Customized Pull Systems for Single-Product Flow Lines

Traditionally pull production systems are managed through classic control systems such as Kanban, Conwip, or Base stock, but this paper proposes ‘customized’ pull control. Customization means that a given production line is managed through a pull control system that in principle connects each stage of that line with each preceding stage; optimization of the corresponding simulation model, however, shows which of these potential control loops are actually implemented. This novel approach may result in one of the classic systems, but it may also be another type: (1) the total line may be decomposed into several segments, each with its own classic control system (e.g., segment 1 with Kanban, segment 2 with Conwip); (2) the total line or segments may combine different classic systems; (3) the line may be controlled through a new type of system. These different pull systems are found when applying the new approach to a set of twelve production lines. These lines are configured through the application of a statistical (Plackett-Burman) design with ten factors that characterize production lines (such as line length, demand variability, and machine breakdowns).Pull production / inventory;sampling;optimization;evolutionary algorithm

Proactive model to determine information technologies supporting expansion of air cargo network

Shippers and recipients expect transportation companies to provide more than just the movement of a package between points; certain information must be available to them as well, to enable forecasts and plans within the supply chain. The transportation companies also need the information flow that undergirds a transportation grid, to support ad-hoc routing and strategic structural re-alignment of business processes. This research delineates the information needs for an expanding air cargo network, then develops a new model of the information technologies needed to support expansion into a new country. The captured information will be used by shippers, recipients, and the transportation provider to better guide business decisions. This model will provide a method for transportation companies to balance the tradeoffs between the operating efficiencies, capital expenditures, and customer expectations of their IT systems. The output of the model is a list of technologies – optimized by cost – which meet the specific needs of internal and external customers when expanding air cargo networks into a new country

A comprehensive literature classification of simulation optimisation methods

Simulation Optimization (SO) provides a structured approach to the system design and configuration when analytical expressions for input/output relationships are unavailable. Several excellent surveys have been written on this topic. Each survey concentrates on only few classification criteria. This paper presents a literature survey with all classification criteria on techniques for SO according to the problem of characteristics such as shape of the response surface (global as compared to local optimization), objective functions (single or multiple objectives) and parameter spaces (discrete or continuous parameters). The survey focuses specifically on the SO problem that involves single per-formance measureSimulation Optimization, classification methods, literature survey

Intelligent systems in manufacturing: current developments and future prospects

Global competition and rapidly changing customer requirements are demanding increasing changes in manufacturing environments. Enterprises are required to constantly redesign their products and continuously reconfigure their manufacturing systems. Traditional approaches to manufacturing systems do not fully satisfy this new situation. Many authors have proposed that artificial intelligence will bring the flexibility and efficiency needed by manufacturing systems. This paper is a review of artificial intelligence techniques used in manufacturing systems. The paper first defines the components of a simplified intelligent manufacturing systems (IMS), the different Artificial Intelligence (AI) techniques to be considered and then shows how these AI techniques are used for the components of IMS

Design for Waste Reduction and Efficiency Improvement for the Construction Usage of the Tower Crane

Webcor Concrete Group’s on-site tower crane is currently experiencing unknown forms of inefficiency. The project team used the DMAIC methodology to implement Define, Measure, Analyze, Improve, and Control in order to guide and structure the project. After the project team formulated a problem statement, observations were collected of tower crane deliveries resulting in 470 individual data points. The data was then analyzed using basic statistics, histograms, and lean manufacturing tools in order to identify wastes and inefficiencies. Once the wastes and inefficiencies were identified, root cause analysis was performed. The identified root causes were then used as the basis for improving the current state of the project with design alternatives. Many designs were considered but only 3 were developed to the point where they could be tested. These designs were 5D BIM modeling, the allocation of additional resources in the form of additional carpenters, and kanban spaces with 6s designed to streamline the material delivery process of the tower crane. The three designs were tested using a simulation model producing varying levels of improvement to the 10 day cycle. An economic justification was conducted which showed that kanban spaces was most cost effective. Using the information that the project team learned analyzing and testing the designs along with criteria defined by Webcor, a multi-criteria decision analysis matrix was created to determine the most appropriate design when taking into account Webcor’s priorities. The matrix found kanban spaces to be the best design with do nothing being the next best alternative. Through simulation of the kanban spaces, throughput was increased by 8%. It is the formal recommendation of the project team to further pursue the design solution of kanban spaces as it is cost effective keeps Webcor’s highest priorities in mind, and eliminates waste identified in the tower crane’s operations

Customized Pull Systems for Single-Product Flow Lines

Traditionally pull production systems are managed through classic control systems such as Kanban, Conwip, or Base stock, but this paper proposes ‘customized’ pull control. Customization means that a given production line is managed through a pull control system that in principle connects each stage of that line with each preceding stage; optimization of the corresponding simulation model, however, shows which of these potential control loops are actually implemented. This novel approach may result in one of the classic systems, but it may also be another type: (1) the total line may be decomposed into several segments, each with its own classic control system (e.g., segment 1 with Kanban, segment 2 with Conwip); (2) the total line or segments may combine different classic systems; (3) the line may be controlled through a new type of system. These different pull systems are found when applying the new approach to a set of twelve production lines. These lines are configured through the application of a statistical (Plackett-Burman) design with ten factors that characterize production lines (such as line length, demand variability, and machine breakdowns).

Modelling Freight Allocation and Transportation Lead-Time

The authors have investigated sustainable environment delivery systems and identified transportation lead-time investigation cases. This research study aimed to increase freight delivery lead-time and minimize distance in transportation. To reach the goal, the paper\u27s authors, after analysis of the hierarchy of quantitative methods and models, proposed the framework for modeling freight allocation and transportation lead-time and delivered a study that includes discrete event simulation. During the simulation, various scenarios have been revised. Following the simulation mentioned above analysis, around 3.8 % of distance could be saved during freight delivery if lead-time for transportation were revised by choosing five days criteria for modeling freight allocation. The savings depend on the number of received orders from different geographic locations

Designing pull production control systems:Customization and robustness

In this dissertation we address the issues of selecting and configuring pull production control systems for single-product flowlines. We start with a review of pull systems in the literature, yielding a new classification. Then we propose a novel selection procedure based on a generic system that we test on a case also studied in the literature. We further study our procedure for a variety of twelve production lines. We find new types of pull systems that perform well. Next, we raise the issue of designing pull systems under uncertainty. We propose a novel procedure to minimize the risk of poor performance. Results show that risk considerations strongly influence the selection of a specific pull system

Autonomous Finite Capacity Scheduling using Biological Control Principles

The vast majority of the research efforts in finite capacity scheduling over the past several years has focused on the generation of precise and almost exact measures for the working schedule presupposing complete information and a deterministic environment. During execution, however, production may be the subject of considerable variability, which may lead to frequent schedule interruptions. Production scheduling mechanisms are developed based on centralised control architecture in which all of the knowledge base and databases are modelled at the same location. This control architecture has difficulty in handling complex manufacturing systems that require knowledge and data at different locations. Adopting biological control principles refers to the process where a schedule is developed prior to the start of the processing after considering all the parameters involved at a resource involved and updated accordingly as the process executes. This research reviews the best practices in gene transcription and translation control methods and adopts these principles in the development of an autonomous finite capacity scheduling control logic aimed at reducing excessive use of manual input in planning tasks. With autonomous decision-making functionality, finite capacity scheduling will as much as practicably possible be able to respond autonomously to schedule disruptions by deployment of proactive scheduling procedures that may be used to revise or re-optimize the schedule when unexpected events occur. The novelty of this work is the ability of production resources to autonomously take decisions and the same way decisions are taken by autonomous entities in the process of gene transcription and translation. The idea has been implemented by the integration of simulation and modelling techniques with Taguchi analysis to investigate the contributions of finite capacity scheduling factors, and determination of the ‘what if’ scenarios encountered due to the existence of variability in production processes. The control logic adopts the induction rules as used in gene expression control mechanisms, studied in biological systems. Scheduling factors are identified to that effect and are investigated to find their effects on selected performance measurements for each resource in used. How they are used to deal with variability in the process is one major objective for this research as it is because of the variability that autonomous decision making becomes of interest. Although different scheduling techniques have been applied and are successful in production planning and control, the results obtained from the inclusion of the autonomous finite capacity scheduling control logic has proved that significant improvement can still be achieved