Homogeneous Asymptotically Reliable Serial Production Lines: Theory and a Case Study

In this paper, a model of homogeneous, asymptotically reliable serial production lines is introduced, analyzed, and applied to the problem of 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 the one hand, simpler for analysis than traditional models discussed in the literature for the last 25 years and, on the other, sufficiently rich to reflect the behavior of real manufacturing systems. The asymptotic theory developed here gives analytical formulas for production rates as a function of system parameters and, therefore, can be used as an inexpensive tool for the analysis and design of manufacturing processes in mass production systems, eliminating, in some cases, the necessity of complex and costly computer simulations.