The reliability of fixed-path material handling systems can be a serious and costly reallife problem in many flexible manufacturing environments, particularly those environments in which a single unit of material has a significant associateddollar value. Traditionally, research in the design of fixed-path material handling systems has primarily studied system performance as a function of guide path design, location of pickup and delivery points, and fleet size while ignoring the reliabilityeffects of the various material handling system components. In reality, however, system components are not completely reliable and their failures do affect overall system performance. This article develops and demonstrates an analytical model fordesigning guide paths for fixed-path material handling systems as a function of performance and reliability. The model is developed on the basis that intersections, pickup and delivery stations, and vehicle operating times affect the overall reliabilityof the system. Thus, it is possible to design a guide path in such a way as to mitigate the performance effects of unreliable material handling components. An example is presented to demonstrate the implementation of this model and performanceimprovements over previous results.
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