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

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

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).

An Artificial Neural Network Approach to Learning from Factory Performance in a Kanban-Based System

Many Just-In-Time (JIT) manufacturing environments generate operational data reflecting both efficient and inefficient factory performance. Frequently data for inefficient performance is lost or discarded for fear of replicating poor performance. The purpose of this paper is two fold. First, historical JIT shop data is analyzed using a genetic algorithm (GA) to determine which shop factors are important determinants offactory performance. Second, subsequent to these important factors being identified by a GA, an artificial neural network (ANN) is used to learn the relationships between these factors and factory performance. The ANN can then be used to predict factory performance for future shop conditions and enhance shop performance. While ANN learning techniques have previously been applied to JIT production systems (Wray, Rakes, and Rees, 1997) (Markham, Mathieu, and Wray, 2000), these techniques have only been trained on data sets that reflect an efficient factory. Mathieu, Wray, and Markham (2002) investigated inefficient and efficient JIT factory performance but did not deploy either ANNs or a GA. In this paper an example application is presented using a GA to specify important shop factors and to predict saturated, starved or efficient factory performance based on dynamic shop floor data

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

A study of a kanban based assembly line feeding system through integration of simulation and particle swarm optimization

With increase in differentiation and decreasing batch size of products, feeding the assembly line at regular intervals is considered to be a critical problem in today's manufacturing sector. Yet no clear solution has been developed for this problem; therefore, the main focus of this research is to discuss the different aspects of line feeding, the latest trend in literature, and to propose an innovative method to support solving the problem. A discrete event simulation model is developed and a mathematical model based on particle swarm optimization is used to support the simulation. The hybrid model is finally applied to practical situations. Results show how different settings of kanban influence the performance of the assembly line feeding system. The biggest novelty item is certainly the recognition of the trade-off between kanban size and number of kanban and the importance of investigating its behaviour during the design of the system. (C) 2019 by the authors; licensee Growing Science, Canad

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 measur

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 measur