Fall 1996

IEOR 5990: Design and Analysis of Manufacturing Systems

TTH: 11:15 - 13:10

Course objectives: This course is intended to provide an introduction to the design, analysis and control of manufacturing systems. Systems of interest include automated flow lines, assembly systems, cellular and flexible manufacturing systems. Both hardware and software requirements of such systems will be reviewed. However, emphasis will be on methodologies of system design, modeling and control. Issues addressed will include part flow management, lead time analysis, facilities planning and layout, real time production control and scheduling, and information flow management. Special attention will be paid to emerging trends in manufacturing such as JIT, agile manufacturing, theory of constraints, computer integration, and distributed manufacturing.

Prerequisites: Although not required, introductory courses in operations research, production planning and control, and manufacturing processes are useful.

Instructor: Prof. Saifallah Benjaafar - ME 205 - Tel: 6-7239 - email: saif@maroon.tc.umn.edu

Text: Automation, Production Systems, and Computer-Integrated Manufacturing, Mikell P. Groover, Prentice-Hall, 1991. A substantial amount of the readings will come from assorted papers from recent literature.

Instructor: Prof. Saifallah Benjaafar - ME 205 - Tel: 6-7239 - email: saif@staff.tc.umn.edu

Office hours: Wednesday: 2:00 - 1:00 and Friday 2:00 - 4:00 (or by appointment).

Teaching assistant: Mehdi Sheikhzadeh, ME 15B, email: mehdi@me.umn.edu.

Homework: Assigned weekly and is due a week from the assignment date (unless instructed otherwise). Homework solutions will be either distributed in class or placed on reserve in Walter Library. In addition, each student will be assigned a paper for in-class presentation and critique. All students are required to provide a one page summary of each presented paper. Summaries are due the day of the corresponding presentation.

Exams: Two in-class exams. Tentative dates are: October 29 and November 26. No final exam. Exam solutions and sample exams will be either placed on reserve in Walter Library or distributed in class.

Term Project: Two progress reports will be due October 15 and November 5, respectively. Project presentations will be scheduled during the last week of class. Project reports will be due on the last day of finals week.

Grading: Final grades will be assigned based on the following breakdown:

Exam 1: 25%, Exam 2: 25%, HWK: 25%, and Project: 25%.

Computer access: Access to the following computing laboratory is provided: ME 308 (IBM & SGI), EE/CS 3-166 (MAC & IBM), and EE/CS 4-204 (Mac, Sun & Next). Lab attendants should be able to help you with workstation access and operating systems problems. Graduate students have also acccess to the CIMLAB in Old EE 248.

Re-grades: You may submit an assignment or an exam for a re-grade within 5 working days following its return date. Re-grade requests are not accepted after this time limit. The requests must be accompanied by a written explanation of where you feel the original grading was inaccurate.

Incompletes: The grade of "I" is awarded only in the case of exceptional and verifiable severe illness or tragedy. An "I" will not be awarded because you are doing poorly in the class.

Class attendance: While attendance will not be taken, attendance of all lectures is expected. You will be held responsible for all material presented and work assigned in class. Copies of notes for any missed lectures will not be provided.

The following is a tentative schedule of lecture topics:

Week 1: Introduction to Manufacturing Systems (chapters 1 and 2 & handouts)

Week 2: Flow lines (Chapters 4 and 5)

Week 3: Assembly Systems (Chapter 6 and 7)

Week 4: Cellular Manufacturing Systems (chapter 16 & handouts)

Week 5: Flexible Manufacturing Systems (Chapters 17 & handouts)

Week 7: Computer Integrated Manufacturing Systems (Chapters 23-27 & handouts)

Week 8: Performance Evaluation: Queuing Networks, Simulation, and Petri-Nets (Handouts)

Week 9: Performance Evaluation: Queuing Networks, Simulation, and Petri-Nets (Handouts)

Week 10: Factory of the Future and Project Presentations (Handouts)

The following is a tentative list of the papers for in-class presentation:

[1] Hopp, W. J., M. L. Spearman, and D. L. Woodruff. "Practical Strategies for Lead Time Reduction," Manufacturing Review, Vol. 3, No. 2, 1990.

[2] Sugimori, Y., K. Kusunoki, F. Cho and S. Uchikawa, "Toyota Production System," International Journal of Production Research, Vol. 15, No. 6, 1977.

[3] Goldratt, E. M., "Computerized Shop Floor Scheduling," International Journal of Production Research, Vol. 26, No. 3, 1985.

[4] Spearman, M., D. Woodruff, and W. Hopp, "CONWIP: A Pull Alternative to Kanban," International Journal of Production Research, Vol. 28, No. 5, pp. 879-894, 1990.

[5] Jovane, F. and L. Alting, "A Key issue in Product Life Cycle: Disassembly," Annals of the CIRP, Vol. 42, No. 2, pp. 651-658, 1993.

[6] Drolet, J. R. and C. L. Moodie, "A Virtual Cell Scheduling Algorithm," Technical Report, Purdue University, 1989.

[7] Upton, D., "A Flexible Structure for Computer Controlled Manufacturing Systems," Manufacturing Review, Vol. 5, No. 1, pp. 58-74, 1992.

[8] Chang, T. C., "QTC - An Integrated Manufacturing Cell with Process Planning Capability," Manufacturing Cells, Butterworth, 1991.

[9] Benjaafar, S., "Intelligent Simulation for Flexible Manufacturing Systems: An Integrated Approach," Computers and Industrial Engineering, Vol. 22, No. 3, pp. 297-311, 1992.

[10] Lin, G. Y. and J. J. Solberg, "Integrated Shop Floor Control Using Autonomous Agents," IIE Transactions, Vol. 24, No. 3, 1992.

The following is a tentative list of video tapes for in-class viewing:

[1] Rapid Response Manufacturing, SME, 31 minutes.

[2] Agile Manufacturing, SME, 52 minutes.

[3] Flexible Manufacturing Cells, SME, 24 minutes.

[4] Small Lot Production, SME, 22 minutes.

[5] Flexible Manufacturing Systems, SME, 55 minutes.

Additional Texts

Modeling and Analysis of Manufacturing Systems, Ronald G. Askin and Charles Standridge, John Wiley, 1993.

Computer Aided Manufacturing, Chang, T. C., Wysk, R. A. and H. Wang, Prentice-Hall, 1991.

Performance Modeling of Automated Manufacturing Systems, N. Viswanadham and Y. Narahari, Prentice Hall, 1992.

Factory Physics, W. W. Hopp and M. L. Spearman, Irwin, 1995.

Computer Integrated Manufacturing and Engineering , U. Rembold and B. O. Nnaji, and A. Storr, Addison-Wesley, 1994.

Manufacturing Systems: Theory and Practice, Chryssolouris, G., Springer-Verlag, 1992.

Flexible Manufacturing Systems in Practice - Applications, Design, and Simulations, Talavage, J. and R. G. Hannam, New York, Marcel Dekker, 1988.

Journals in Production and Manufacturing

International Journal of Production Research

Journal of Manufacturing Systems


International Journal of Flexible Manufacturing Systems

IIE Transactions

Robotics and Computer Integrated Manufacturing

Computers in Industry

Computers and Industrial Engineering

European Journal of Operational Research

Operations Research

Management Science

Manufacturing Review

Decision Sciences

Queuing Systems

Journal of Operations Management

Production and Operations Management

International Journal of Production and Operations Management

IEEE Transactions on Robotics and Automation

IEEE Transactions on Automatic Control

IEEE Transactions on Systems, Man, and Cybernetics

ASME Journal for Industry

Computers and Operations Research


Industrial Engineering

OR/MS Today

Manufacturing Engineering

Production Engineering

APICS Production and Inventory Control

Mechanical Engineering


Handbook of Industrial Engineering

Handbook of Operations Research

The Flexible Manufacturing Systems Handbook

Flexible Automation, The International Guidebook on Computer Integrated Manufacturing