, Lubbock 1966).

    Ward, J. L., The Development of a Performance Characteris

    tic Model for a Closed Loop Conveyor System, unpublished

    MS thesis, Texas Technological College, Lubbock, 1965).

    White, J. A., Schmidt, J. W. and Bennett,

    G.

    K., Analysisof

    Queueing Systems

    Academic Press, Inc.,

    1975).

    White, J. A., Conveyor Theory: A Normative Approach, un-

    published working paper.

    White, J. A. and Woodbury, W C., Validation of a Conserva-

    tion of

    low

    Approach in Modelling a RecirculatingConveyor:'

    unpublished working paper, School of Industrial and Systems

    Engineering, Georgia Institute of Technology

    1976).

    Eginhard J. Muth is a Professor

    in

    the Department of Industrial and

    Systems Engineering at the University of Florida. He received his

    Diplom-Ingenieur degree in electrical engineering from the University

    of Karlsruhe, Germany, and

    his

    MS and PhD in systems sciencefrom

    the Polytechnic Institute of Brooklyn. He joined the University *of

    Florida in 1969 and prior to that spent 18 years in industry in a

    variety of engineering assignments. His research interests include reli-

    ability theory and modeling of materials handling processes. His

    publications have appeared in various professional ournals. He is the

    author of a book on transform methods. Dr. Muth is a member of

    IEEE and ORSA.

    John A. White is a Professor in the School of Industrial

    and

    Systems

    Engineering at Georgia Institute of Technology. He holds a BSIE

    from the University of Arkansas, an MSIE from Virginia Polytechnic

    Institute and State University, and a PhD from The Ohio State

    University. He is currently performing research in the areas of

    material handling and warehousing. He has published papers in

    several professional journals and has coauthored 3 texts, with 2

    others forthcoming in 1980. He is a member of ASEE, IMMS,

    NCPDM, ORSA, TIMS, SME, and WERC, and serves as a Department

    Editor for

    AIIE Dansactions

    December

    1979

    AIIE

    TRANSACTIONS

    277