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Over the past few decades, buffer allocation problems have been investigated extensively. It is widely known that buffers play important roles in the manufacturing system, including preparing disruption and improving efficiency. However, due to a physical limit for buffer space and the related cost burden, optimal buffer allocation has become an important issue. In this paper, a solution for optimal buffer allocation in a flexible manufacturing system (FMS) with finite buffers is presented. Unlike most previous studies, which mainly focused on input buffers only and operation dispatching in simple production lines, this paper considers both input and output buffers together in complex production lines where multiple workstations, multiple automatic guided vehicles, and complicated paths exist. Also, we address a practical buffer allocation problem by increasing total number of buffers and changing a buffer profile (capacities of multiple input/output buffers). A simulation and a genetic algorithm are used to solve our problem. While the simulation models the process of the complex FMS, the genetic algorithm determines the optimal buffer allocation. The proposed solution performs better than the conventional heuristic used in practice.

Optimal Buffer Allocation in Flexible Manufacturing Systems Using Genetic Algorithm and Simulation