2.852 Syllabus -- Spring 2004

# # 2.852 Syllabus -- Spring 2004

To go to Gershwin's homepage click HERE

Final Exam!! Not a moment too soon! Contact one of us right away if there are any (unintended) problems with it.

You are probably wondering what Youngjae thinks about when he is not working. Here is a photo of him relaxing with Max, the optimizing dog. They are both thinking about their favorite things.

2.852 -- Manufacturing Systems Analysis

Spring 2004

Monday and Wednesday

11:30 - 1:00 --

Room 2-142

Objectives of Course

Describe some important issues in the design and operation of manufacturing systems.
Explain important measures of system performance.
Show the importance of random, potentially disruptive events.
Give some intuition about behavior of these systems.
Explain the importance of capacity, and how it can vary randomly over time.
Teach enough mathematics (especially probability) to describe manufacturing systems behavior.
Show how in-process inventory is sometimes a necessary evil -- that is, show the benefits as well as costs.
Present some practical tools for systems design.
Describe issues in real-time scheduling, and show why deterministic scheduling is often not adequate.
Present some simple scheduling rules.

Syllabus

approximate, tentative

Lecture	Date	Chapter*	Topic
1	2/4	2	Introduction
2	2/9	2	Probability -- Basic Concepts
3	2/11	2	Markov Chains and Processes
4	2/17	2	Markov Chains and Processes
5	2/18	2	The M/M/1 Queue
6	2/23	2	Controlled Machine
7	2/25	3	Transfer Lines -- models and bounds
8	3/1	3	Transfer Lines -- models and bounds
9	3/3	3	Deterministic processing time transfer line -- 2-machine
10	3/8	3	Deterministic processing time transfer line -- 2 machine
11	3/10	3	Deterministic processing time transfer line -- 2 machine
12	3/15	3	DET2TL performance; Exponential processing time transfer line -- 2 machine
13	3/17	3	Exponential processing time transfer line -- 2 machine
	3/22		Spring Break: No Class!
	3/24		Spring Break: No Class!
14	3/29	3	Exponential processing time transfer line -- 2 machine
15	3/31	3	EXP2TL, CON2TL performance; Continuous material transfer line -- 2 machine
16	4/5	3	Continuous material transfer line -- 2 machine - MIDTERM ASSIGNED
17	4/7	4	Deterministic processing time transfer line -- many machines
18	4/12	4	Deterministic processing time transfer line -- many machines -- MIDTERM DUE
19	4/14	4	Deterministic processing time transfer line -- long line optimization
	4/19	4	Patriot's Day: No Class!
20	4/21	4	Long lines
21	4/26	4	Assembly/Disassembly Systems
22	4/28	5	Assembly/Disassembly Systems
23	5/3	7	Real-time scheduling
24	5/5		Real-time scheduling -- Some lecture notes -- FINAL EXAMINATION ASSIGNED
25	5/10		Current Research: Quality and Quantity
26	5/12		Current Research: (1) SBG -- (2) YJJ -- (3) Report by Anonymous Student Who Also Writes Horror Stories -- FINAL EXAMINATION DUE

tentative, preliminary, approximate, subject to change

* Manufacturing Systems Engineering by Stanley B. Gershwin, Prentice Hall, 1994.
If we can arrange it, there will be an optional visit to a local factory in the first half of the term.

General Information


PREREQUISITES	probability and optimization or permission of the instructor Probability (6.041 or 18.05) is the important prerequisite.
QUIZZES	take-home midterm and final
PROJECT	optional, to replace half of final
GRADES or	10% homework, 30% midterm, 60% final 10% homework, 30% midterm, 30% final, 30% project
TEXT	Manufacturing Systems Engineering by Stanley B. Gershwin Prentice Hall, 1994. Out of print. Available from author.
COMPUTER	Athena and web page
INSTRUCTOR	Stanley B. Gershwin 35-331 253-2149 gershwin@mit.edu
TEACHING ASSISTANT	Youngjae Jang 35-336 253-4595 by appointment youngjae@MIT.EDU

Homework Schedule

Assignment	Chapter	Problems	Lecture due
1	2	1, 4, 10, 11	6
2	2	13, 14, 15, 16, 17, 18	9
3	3	3, 4, 5, 11, 13, 17	12
4	3	24, 26, 27, 28	14
5	4	1, 3, 5, 9, 10, 11	20
6	_	CANCELLED	_

Optional Projects

The goal of the project option is to give you an opportunity to demonstrate your mastery of the ideas of the course in a less restrictive, more realistic manner than in an exam or a homework assignment. In most cases, the project will require you to combine material from the course with other material. People who have worked in factories have a definite advantage. The project is optional, to replace the first half of the final.

Procedure

1. Write a one-to-two page project proposal by Lecture 15. If I approve, you may do the project.

2. I may ask for a revision of the proposal.

3. Give me an informal written progress report by Lecture 21. I may ask you not to proceed with the project if I don't think you have enough time to do a good job.

4. Hand in a project report with the second half of the final. The length of the report is negotiable, with the expectation that it will be in the neighborhood of 20 pages double-spaced.

In the proposal, describe the goal of the work and the procedure that you will follow.

Sample project ideas The following is a set of sample ideas. You are not restricted to them. In fact, if too many people want to do the same thing, some proposals will be rejected for that reason alone. Feel free to submit other ideas.

If you have some factory experience, apply the models and methods of this course to a factory (or a portion of a factory) that you are familiar with. Show how to improve the design of the factory, or how to design an operating policy.
If you have some factory experience, critique the models and methods of this course. Describe their limitations, that is, why they would not be helpful in redesigning or operating the factory you are familiar with. Propose one or more alternate models, and go as far as possible in analyzing and developing them.
Develop some tools that will help the optimization of a production system design. A 1993 student did this for transfer lines. A 1994 student continued the work, and based a Master's thesis and published a paper on it. There is still plenty of work to do in this area.
Add financial calculations to the transfer line models. That is, do a present value analysis, cash-flow analysis, etc.
Do some interesting, but not too ambitious, original mathematics. Examples might include: prove conservation of flow for one of the transfer line models; get an analytical solution for a simple hedging point system; propose a new algorithm to approximate hedging points; come up with ideas for extending the transfer line decomposition to non-tandem lines and test with simulation; etc. It is hard to know in advance what will be easy and what will be difficult. (That makes it hard to make suggestions, and impossible to guarantee that the suggestions are doable.) For me to approve such a project, you must include an outline of the proof (or preliminary simulation results, or whatever) when you hand in the proposal.

Closely related course. Similar to this one, but broader (and therefore less deep).

MIT 2.853, 2.854; SMA 6304.

Interesting links, found and selected at random Watch this space. More will be added as I surf the web when I should be working.

My site. A lot of it is obsolete (especially my picture!) but there is one really popular item on it.

http://www.win.tue.nl/~iadan/sdp/.

http://l1.lamsade.dauphine.fr/~giard/99-05.htm.

http://home.ku.edu.tr/~btan/publications/BookChapters/BookC_Pull01.pdf

http://www.jkrconsult.com/capbib.htm

http://www.mie.uth.gr/labs/pml/LibTsaInterfaces32(3).pdf

http://www.bilkent.edu.tr/~ie477/case/PeugeotCitroen.pdf

http://www.pom-consult.de/indexe.html

http://www.amemco.net/

Miscellaneous handouts from 2002: Not much more will be added here.

Take a look at the "deterministic" two-machine line state space graph, .ps or .gif.

Take a look at the "exponential" two-machine line state space graph, .ps or .gif.