Due to the lack of viable modeling techniques, abnormal situations at the operational level in a dynamic manufacturing environment cannot be handled by shop floor production control systems that are only applicable to steady-state performance. A tool is needed for the management in dealing with unexpected real-time events. In this paper, we present a decision support system (DSS) that estimates late-finishing parts in an assembly system due to machine breakdown, part supply shortage and processing of high-priority jobs. The application program, desc (Dynamic Evaluator of Simulated Consequences), is based on dynamic metamodels developed from computer simulation results. The DSS development procedure is discussed and its use is demonstrated by an example using data from a printed circuit board (PCB) assembly plant. Since no time-consuming simulation is necessary at the shop floor, the metamodel-based DSS can provide valuable information for making real-time production control decisions.
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