Skip to main content
SpringerLink
Log in

The state of the art on buffer allocation problem: a comprehensive survey

  • Published:
Journal of Intelligent Manufacturing Aims and scope Submit manuscript

Abstract

The buffer allocation problem is an NP-hard combinatorial optimization problem and it is an important research issue in designing manufacturing systems. The problem deals with finding optimal buffer sizes to be allocated into buffer areas in a production system to achieve a specific objective. This paper presents a comprehensive survey on buffer allocation problem in production systems. To provide a systematic review of current relevant research, first studies are grouped in two categories: 1. Reliable production lines, 2. Unreliable production lines. Next, the studies in each group are reviewed based on topology of the production line, the solution methodologies suggested and the objective function employed. The aim of this review is twofold. First, it provides an overview of recent advances in the field in order to highlight the new trends in solution methodology. Second, it presents ideas for future research by identifying gaps in the current literature.

This is a preview of subscription content, log in via an institution to check access.

Access this article

Log in via an institution

Price excludes VAT (USA)
Tax calculation will be finalised during checkout.

Instant access to the full article PDF.

Institutional subscriptions

Similar content being viewed by others

References

  • Abdul-Kader W., Gharbi A. (2002) Capacity estimation of a multi-product unreliable production line. International Journal of Production Research 40(18): 4815–4834

    Article  Google Scholar 

  • Abdul-Kader W., Ganjavi O., Baki F. (2011) A nonlinear model for optimizing the performance of a multi-product production line. International Transactions in Operational Research 18(5): 561–577

    Article  Google Scholar 

  • Aksoy K. H., Gupta S. M. (2005) Buffer allocation plan for a remanufacturing cell. Computers, Industrial Engineering 48: 657–677

    Article  Google Scholar 

  • Aksoy K. H., Gupta S. M. (2010) Near optimal buffer allocation in remanufacturing systems with N-policy. Computers,Industrial Engineering 59: 496–508

    Article  Google Scholar 

  • Aksoy K. H., Gupta S. M. (2011) Optimal management of remanufacturing systems with server vacations. International Journal of Advanced Manufacturing Technology 54(9-12): 1199–1218

    Article  Google Scholar 

  • Allon G., Kroese D. P., Raviv T., Rubinstein R. Y. (2005) Application of the cross-entropy method to the buffer allocation problem in a simulation-based environment. Annals of Operations Research 134(1): 137–151

    Article  Google Scholar 

  • Altiparmak F., Dengiz B., Bulgak A. A. (2007) Buffer allocation and performance modeling in asynchronous assembly system operations: An artificial neural network metamodeling approach. Applied Soft Computing 7: 946–956

    Article  Google Scholar 

  • Amiri, M., Mohtashami, A. (2011). Buffer allocation in unreliable production lines based on design of experiments, simulation, and genetic algorithm. International Journal of Advanced Manufacturing, doi:10.1007/s00170-011-3802-8.

  • Battini D., Persona A., Regattieri A. (2009) Buffer size design linked to reliability performance: A simulative study. Computers , Industrial Engineering 56(4): 1633–1641

    Article  Google Scholar 

  • Bertazzi L. (2011) Determining the optimal dimension of a work-in-process storage area. International Journal of Production Economics 131(2): 483–489

    Article  Google Scholar 

  • Bulgak A. A. (2006) Analysis and design of split and merge unpaced assembly systems by metamodelling and stochastic search. International Journal of Production Research 44(18-19): 4067–4080

    Article  Google Scholar 

  • Buzacott J. A., Shanthikumar J. G. (1993) Stochastic models of manufacturing systems. Prentice-Hall, New Jersey

    Google Scholar 

  • Can, B., Beham, A., Heavey, C. (2008) A comparative study of genetic algorithm components in simulation-based optimisation. Proceedings of the 2008 winter simulation conference, 1829–1837.

  • Can, B., Heavey, C. (2009). Sequential metamodelling with genetic programming and particle swarms. Proceedings of the 2009 Winter Simulation Conference, 3150-3157.

  • Can B., Heavey C. (2011) Comparison of experimental designs for simulation-based symbolic regression of manufacturing systems. Computers , Industrial Engineering 61(3): 447–462

    Article  Google Scholar 

  • Can B., Heavey C. (2012) A comparison of genetic programming and artificial neural networks in metamodeling of discrete-event simulation models. Computers, Operations Research 39(2): 424–436

    Article  Google Scholar 

  • Chaharsooghi S. K., Nahavandi N. (2003) Buffer allocation problem, a heuristic approach. Scientia Iranica 10(4): 401–409

    Google Scholar 

  • Chan F. T. S., Ng E. Y. H. (2002) Comparative evaluations of buffer allocation strategies in a serial production line. The International Journal of Advanced Manufacturing Technology 19: 789–800

    Article  Google Scholar 

  • Chehade, H., Yalaoui, F., Amodeo, L., & Dugardin, F. (2010). Buffers sizing in assembly lines using a Lorenz multiobjective ant colony optimization algorithm. IEEE International Conference on Machine and Web Intelligence, 283–287.

  • Chow W.-M. (1987) Buffer capacity analysis for sequential production lines with variable process times. International Journal of Production Research 25(8): 1183–1196

    Google Scholar 

  • Colledani, M., Grasso M., Matta A., & Tolio, T. (2004). A new analytical method for buffer space allocation in production lines. 37th CIRP international seminar on manufacturing systems, pp. 231–237.

  • Colledani M., Ekvall M., Lundholm T., Moriggi P., Polato A., Tolio T. (2010) Analytical methods to support continuous improvements at Scania. International Journal of Production Research 48(7): 1913–1945

    Article  Google Scholar 

  • Cruz F. R. B., Duarte A. R., Van Woensel T. (2008) Buffer allocation in general single-server queuing networks. Computers, Operations Research 35(11): 3581–3598

    Article  Google Scholar 

  • Cruz F. R. B., Van Woensel T., Smith J. M. (2010) Buffer and throughput trade-offs in M/G/1/K queuing networks: A bi-criteria approach. International Journal of Production Economics 125: 224–234

    Article  Google Scholar 

  • Cruz, F. R. B., Kendall, G., While, L., Duarte, A. R., Brito, N. L. C. (2012). Throughput maximization of queueing networks with simultaneous minimization of service rates and buffers. Mathematical Problems in Engineering (in press).

  • Dallery Y., Gershwin S. B. (1992) Manufacturing flow line systems: A review of models and analytical results. Queuing Systems 12(1-2): 3–94

    Article  Google Scholar 

  • Daskalaki S., Smith J. M. (2004) Combining routing and buffer allocation problems in serial-parallel queuing networks. Annals of Operations Research 125: 47–68

    Article  Google Scholar 

  • Deb K., Pratap A., Agarwal S., Meyarivan T. (2002) A fast and elitist multiobjective genetic algorithm: NSGA-II. IEEE Transactions on Evolutionary Computation 6(2): 182–197

    Article  Google Scholar 

  • Demir, L., & Tunali, S. (2008). A new approach for optimal buffer allocation in unreliable production lines. Pcoceedings of 38th International Conference on Computers , Industrial Engineering, 1962-1970.

  • Demir, L., Tunali, S., & Eliiyi, D. T. (2010). An adaptive tabu search approach for buffer allocation problem in unreliable production lines. 24th Mini EURO conference on continuous optimization and information-based technologies in the financial sector, Selected Papers, pp. 207–212.

  • Demir L., Tunali S., Løkketangen A. (2011) A tabu search approach for buffer allocation in production lines with unreliable machines. Engineering Optimization 43(2): 213–231

    Article  Google Scholar 

  • Demir L., Tunali S., Eliiyi D. T. (2012) An adaptive tabu search approach for buffer allocation problem in unreliable non-homogenous production lines. Computers, Operations Research 39(7): 1477–1486

    Article  Google Scholar 

  • Diamantidis A. C., Papadopoulos C. T. (2004) A dynamic programming algorithm for the buffer allocation problem in homogeneous asymptotically reliable serial production lines. Mathematical Problems in Engineering 3: 209–223

    Article  Google Scholar 

  • Dolgui A., Eremeev A., Kolokolov A., Sigaev V. (2002) A genetic algorithm for the allocation of buffer storage capacities in a production line with unreliable machines. Journal of Mathematical Modeling and Algorithms 1: 89–104

    Article  Google Scholar 

  • Dolgui A., Eremeev A., Sigaev V. (2007) HBBA: Hybrid algorithm for buffer allocation in tandem production lines. Journal of Intelligent Manufacturing 18: 411–420

    Article  Google Scholar 

  • Enginarlar E., Li J., Meerkov S. M., Zhang R. Q. (2002) Buffer capacity for accommodating machine downtime in serial production lines. International Journal of Production Research 40: 601–624

    Article  Google Scholar 

  • Enginarlar E., Li J., Meerkov S. M. (2005) How lean can lean buffers be?. IIE Transactions 37: 333–342

    Article  Google Scholar 

  • Fuxman L. (1998) Optimal buffer allocation in asynchronous cyclic mixed model assembly lines. Production and Operations Management 7(3): 294–311

    Article  Google Scholar 

  • Gasimov R. N., Ustun O. (2007) Solving the quadratic assignment problem using F-MSG algorithm. Journal of Industrial and Management Optimization 3(2): 173–191

    Article  Google Scholar 

  • Gershwin S. B., Schor J. E. (2000) Efficient algorithms for buffer space allocation. Annals of Operations Research 93: 117–144

    Article  Google Scholar 

  • Gurkan G. (2000) Simulation optimization of buffer allocations in production lines with unreliable machines. Annals of Operations Research 93: 177–216

    Article  Google Scholar 

  • Han M-S., Park D-J. (2002) Optimal buffer allocation of serial production lines with quality inspection machines. Computers, Industrial Engineering 42: 75–89

    Article  Google Scholar 

  • Harris J. H., Powell S. G. (1999) An algorithm for optimal buffer placement in reliable serial lines. IIE Transactions 31: 287– 302

    Google Scholar 

  • Heavey C., Papadopoulos H. T., Browne J. (1993) The throughput rate of multistation unreliable production lines. European Journal of Operational Research 68: 69–89

    Article  Google Scholar 

  • Helber S. (2001) Cash-flow-oriented buffer allocation in stochastic flow lines. International Journal of Production Research 39(14): 3061–3083

    Article  Google Scholar 

  • Helber S., Schimmelpfeng K., Stolletz R., Lagershausen S. (2011) Using linear programming to analyze and optimize stochastic flow lines. Annals of Operations Research 182(1): 193–211

    Article  Google Scholar 

  • Hemachandra N., Eedupuganti S. K. (2003) Performance analysis and buffer allocations in some open assembly systems. Computers, Operations Research 30: 695–704

    Article  Google Scholar 

  • Hillier S. M. (2000) Characterizing the optimal allocation of storage space in production line systems with variable processing times. IIE Transactions 32: 1–8

    Google Scholar 

  • Hillier S. M., Hillier F. S. (2006) Simultaneous optimization of work and buffer space in unpaced production lines with random processing times. IIE Transactions 38: 39–51

    Article  Google Scholar 

  • Huang M-G., Chang P-L., Chou Y-C. (2002) Buffer allocation in flow-shop-type production systems with general arrival and service patterns. Computers, Operations Research 29: 103– 121

    Article  Google Scholar 

  • Jeong K-C., Kim Y-D. (2000) Heuristics for selecting machines and determining buffer capacities in assembly systems. Computers, Industrial Engineering 38: 341–360

    Article  Google Scholar 

  • Kim S., Lee H-J. (2001) Allocation of buffer capacity to minimize average work-in-process. Production Planning, Control 12(7): 706–716

    Article  Google Scholar 

  • Koenigsberg E. (1959) Production lines and internal storage—A review. Management Science 5: 410–433

    Article  Google Scholar 

  • Kose, S. Y. (2010). Capacity improvement in a real manufacturing system using a hybrid simulation/genetic algorithm approach. M.S. Thesis, Dokuz Eylul University, Graduate School of Natural and Applied Sciences.

  • Kwon S-T. (2006) On the optimal buffer allocation of an FMS with finite in-process buffers. LNCS 3982: 767–776

    Google Scholar 

  • Lee S-D. (2000) Buffer sizing in complex cellular manufacturing systems. International Journal of Systems Science 31(8): 937–948

    Article  Google Scholar 

  • Lee S-D., Ho S-H. (2002) Buffer sizing in manufacturing production systems with complex routings. International Journal of Computer Integrated Manufacturing 15(5): 440–452

    Article  Google Scholar 

  • Lee H-T., Chen S-K., Shunder Chang S. (2009) A meta-heuristic approach to buffer allocation in production line. Journal of C.C.I.T. 38(1): 167–178

    Google Scholar 

  • Louw L., Page D. C. (2004) Queuing network analysis approach for estimating the sizes of the time buffers in Theory of Constraints-controlled production systems. International Journal of Production Research 42(6): 1207–1226

    Article  Google Scholar 

  • Lutz C. M., Davis K. R., Sun M. (1998) Determining buffer location and size in production lines using tabu search. European Journal of Operational Research 106: 301–316

    Article  Google Scholar 

  • Massim Y., Yalaoui F., Amodeo L., Chatelet E., Zeblah A. (2010) Efficient combined immune-decomposition algorithm for optimal buffer allocation in production lines for throughput and profit maximization. Computers , Operations Research 37(4): 611–620

    Article  Google Scholar 

  • Massim, Y., Yalaoui, F., Chatelet, E., Yalaoui, A., & Zeblah, A. (2012). Efficient immune algorithm for optimal allocations in series-parallel continuous manufacturing systems. Journal of Intelligent Manufacturing, doi:10.1007/s10845-010-0463-7

  • Matta A., Runchina M., Tolio T. (2005) Automated flow lines with shared buffer. OR Spectrum 27: 265–286

    Article  Google Scholar 

  • McNamara T., Shaaban S., Hudson S. (2011) Unpaced production lines with three simultaneous imbalance sources. Industrial Management, Data Systems 111(9): 1356–1380

    Article  Google Scholar 

  • Meester L. E., Shanthikumar J. G. (1990) Concavity of the throughput of tandem queuing systems with finite buffer storage space. Advances in Applied Probability 22: 764–767

    Article  Google Scholar 

  • Nahas N., Ait-Kadi D., Nourelfath M. (2006) A new approach for buffer allocation in unreliable production lines. International Journal of Production Economics 103: 873–881

    Article  Google Scholar 

  • Nahas N., Ait-Kadi D., Nourelfath M. (2009) Selecting machines and buffers in unreliable series-parallel production lines. International Journal of Production Research. 47(14): 3741– 3774

    Article  Google Scholar 

  • Nieuwenhuyse I. V., Vandaele N., Rajaram K., Karmarkar U. S. (2007) Buffer sizing in multi-product multi-reactor batch processes: Impact of allocation and campaign sizing policies. European Journal of Operational Research 179: 424–443

    Article  Google Scholar 

  • Nourelfath M., Nahas N., Ait-Kadi D. (2005) Optimal design of series production lines with unreliable machines and finite buffers. Journal of Quality in Maintenance Engineering 11(2): 121–138

    Article  Google Scholar 

  • Othman Z., Kamaruddin S., Ismail M. S. (2007) Optimal buffer allocation for unpaced balanced and unbalanced mean processing time. Journal Teknologi 46(A): 31–42

    Google Scholar 

  • Papadopoulos H. T., Heavey C., Browne J. (1993) Queuing Theory in Manufacturing Systems Analysis and Design. Chapman and Hall, London

    Google Scholar 

  • Papadopoulos H. T., Heavey C. (1996) Queuing theory in manufacturing systems analysis and design: A classification of models for production and transfer lines. European Journal of Operational Research 92: 1–27

    Article  Google Scholar 

  • Papadopoulos H. T., Vidalis M. I. (1998) Optimal buffer storage allocation in balanced reliable production lines. International Transactions on Operational Research 5(4): 325–339

    Article  Google Scholar 

  • Papadopoulos H. T., Vidalis M. I. (2001) A heuristic algorithm for the buffer allocation in unreliable unbalanced production lines. Computers, Industrial Engineering 41: 261–277

    Article  Google Scholar 

  • Papadopoulos C. T., O’Kelly M. E. J., Vidalis M. J., Spinellis D. (2009) Analysis and design of discrete part production lines. Springer Science+Business Media, New York

    Google Scholar 

  • Park T. (1993) A two-phase heuristic algorithm for determining buffer sizes of production lines. International Journal of Production Research 31(3): 613–631

    Article  Google Scholar 

  • Powell S. G., Pyke D. F. (1998) Buffering unbalanced assembly systems. IIE Transactions 30: 55–65

    Article  Google Scholar 

  • Qudeiri J. A., Yamamoto H., Ramli R., Al-Momani K. R. (2007) Development of production simulator for buffer size decisions in complex production systems using genetic algorithms. Journal of Advanced Mechanical Design, Systems, and Manufacturing 1(3): 418–429

    Article  Google Scholar 

  • Qudeiri J. A., Yamamoto H., Ramli R., Jamali A. (2008) Genetic algorithm for buffer size and work station capacity in serial–parallel production lines. Artificial Life and Robotics 12: 102–106

    Article  Google Scholar 

  • Radhoui M., Rezg N., Chelbi A. (2010) Joint quality control and preventive maintenance strategy for imperfect production processes. Journal of Intelligent Manufacturing 21: 205–212

    Article  Google Scholar 

  • Raman, N. A., Jamaludin, E. K. R. (2008). Implementation of Toyota Production System (TPS) in the production line of a local automotive parts manufacturer. Proceedings of International Conference on Mechanical, Manufacturing Engineering.

  • Ribeiro M. A., Silveira J. L., Qassim R. Y. (2007) Joint optimization of maintenance and buffer size in a manufacturing system. European Journal of Operational Research 176: 405–413

    Article  Google Scholar 

  • Roser, C., Nakano, M., Tanaka, M. (2003). Buffer allocation model based on a single simulation. Proceedings of the Winter Simulation Conference, 1238-1246

  • Sabuncuoglu I., Erel E., Kok A. G. (2002) Analysis of assembly systems for interdeparture time variability and throughput. IIE Transactions 34: 23–40

    Google Scholar 

  • Sabuncuoglu I., Erel E., Gocgun Y. (2006) Analysis of serial production lines: Characterization study and a new heuristic procedure for optimal buffer allocation. International Journal of Production Research 44(13): 2499–2523

    Article  Google Scholar 

  • Seo D-W., Lee H. (2011) Stationary waiting times in m-node tandem queues with production blocking. IEEE Transactions on Automatic Control 56(4): 958–961

    Article  Google Scholar 

  • Seong D., Chang Y. S., Hong Y. (1995) Heuristic algorithms for buffer allocation in a production line with unreliable machines. International Journal of Production Research 33(7): 1989–2005

    Article  Google Scholar 

  • Seong D., Chang Y. S., Hong Y. (2000) An algorithm for buffer allocation with linear resource constraints in a continuous-flow unreliable production line. Asia-Pacific Journal of Operational Research 17: 169–180

    Google Scholar 

  • Shi L., Men S. (2003) Optimal buffer allocation in production lines. IIE Transactions 35: 1–10

    Article  Google Scholar 

  • Shi C., Gershwin S. B. (2009) An efficient buffer design algorithm for production line profit maximization. International Journal of Production Economics 122: 725–740

    Article  Google Scholar 

  • Smith J. M., Cruz F. R. B. (2005) The buffer allocation problem for general finite buffer queuing networks. IIE Transactions 37(4): 343–365

    Article  Google Scholar 

  • Smith J. M., Cruz F. R. B., Van Woensel T. (2010) Topological network design of general, finite, multi-server queueing networks. European Journal of Operational Research 201(2): 427–441

    Article  Google Scholar 

  • Sörensen K., Janssens G. K. (2001) Buffer allocation and required availability in a transfer line with unreliable machines. International Journal of Production Economics 74: 163–173

    Article  Google Scholar 

  • Spinellis D. D., Papadopoulos C. T. (2000) A simulated annealing approach for buffer allocation in reliable production lines. Annals of Operations Research 93: 373–384

    Article  Google Scholar 

  • Spinellis D. D., Papadopoulos C. T. (2000) Stochastic algorithms for buffer allocation in reliable production lines. Mathematical Problems in Engineering 5: 441–458

    Article  Google Scholar 

  • Spinellis D., Papadopoulos C., Smith J. M. (2000) Large production line optimization using simulated annealing. International Journal of Production Research 38(3): 509–541

    Article  Google Scholar 

  • Srinivas C., Satyanarayana B., Ramji K., Ravela N. (2011) Determination of buffer size in single and multi row flexible manufacturing systems through simulation. International Journal of Engineering Science and Technology 3(5): 3889–3899

    Google Scholar 

  • Tempelmeier H. (2003) Practical considerations in the optimization of flow production systems. International Journal of Production Research 41(1): 149–170

    Article  Google Scholar 

  • Um, I., Lee, H., Cheon, H. (2007). Determination of buffer sizes in flexible manufacturing system by using the aspect-oriented simulation. International Conference on Control, Automation and Systems, pp. 1729–1733.

  • Van Woensel T., Andriansyah R., Cruz F. R. B., Smith J. M., Kerbache L. (2010) Buffer and server allocation in general multi-server queuing networks. International Transactions in Operational Research 17: 257–286

    Article  Google Scholar 

  • Vergara H.A., Kim D.S. (2009) A new method for the placement of buffers in serial production lines. International Journal of Production Research 47(16, 15): 4437–4456

    Article  Google Scholar 

  • Vitanov, I. V., Vitanov, V. I., & Harrison, D. K. (2009). Buffer capacity allocation using ant colony optimization algorithm. Proceedings of the 2009 winter simulation conference, pp. 3158–3168.

  • Vouros G. A., Papadopoulos H. T. (1998) Buffer allocation in unreliable production lines using a knowledge-based system. Computers, Operations Research 25(12): 1005–1067

    Article  Google Scholar 

  • Yamada T., Matsui M. (2003) A management design approach to assembly line systems. International Journal of Production Economics 84: 193–204

    Article  Google Scholar 

  • Yamamoto H., Qudeiri J. A., Marui E. (2008) Definition of FTL with bypass lines and its simulator for buffer size decision. International Journal of Production Economics 112: 18–25

    Article  Google Scholar 

  • Yamashita H., Altiok T. (1998) Buffer capacity allocation for a desired throughput in production lines. IIE Transactions 30: 883–891

    Google Scholar 

  • Yuzukirmizi M., Smith J. M. (2008) Optimal buffer allocation in finite closed networks with multiple servers. Computers, Operations Research 35: 2579–2598

    Article  Google Scholar 

  • Zequeira R., Prida B., Valdes J. E. (2004) Optimal buffer inventory and preventive maintenance for an imperfect production process. International Journal of Production Research 42(5): 959–974

    Article  Google Scholar 

  • Zequeira R., Valdes J. E., Berenguer C. (2008) Optimal buffer inventory and opportunistic preventive maintenance under random production capacity availability. International Journal of Production Economics 111: 686–696

    Article  Google Scholar 

  • Zhou W., Lian Z. (2011) A tandem network with a sharing buffer. Applied Mathematical Modelling 35(9): 4507–4515

    Article  Google Scholar 

Download references

Author information

Authors and Affiliations

  1. Department of Industrial Engineering, Pamukkale University, Kinikli Campus, Denizli, 20070, Turkey

    Leyla Demir

  2. Department of Business Administration, Izmir University of Economics, Sakarya Cad. No:156, Balcova-Izmir, Turkey

    Semra Tunali

  3. Department of Industrial Systems Engineering, Izmir University of Economics, Sakarya Cad. No:156, Balçova-Izmir, Turkey

    Deniz Tursel Eliiyi

Authors
  1. Leyla Demir
    View author publications

    You can also search for this author in PubMed Google Scholar

  2. Semra Tunali
    View author publications

    You can also search for this author in PubMed Google Scholar

  3. Deniz Tursel Eliiyi
    View author publications

    You can also search for this author in PubMed Google Scholar

Corresponding author

Correspondence to Leyla Demir.

Rights and permissions

Reprints and permissions

About this article

Cite this article

Demir, L., Tunali, S. & Eliiyi, D.T. The state of the art on buffer allocation problem: a comprehensive survey. J Intell Manuf 25, 371–392 (2014). https://doi.org/10.1007/s10845-012-0687-9

Download citation

  • Received:

  • Accepted:

  • Published:

  • Issue Date:

  • DOI: https://doi.org/10.1007/s10845-012-0687-9

Keywords

Search

Navigation