A Discrete-Time Queueing Model of a Bottleneck with an Energy-Saving Mechanism Based on Setup and Shutdown Times

Producers are encouraged to reduce their energy consumption of manufacturing systems by applying less-energy-intensive modern technologies and advanced machine tools and operating methods at the system level. In the paper, organizational and analytical solutions are combined to model the sustainable production system. Managers can study the behavior of a production system organized using energy-saving rules by changing key parameters of the input model (arrival intensity, bottleneck service rate, buffer size, setup and shutdown time) to analyze the queue size of the production system and therefore performance. A discrete-time queueing model of a single-bottleneck production line with a finite input buffer capacity is proposed. Jobs occur according to a binomial process and are processed individually, one by one, according to the natural FIFO service discipline, with a general discrete-type cumulative distribution function. The total number of jobs present in the system is bounded by a non-random fixed value N. Every time the system becomes empty, an energy-saving mechanism is started: the processing machine (server) is turned off during a geometrically distributed shutdown time. Similarly, the first job arriving into the empty system initializes a geometrically distributed setup time. Identifying renewal moments in the evolution of the model, a system of difference equations is built for the transient queue-size distribution conditioned by the state of the system at the opening. The solution is obtained explicitly in terms of probability-generating functions. In addition, the Drum-Buffer-Rope concept is proposed to reduce the energy consumption of the production line. The throughput of the production system is maximized by adjusting the time between the order arrivals and the size of the input buffer to the capacity of the bottleneck. Turning off a machine under certain conditions and slowing down non-critical machines are strategies to reduce energy consumption. A detailed illustrating numerical and simulation study of the considered model is attached as well, in which the sensitivity of the queue-size behavior to changes of the key input model parameters is investigated.