Hierarchical production policies in stochastic two-machine flowshops with finite buffers

Abstract

This paper concerns production planning in manufacturing systems with two unreliable machines in tandem. The problem is formulated as a stochastic control problem in which the objective is to minimize the expected total cost of production, inventories, and backlogs. Since the sizes of the internal and external buffers are finite, the problem is one with state constraints. As the optimal solutions to this problem are extremely difficult to obtain due to the uncertainty in machine capacities as well as the presence of state constraints, a deterministic limting problem in which the stochastic machine capacities are replaced by their mean capacities is considered instead. The weak Lipschitz property of the value functions for the original and limiting problems is introduced and proved; a constraint domain approximation approach is developed to show that the value function of the original problem converges to that of the limiting problem as the rate of change in machine states approaches infinity. Asymptotic optimal production policies for the orginal problem are constructed explicity from the near-optimal policies of the limiting problem, and the error estimate for the policies constructed is obtained. Algorithms for constructing these policies are presented.