Procedures to accommodate system fluctuations that result in buffer compromised systems governed by the theory of constraints

Decision making support in a stochastic environment represents a challenging aspect for any manufacturing organisation. Disturbances in manufacturing supply chains shift operational risks as a function of time. The development of Industry 4.0 related technologies enables manufacturers to more efficiently mitigate operational risks and improve end to end efficiencies. The current research investigates technologies and concepts in the emerging blueprint of 4.0 that add value to organisational decision making capabilities. A multimethod agent based simulation model is developed within the boundaries of a Theory of Constraints (ToC) system to assess the effectiveness of the current Mode Of Operation (MOO) for prioritisation of Work In Process (WIP). The investigation is conducted using a defined WIP complement and resource pool allocation. The results show that it is possible to optimise flow through the manufacturing line through consideration of prioritisation MOO. The approach represents a transition to a new optimised state for the organisation under study; as it ventures into the realm of Industry 4.0 through use of agent based simulation modelling and analysis.