Abstract: This paper presents a methodology for serial production planning problem in wire and cable manufacturing process that addresses the problem of input-output imbalance in different consecutive stations, hoping to minimize the halt of machines in each stage. To this end, a linear Goal Programming (GP) model is developed, in which four main categories of constraints as per the number of runs per machine, machines’ sequences, acceptable inventories of machines at the end of each period, and the necessity of fulfillment of the customers’ orders are considered. The model is formulated based upon on the real data obtained from IKO TAK Company, an important supplier of wire and cable for oil and gas and automotive industries in Iran. By solving the model in GAMS software the optimal number of runs, end-of-period inventories, and the possible minimum idle time for each machine are calculated. The application of the numerical results in the target company has shown the efficiency of the proposed model and the solution in decreasing the lead time of the end product delivery to the customers by 20%. Accordingly, the developed model could be easily applied in wire and cable companies for the aim of optimal production planning to reduce the halt of machines in manufacturing stages.
Abstract: Fuzzy AHP (Analytic Hierarchy Process) method is decision-making way at the end of integrating the current AHP method with fuzzy structure. In this study, the processes of production planning, inventory management and purchasing department of a system were analysed and were requested to decide the performance criteria of each area. At this point, the current work processes were analysed by various decision-makers and comparing each criteria by giving points according to 1-9 scale were completed. The criteria were listed in order to their weights by using Fuzzy AHP approach and top three performance criteria of each department were determined. After that, the performance criteria of supply chain consisting of three departments were asked to determine. The processes of each department were compared by decision-makers at the point of building the supply chain performance system and getting the performance criteria. According to the results, the criteria of performance system of supply chain by using Fuzzy AHP were determined for which will be used in the supply chain performance system in the future.
Abstract: To have effective production planning, it is necessary to control the quality of processes. This paper aims at improving the performance of the disposable essentials process using statistical quality control and goal programming in a vague environment. That is expressed uncertainty because there is always a measurement error in the real world. Therefore, in this study, the conditions are examined in a vague environment that is a distance-based environment. The disposable essentials process in Kach Company was studied. Statistical control tools were used to characterize the existing process for four factor responses including the average of disposable glasses’ weights, heights, crater diameters, and volumes. Goal programming was then utilized to find the combination of optimal factors setting in a vague environment which is measured to apply uncertainty of the initial information when some of the parameters of the models are vague; also, the fuzzy regression model is used to predict the responses of the four described factors. Optimization results show that the process capability index values for disposable glasses’ average of weights, heights, crater diameters and volumes were improved. Such increasing the quality of the products and reducing the waste, which will reduce the cost of the finished product, and ultimately will bring customer satisfaction, and this satisfaction, will mean increased sales.
Abstract: In this paper, we suggest a simulation tool to make a decision of monthly production planning for maximizing a profit of Specialty store retailer of Private label Apparel (SPA) firms. Most of SPA firms are fabless and make outsourcing deals for productions with factories of their subcontractors. Every month, SPA firms make a booking for production lines and manpower in the factories. The booking is conducted a few months in advance based on a demand prediction and a monthly production planning at that time. However, the demand prediction is updated month by month, and the monthly production planning would change to meet the latest demand prediction. Then, SPA firms have to change the capacities initially booked within a certain range to suit to the monthly production planning. The booking system is called “capacity-booking”. These days, though it is an issue for SPA firms to make precise monthly production planning, many firms are still conducting the production planning by empirical rules. In addition, it is also a challenge for SPA firms to match their products and factories with considering their demand predictabilities and regulation abilities. In this paper, we suggest a model for considering these two issues. An objective is to maximize a total profit of certain periods, which is sales minus costs of production, inventory, and capacity-booking penalty. To make a better monthly production planning at SPA firms, these points should be considered: demand predictabilities by random trends, previous and next month’s production planning of the target month, and regulation abilities of the capacity-booking. To decide matching products and factories for outsourcing, it is important to consider seasonality, volume, and predictability of each product, production possibility, size, and regulation ability of each factory. SPA firms have to consider these constructions and decide orders with several factories per one product. We modeled these issues as a linear programming. To validate the model, an example of several computational experiments with a SPA firm is presented. We suppose four typical product groups: basic, seasonal (Spring / Summer), seasonal (Fall / Winter), and spot product. As a result of the experiments, a monthly production planning was provided. In the planning, demand predictabilities from random trend are reduced by producing products which are different product types. Moreover, priorities to produce are given to high-margin products. In conclusion, we developed a simulation tool to make a decision of monthly production planning which is useful when the production planning is set every month. We considered the features of capacity-booking, and matching of products and factories which have different features and conditions.
Abstract: Due to shortening product and technology lifecycles, many companies use standardization approaches in product development and factory planning to reduce costs and time to market. Unlike large companies, where modular systems are already widely used, small and medium-sized companies often show a much lower degree of standardization due to lower scale effects and missing capacities for the development of these standards. To overcome these challenges, the development of industry sector specific standards in cooperations or by third parties is an interesting approach. This paper analyzes which branches that are mainly dominated by small or medium-sized companies might be especially interesting for the development of factory standards using the example of the German industry. For this, a key performance indicator based approach was developed that will be presented in detail with its specific results for the German industry structure.
Abstract: The Flow Shop Scheduling Problem (FSSP) is a typical problem that is faced by production planning managers in Flexible Manufacturing Systems (FMS). This problem consists in finding the optimal scheduling to carry out a set of jobs, which are processed in a set of machines or shared resources. Moreover, all the jobs are processed in the same machine sequence. As in all the scheduling problems, the makespan can be obtained by drawing the Gantt chart according to the operations order, among other alternatives. On this way, an FMS presenting the FSSP can be modeled by Petri nets (PNs), which are a powerful tool that has been used to model and analyze discrete event systems. Then, the makespan can be obtained by simulating the PN through the token game animation and incidence matrix. In this work, we present an adaptive PN to obtain the makespan of FSSP by applying PN analytical tools.
Abstract: The efficient and economic allocation of resources is
one main goal in the field of production planning and control.
Nowadays, a new variable gains in importance throughout the
planning process: Energy. Energy-efficiency has already been widely
discussed in literature, but with a strong focus on reducing the overall
amount of energy used in production. This paper provides a brief
systematic approach, how energy-supply-orientation can be used for
an energy-cost-efficient production planning and thus combining the
idea of energy-efficiency and energy-flexibility.
Abstract: One of the most famous techniques which affect the
efficiency of a production line is the assembly line balancing (ALB)
technique. This paper examines the balancing effect of a whole
production line of a real auto glass manufacturer in three steps. In the
first step, processing time of each activity in the workstations is
generated according to a practical approach. In the second step, the
whole production process is simulated and the bottleneck stations
have been identified, and finally in the third step, several
improvement scenarios are generated to optimize the system
throughput, and the best one is proposed. The main contribution of
the current research is the proposed framework which combines two
famous approaches including Assembly Line Balancing and
Optimization via Simulation technique (OvS). The results show that
the proposed framework could be applied in practical environments,
easily.
Abstract: An efficient remanufacturing network lead to an
efficient design of sustainable manufacturing enterprise. In
remanufacturing network, products are collected from the customer
zone, disassembled and remanufactured at a suitable remanufacturing
facility. In this respect, another issue to consider is how the returned
product to be remanufactured, in other words, what is the best layout
for such facility. In order to achieve a sustainable manufacturing
system, Cellular Manufacturing System (CMS) designs are highly
recommended, CMSs combine high throughput rates of line layouts
with the flexibility offered by functional layouts (job shop).
Introducing the CMS while designing a remanufacturing network will
benefit the utilization of such a network. This paper presents and
analyzes a comprehensive mathematical model for the design of
Dynamic Cellular Remanufacturing Systems (DCRSs). In this paper,
the proposed model is the first one to date that considers CMS and
remanufacturing system simultaneously. The proposed DCRS model
considers several manufacturing attributes such as multi period
production planning, dynamic system reconfiguration, duplicate
machines, machine capacity, available time for workers, worker
assignments, and machine procurement, where the demand is totally
satisfied from a returned product. A numerical example is presented
to illustrate the proposed model.
Abstract: A well designed and executed Production Planning
and Control (PPC) system is one of the key levers for superior
performance in the current manufacturing set-up. Hence, measuring
the PPC system performance has become a necessity for long term
success. The present study examined PPC related issues which
impact the production capacity and productivity of leather companies
with special focus on Kombolcha Tannery Share Company (KTSC),
Ethiopia. Physical observation, interview, and questionnaire were
used to generate necessary information from the respondents and
reach valid conclusions. Company annual reports were referred and
analyzed to triangulate primary data. Consequently, the study
revealed that KTSC runs below its capacity due to its inefficient PPC
system being in use for which the root causes were identified. The
study thereby conceptualizes a PPC system improvement framework
comprising three pillars viz., management culture, internal capability
and performance measurement together with key considerations in
each case. The study findings enable the company to recognize the
importance of efficient PPC system as a source of competitive
advantage. It also aid managers in evaluating various PPC execution
schemes to enhance productivity.
Abstract: Small and medium-sized enterprises (SME) are the backbone of central Europe’s economies and have a significant contribution to the gross domestic product. Production planning and scheduling (PPS) is still a crucial element in manufacturing industries of the 21st century even though this area of research is more than a century old. The topic of PPS is well researched especially in the context of large enterprises in the manufacturing industry. However the implementation of PPS methodologies within SME is mostly unobserved. This work analyzes how PPS is implemented in SME with the geographical focus on Switzerland and its vicinity. Based on restricted resources compared to large enterprises, SME have to face different challenges. The real problem areas of selected enterprises in regards of PPS are identified and evaluated. For the identified real-life problem areas of SME clear and detailed recommendations are created, covering concepts and best practices and the efficient usage of PPS. Furthermore the economic and entrepreneurial value for companies is lined out and why the implementation of the introduced recommendations is advised.
Abstract: This research investigates the distribution of food
demand for animal food and the optimum amount of that food
production at minimum cost. The data consist of customer purchase
orders for the food of laying hens, price of food for laying hens, cost
per unit for the food inventory, cost related to food of laying hens in
which the food is out of stock, such as fine, overtime, urgent
purchase for material. They were collected from January, 1990 to
December, 2013 from a factory in Nakhonratchasima province. The
collected data are analyzed in order to explore the distribution of the
monthly food demand for the laying hens and to see the rate of
inventory per unit. The results are used in a stochastic linear
programming model for aggregate planning in which the optimum
production or minimum cost could be obtained. Programming
algorithms in MATLAB and tools in Linprog software are used to get
the solution. The distribution of the food demand for laying hens and
the random numbers are used in the model. The study shows that the
distribution of monthly food demand for laying has a normal
distribution, the monthly average amount (unit: 30 kg) of production
from January to December. The minimum total cost average for 12
months is Baht 62,329,181.77. Therefore, the production planning
can reduce the cost by 14.64% from real cost.
Abstract: Several researches have been conducted to study
consumption of energy in cutting process. Most of these researches
are focusing to measure the consumption and propose consumption
reduction methods. In this work, the relation between the cutting
parameters and the consumption is investigated in order to establish a
generalized energy consumption model that can be used for process
and production planning in real production lines. Using the
generalized model, the process planning will be carried out by taking
into account the energy as a function of the selected process
parameters. Similarly, the generalized model can be used in
production planning to select the right operational parameters like
batch sizes, routing, buffer size, etc. in a production line. The
description and derivation of the model as well as a case study are
given in this paper to illustrate the applicability and validity of the
model.
Abstract: This work addresses the problem of production planning that arises in the production of aromatic coconuts from Samudsakhorn province in Thailand. The planning involves the forwarding of aromatic coconuts from the harvest areas to the factory, which is classified into two groups; self-owned areas and contracted areas, the decisions of aromatic coconuts flow in the plant, and addressing a question of which warehouse will be in use. The problem is formulated as a mixed-integer linear programming model within supply chain management framework. The objective function seeks to minimize the total cost including the harvesting, labor and inventory costs. Constraints on the system include the production activities in the company and demand requirements. Numerical results are presented to demonstrate the feasibility of coconuts supply chain model compared with base case.
Abstract: For years now, it has been recognized that logistic performance capability contributes enormously to a production enterprise’s competitiveness and as such is a critical control lever. In doing so, the orientation on customer wishes (e.g. delivery dates) represents a key parameter not only in the value-adding production but also in product regeneration. Since production and regeneration processes have different characteristics, production planning and control measures cannot be directly transferred to regeneration processes. As part of a special research project, the Institute of Production Systems and Logistics Hannover is focused on increasing the logistic performance capability of regeneration processes for complex capital goods. The aim is to ensure logistic targets are met by implementing a model specifically designed to align the capacities and load in regeneration processes.
Abstract: This paper deals with modeling and optimization of two NP-hard problems in production planning of flexible manufacturing system (FMS), part type selection problem and loading problem. The part type selection problem and the loading problem are strongly related and heavily influence the system’s efficiency and productivity. These problems have been modeled and solved simultaneously by using real coded genetic algorithms (RCGA) which uses an array of real numbers as chromosome representation. The novel proposed chromosome representation produces only feasible solutions which minimize a computational time needed by GA to push its population toward feasible search space or repair infeasible chromosomes. The proposed RCGA improves the FMS performance by considering two objectives, maximizing system throughput and maintaining the balance of the system (minimizing system unbalance). The resulted objective values are compared to the optimum values produced by branch-and-bound method. The experiments show that the proposed RCGA could reach near optimum solutions in a reasonable amount of time.
Abstract: The planning in manufacturing system is becoming complicated day by day due to the expanding networks and shortage of skilled people to manage change. Consequently, faster lead time and rising demands for eco-efficient evaluation of manufacturing products and processes need exploitation of new and intelligent knowledge management concepts for manufacturing planning. This paper highlights motivation for incorporation of new features in the manufacturing planning system. Furthermore, it elaborates requirements for the development of intelligent knowledge management concept to support planning related decisions. Afterwards, the derived concept is presented in this paper considering two case studies. The first case study is concerned with the automotive ramp-up planning. The second case study specifies requirements for knowledge management system to support decisions in eco-efficient evaluation of manufacturing products and processes
Abstract: Due to the growing dynamic and complexity within
the market environment production enterprises in particular are faced
with new logistic challenges. Moreover, it is here in this dynamic
environment that the Logistic Operating Curve Theory also reaches
its limits as a method for describing the correlations between the
logistic objectives. In order to convert this theory into a method for
dynamically monitoring productions this paper will introduce
methods for reliably and quickly identifying structural changes
relevant to logistics.
Abstract: One of the most important problems in production planning of flexible manufacturing system (FMS) is machine tool selection and operation allocation problem that directly influences the production costs and times .In this paper minimizing machining cost, set-up cost and material handling cost as a multi-objective problem in flexible manufacturing systems environment are considered. We present a 0-1 integer linear programming model for the multiobjective machine tool selection and operation allocation problem and due to the large scale nature of the problem, solving the problem to obtain optimal solution in a reasonable time is infeasible, Paretoant colony optimization (P-ACO) approach for solving the multiobjective problem in reasonable time is developed. Experimental results indicate effectiveness of the proposed algorithm for solving the problem.
Abstract: This paper and its companion (Part 2) deal with
modeling and optimization of two NP-hard problems in production
planning of flexible manufacturing system (FMS), part type selection
problem and loading problem. The part type selection problem and
the loading problem are strongly related and heavily influence the
system-s efficiency and productivity. The complexity of the problems
is harder when flexibilities of operations such as the possibility of
operation processed on alternative machines with alternative tools are
considered. These problems have been modeled and solved
simultaneously by using real coded genetic algorithms (RCGA)
which uses an array of real numbers as chromosome representation.
These real numbers can be converted into part type sequence and
machines that are used to process the part types. This first part of the
papers focuses on the modeling of the problems and discussing how
the novel chromosome representation can be applied to solve the
problems. The second part will discuss the effectiveness of the
RCGA to solve various test bed problems.