Institute for Systems Research Technical Reports

Permanent URI for this collectionhttp://hdl.handle.net/1903/4376

This archive contains a collection of reports generated by the faculty and students of the Institute for Systems Research (ISR), a permanent, interdisciplinary research unit in the A. James Clark School of Engineering at the University of Maryland. ISR-based projects are conducted through partnerships with industry and government, bringing together faculty and students from multiple academic departments and colleges across the university.

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Author: search.filters.author.Mellacheruvu, Praveen V.Subject: search.filters.subject.manufacturing systems

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    Sensitivity Analysis and Discrete Stochastic Optimization for Semiconductor Manufacturing Systems
    (2000) Mellacheruvu, Praveen V.; Herrmann, Jeffrey W.; Fu, Michael C.; ISR
    The semiconductor industry is a capital-intensive industry with rapid time-to-market, short product development cycles, complex product flows and other characteristics. These factors make it necessary to utilize equipment efficiently and reduce cycle times. Further, the complexity and highly stochastic nature of these manufacturing systems make it difficult to study their characteristics through analytical models. Hence we resort to simulation-based methodologies to model these systems.

    This research aims at developing and implementing simulation-based operations research techniques to facilitate System Control (through sensitivity analysis) and System Design (through optimization) for semiconductor manufacturing systems.

    Sensitivity analysis for small changes in input parameters is performed using gradient estimation techniques. Gradient estimation methods are evaluated by studying the state of the art and comparing the finite difference method and simultaneous perturbation method by applying them to a stochastic manufacturing system. The results are compared with the gradients obtained through analytical queueing models. The finite difference method is implemented in a heterogeneous simulation environment (HSE)-based decision support tool for process engineers. This tool performs heterogeneous simulations and sensitivity analyses.

    The gradient-based techniques used for sensitivity analysis form the building blocks for a gradient-based discrete stochastic optimization procedure. This procedure is applied to the problem of allocating a limited budget to machine purchases to achieve throughput requirements and minimize cycle time. The performance of the algorithm is evaluated by applying the algorithm on a wide range of problem instances.

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    Comparing Gradient Estimation Methods Applied to Stochastic Manufacturing Systems
    (2000) Mellacheruvu, Praveen V.; Fu, Michael C.; Herrmann, Jeffrey W.; ISR
    This paper compares two gradient estimation methods that can be usedfor estimating the sensitivities of output metrics with respectto the input parameters of a stochastic manufacturing system.A brief description of the methods used currently is followedby a description of the two methods: the finite difference methodand the simultaneous perturbation method. While the finitedifference method has been in use for a long time, simultaneousperturbation is a relatively new method which has beenapplied with stochastic approximation for optimizationwith good results. The methods described are used to analyzea stochastic manufacturing system and estimate gradients.The results are compared to the gradients calculated fromanalytical queueing system models.

    These gradient methods are of significant use in complex manufacturingsystems like semiconductor manufacturing systems where we havea large number of input parameters which affect the average total cycle time.These gradient estimation methods can estimate the impact thatthese input parameters have and identify theparameters that have the maximum impact on system performance.