An Algorithm of Finite Capacity Material Requirement Planning System for Multi-stage Assembly Flow Shop
This paper aims to develop an algorithm of finite
capacity material requirement planning (FCMRP) system for a multistage
assembly flow shop. The developed FCMRP system has two
main stages. The first stage is to allocate operations to the first and
second priority work centers and also determine the sequence of the
operations on each work center. The second stage is to determine the
optimal start time of each operation by using a linear programming
model. Real data from a factory is used to analyze and evaluate the
effectiveness of the proposed FCMRP system and also to guarantee a
practical solution to the user. There are five performance measures,
namely, the total tardiness, the number of tardy orders, the total
earliness, the number of early orders, and the average flow-time. The
proposed FCMRP system offers an adjustable solution which is a
compromised solution among the conflicting performance measures.
The user can adjust the weight of each performance measure to
obtain the desired performance. The result shows that the combination
of FCMRP NP3 and EDD outperforms other combinations
in term of overall performance index. The calculation time for the
proposed FCMRP system is about 10 minutes which is practical for
the planners of the factory.
[1] Nagendra, P.B. and Das, S.K., "Finite Capacity Scheduling Method for
MRP with Lot Size restrictions." Int. J. Prod. Res, 2001, 39, pp. 1603-
1623.
[2] McCarthy, S.W. and Barber, K.D., "Medium to short term finite
capacity scheduling: a planning methodology for capacity constrained
work -shop". Eng. Cost & Prod. Econ, 1990, 19, pp. 189-199.
[3] White, C. and Hastings, N.A.J., "Scheduling techniques for medium
scale industry." Austral. Soc. Oper. Res, 1983, 3, pp. 1-4.
[4] Taal, M. and Wortmann, J.C., "Integrating MRP and finite capacity
planning". Prod. Plan. & Cont, 1997, 8(3), pp. 245-254.
[5] Bakke, N.A. and Hellberg, R., "The challenges of capacity planning".
Int. J. Prod. Econ, 1993, 30/31, pp. 243-264.
[6] Pandey, P. C., Yenradee, P., and Archariyapruek, S.,"A finite capacity
material requirement planning system". Prod. Plan. & Cont, 2000,
11(2), pp. 113-121.
[7] Wuttipornpun, T. and Yenradee, P., "Development of Finite Capacity
Material Requirement Planning System for Assembly Operations".
Prod. Plan. & Cont, 2004, 15, pp. 534-549.
[8] Wuttipornpun, T., Yenradee, P., Buellens, P., and Oudheusden, D.L., "A
Finite Capacity Material Requirement Planning System for a Multi-
Stage Assembly Factory: Goal Programming Approach". Indust. Eng. &
Manage. Sys, 2005, 4(1), pp. 23-35.
[9] Wuttipornpun, T., Yenradee, P., Buellens, P., and Oudheusden, D.L.,
"Finite Capacity Material Requirement Planning System for a Multistage
Automotive-Part Assembly Factory". Sci. Asia, 2006, 32, pp. 303-
313.
[10] Wuttipornpun, T. and Yenradee, P., "Performance of TOC based finite
capacity material requirement planning system for a multi-stage
assembly factory". Prod. Plan. & Cont, 2007, 18, pp. 703-715.
[11] Ozdamar, L. and Bozyel, M.A., "The capacitated lot sizing problem with
overtime decisions and setup times". Int. Indust. Eng. Trans, 2000, 32,
pp. 1043-1057.
[12] Rajagopalan, S. and Swaminathan, J.M., "A Coordinated Production
Planning Model with Capacity Expansion and Inventory" Management.
Manage. Sci, 2001, 47(11), pp. 1562-1580.
[13] Ornek, A.M. and CENGIZ, O., "Capacitated lot sizing with alternative
routings and overtime decisions". Int. J. Prod. Res, 2006, 44(24), pp.
5363-5389.
[14] Rong, C., Takahashi, K., and Morikawa, K., "MRP rescheduling
heuristics with capacity extension under deterministic demand". Comp.
& Indust. Eng, 2006, pp. 51, 2-13.
[15] Haddock, J. and Hubicki, DE.,"Which lot-sizing techniques are used in
material requirement planning?" Prod. & Invent. Manage. J, 1989,
30(3), pp.53-56.
[1] Nagendra, P.B. and Das, S.K., "Finite Capacity Scheduling Method for
MRP with Lot Size restrictions." Int. J. Prod. Res, 2001, 39, pp. 1603-
1623.
[2] McCarthy, S.W. and Barber, K.D., "Medium to short term finite
capacity scheduling: a planning methodology for capacity constrained
work -shop". Eng. Cost & Prod. Econ, 1990, 19, pp. 189-199.
[3] White, C. and Hastings, N.A.J., "Scheduling techniques for medium
scale industry." Austral. Soc. Oper. Res, 1983, 3, pp. 1-4.
[4] Taal, M. and Wortmann, J.C., "Integrating MRP and finite capacity
planning". Prod. Plan. & Cont, 1997, 8(3), pp. 245-254.
[5] Bakke, N.A. and Hellberg, R., "The challenges of capacity planning".
Int. J. Prod. Econ, 1993, 30/31, pp. 243-264.
[6] Pandey, P. C., Yenradee, P., and Archariyapruek, S.,"A finite capacity
material requirement planning system". Prod. Plan. & Cont, 2000,
11(2), pp. 113-121.
[7] Wuttipornpun, T. and Yenradee, P., "Development of Finite Capacity
Material Requirement Planning System for Assembly Operations".
Prod. Plan. & Cont, 2004, 15, pp. 534-549.
[8] Wuttipornpun, T., Yenradee, P., Buellens, P., and Oudheusden, D.L., "A
Finite Capacity Material Requirement Planning System for a Multi-
Stage Assembly Factory: Goal Programming Approach". Indust. Eng. &
Manage. Sys, 2005, 4(1), pp. 23-35.
[9] Wuttipornpun, T., Yenradee, P., Buellens, P., and Oudheusden, D.L.,
"Finite Capacity Material Requirement Planning System for a Multistage
Automotive-Part Assembly Factory". Sci. Asia, 2006, 32, pp. 303-
313.
[10] Wuttipornpun, T. and Yenradee, P., "Performance of TOC based finite
capacity material requirement planning system for a multi-stage
assembly factory". Prod. Plan. & Cont, 2007, 18, pp. 703-715.
[11] Ozdamar, L. and Bozyel, M.A., "The capacitated lot sizing problem with
overtime decisions and setup times". Int. Indust. Eng. Trans, 2000, 32,
pp. 1043-1057.
[12] Rajagopalan, S. and Swaminathan, J.M., "A Coordinated Production
Planning Model with Capacity Expansion and Inventory" Management.
Manage. Sci, 2001, 47(11), pp. 1562-1580.
[13] Ornek, A.M. and CENGIZ, O., "Capacitated lot sizing with alternative
routings and overtime decisions". Int. J. Prod. Res, 2006, 44(24), pp.
5363-5389.
[14] Rong, C., Takahashi, K., and Morikawa, K., "MRP rescheduling
heuristics with capacity extension under deterministic demand". Comp.
& Indust. Eng, 2006, pp. 51, 2-13.
[15] Haddock, J. and Hubicki, DE.,"Which lot-sizing techniques are used in
material requirement planning?" Prod. & Invent. Manage. J, 1989,
30(3), pp.53-56.
@article{"International Journal of Mechanical, Industrial and Aerospace Sciences:55993", author = "T. Wuttipornpun and U. Wangrakdiskul and W. Songserm", title = "An Algorithm of Finite Capacity Material Requirement Planning System for Multi-stage Assembly Flow Shop", abstract = "This paper aims to develop an algorithm of finite
capacity material requirement planning (FCMRP) system for a multistage
assembly flow shop. The developed FCMRP system has two
main stages. The first stage is to allocate operations to the first and
second priority work centers and also determine the sequence of the
operations on each work center. The second stage is to determine the
optimal start time of each operation by using a linear programming
model. Real data from a factory is used to analyze and evaluate the
effectiveness of the proposed FCMRP system and also to guarantee a
practical solution to the user. There are five performance measures,
namely, the total tardiness, the number of tardy orders, the total
earliness, the number of early orders, and the average flow-time. The
proposed FCMRP system offers an adjustable solution which is a
compromised solution among the conflicting performance measures.
The user can adjust the weight of each performance measure to
obtain the desired performance. The result shows that the combination
of FCMRP NP3 and EDD outperforms other combinations
in term of overall performance index. The calculation time for the
proposed FCMRP system is about 10 minutes which is practical for
the planners of the factory.", keywords = "Material requirement planning, Finite capacity,Linear programming, Permutation, Application in industry.", volume = "4", number = "10", pages = "1010-11", }