A chaotic model of a production flow called the switched arrival system is extended to include switching times and maintenance. The probability distribution of the chaotic return times is calculated. Scheduling maintenance, loss of production due to switching, and control of the chaotic dynamics is discussed. A coupling parameter to couple switched arrival systems serially, based on lost production, is identified. Simulations of three parallel and three serial levels were performed. Global synchronization of the switching frequencies between serial levels is achieved. An analytic model allows one to predict the self-balancing properties of the serial system. (C) 2003 American Institute of Physics.
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