Analysis of long flow lines with quality and operational failures

Abstract This paper presents approximation methods for the performance analysis of long manufacturing lines, i.e. lines with more than two machines and one buffer, that have both quality and operational failures. We describe three different versions of long flow lines that differ in the locations of the inspection stations and in the sets of machines that each inspection station monitors. We explain a transformation method that approximates long manufacturing lines that have quality and operational failures with long lines that only have operational failures. Such lines can be evaluated by decomposition methods. We introduce other approximations to quantify the effects of the separation of inspections from operations. Comparison with simulation shows that the solution methods provide reliable performance estimates.