Allocating flexible servers in serial systems with switching costs

Consider a firm that operates a make-to-order serial production system and employs a cross-trained workforce. We model such a firm as a tandem queuing system in which flexible servers can be allocated across stations, and assume that a switching cost is charged when servers move between stations. We show that even in the two-station two-server case the optimal policy follows a complex state-dependent structure that may be difficult to implement in practice. We propose three alternate heuristic policies and assess their performance. We show that a simpler policy which only moves one server can achieve close to optimal results.