I went straight to bottleneck analysis, which felt right, but I fumbled when they pushed on what happens when the middle buffer fills up and the upstream station has to stall.
Start by clarifying the problem: define the simulation parameters (processing times, buffer capacities, failure rates) and the objective (maximize throughput). Then, propose a systematic approach: model the system as a queueing network, identify bottlenecks, and optimize buffer allocation and scheduling policies. Finally, discuss how you would validate the solution using simulation and iterate.
Pro tip: Emphasize that in a fixed 5-minute window, transient behavior dominates, so you should focus on warm-up effects and initial conditions rather than steady-state metrics. Also, mention that you would use discrete-event simulation to test different configurations quickly.
Ask about processing time distributions, buffer capacities, failure rates, and whether the 5-minute window includes warm-up. Confirm the goal is to maximize completed units, not just throughput.
Represent the pipeline as a tandem queue with finite buffers. Identify the bottleneck station (likely the one with the longest average processing time or highest variability).
Consider buffer allocation (e.g., larger buffers before bottleneck), scheduling policies (e.g., priority rules), and reducing variability (e.g., standardizing tasks). Also consider initial conditions (e.g., pre-fill buffers).
Use discrete-event simulation to test different configurations. Measure completed units within 5 minutes, and analyze sensitivity to parameters. Iterate to find the best setup.
Explain trade-offs: larger buffers increase WIP but may not help if bottleneck is downstream. Discuss how the approach scales to longer horizons or more stations.
AI-generated suggestions, not part of the candidate's original notes. May be inaccurate — verify before relying on them.