Definition of FTL with bypass lines and its simulator for buffer size decision

The production engineer's decision regarding buffer size in a flexible transfer line with bypass lines (FTL-B) is one of the most important factors in maximizing production efficiency and minimizing production cost. In this paper, we define FTL-B. According to the definition, we propose a new gene arrangement, referred to as the multiple distribution method (MDM). We also present a production simulator system (PSS) which consists of a genetic algorithm (GA) system and a discrete simulator to decide a buffer size for any FTL-B. An application example was developed and after a number of operations based on the GA system and discrete simulator, the sizes of all buffers for the FTL-B could be determined. The results of the study can be used to improve the production plant and production engineers can use the results in their decisions for buffer size when they develop the FTL-B.