A System Theory for Production Lines

A system-theoretic approach to serial production lines is described. The approach is based on the notion of Improvability. A production system is called improvable under constraints if limited resources involved in its operation can be redistributed so that a performance index is improved. Unconstrained improvability is a problem of determining the operation the improvement of which leads to the largest improvement of the production system as a whole. In this work, criteria for improvability, both constrained and unconstrained, are derived. These criteria, referred to as Indicators of Improvability, can be applied using the off-line and, more importantly, real-time data. Based on the indicators obtained, production line personnel could design and implement various continuous improvement projects. As an illustration, an application of this approach to an automotive component plant is briefly reviewed.