From ERP to advanced resource planning: Improving the operational performance by getting the inputs right.

In this paper, we show that the planning and decision support capabilities of the MPC (Manufacturing Planning and Control) system, which forms the core of any ERP package, may be greatly enhanced by including an Advanced Resource Planning (ARP) module as an add-on at the midterm planning level. This ARP module enables to estimate the impact of variability, complexity and dynamic system behavior on key planning parameters. As such, it yields realistic information both for short-term planning purposes and for reliable lead time quotations. We show how dynamic behavior impacts the operational performance of a manufacturing system, and discuss the framework for incorporating the ARP module into the ERP system.Planning; Operational performance; Performance; International; Science;

Application of lean scheduling and production control in non-repetitive manufacturing systems using intelligent agent decision support

This thesis was submitted for the degree of Doctor of Philosophy and awarded by Brunel University.Lean Manufacturing (LM) is widely accepted as a world-class manufacturing paradigm, its currency and superiority are manifested in numerous recent success stories. Most lean tools including Just-in-Time (JIT) were designed for repetitive serial production systems. This resulted in a substantial stream of research which dismissed a priori the suitability of LM for non-repetitive non-serial job-shops. The extension of LM into non-repetitive production systems is opposed on the basis of the sheer complexity of applying JIT pull production control in non-repetitive systems fabricating a high variety of products. However, the application of LM in job-shops is not unexplored. Studies proposing the extension of leanness into non-repetitive production systems have promoted the modification of pull control mechanisms or reconfiguration of job-shops into cellular manufacturing systems. This thesis sought to address the shortcomings of the aforementioned approaches. The contribution of this thesis to knowledge in the field of production and operations management is threefold: Firstly, a Multi-Agent System (MAS) is designed to directly apply pull production control to a good approximation of a real-life job-shop. The scale and complexity of the developed MAS prove that the application of pull production control in non-repetitive manufacturing systems is challenging, perplex and laborious. Secondly, the thesis examines three pull production control mechanisms namely, Kanban, Base Stock and Constant Work-in-Process (CONWIP) which it enhances so as to prevent system deadlocks, an issue largely unaddressed in the relevant literature. Having successfully tested the transferability of pull production control to non-repetitive manufacturing, the third contribution of this thesis is that it uses experimental and empirical data to examine the impact of pull production control on job-shop performance. The thesis identifies issues resulting from the application of pull control in job-shops which have implications for industry practice and concludes by outlining further research that can be undertaken in this direction

Controlling the order pool in make-to-order production systems

Voor ‘Make-To-Order’ (MTO, oftewel klantordergestuurde) productiesystemen is de tijd die orders moeten wachten op beschikbare productiecapaciteit cruciaal. Het beheersen van die wachttijd is van groot belang om zowel korte als betrouwbare doorlooptijden te realiseren. Daarom analyseerde en ontwierp Remco Germs regels voor orderacceptatie en ordervrijgave, om daarmee de wachttijden te beheersen. Orderacceptatie en -vrijgave zijn de twee belangrijkste mechanismen om de lengte van wachttijden te beïnvloeden en zodoende de productie te sturen. De logistieke prestatie hangt in grote mate af van specifieke kenmerken van MTO-systemen, zoals routing variabiliteit, beperkte productiecapaciteit, omsteltijden, strikte leveringsvoorwaarden en onzekerheid in het aankomstpatroon van orders. Om een beter begrip te krijgen van de afwegingen die MTO-bedrijven in dit opzicht moeten maken richt het proefschrift zich op de modellering van de belangrijkste kenmerken van MTO-systemen. De inzichten die dat oplevert worden vervolgens gebruikt om orderacceptatie- en ordervrijgaveregels te ontwikkelen die eenvoudig te begrijpen en daarom makkelijk in praktijksituaties te implementeren zijn. Deze relatief eenvoudige beslissingsregels kunnen al leiden tot significante verbeteringen in de logistieke prestaties van MTO-bedrijven. The thesis of Remco Germs analyses and develops order acceptance and order release policies to control queues in make-to-order (MTO) production systems. Controlling the time orders spend waiting in queues is crucial for realizing short and reliable delivery times, two performance measures which are of strategic importance for many MTO com-panies. Order acceptance and order release are the two most important production con-trol mechanisms to influence the length of these queues. Their performance depends on typical characteristics of MTO systems, such as random (batch) order arrival, routing variability, fixed capacities, setup times and (strict) due-dates. To better understand the underlying mechanisms of good order acceptance and order release policies the models in this thesis focus on the main characteristics of MTO systems. The insights obtained from these models are then used to develop order acceptance and order release policies that are easy to understand and thereby easy to implement in practice. The results show that these relatively simple policies may already lead to significant performance improvements for MTO companies.

Just-In-Time in high variety / low volume manufacturing environments.

Available from British Library Document Supply Centre-DSC:DXN049763 / BLDSC - British Library Document Supply CentreSIGLEGBUnited Kingdo

Designing a robust production system for erratic demand environments.

Production systems must have the right type of material in the right quantities when required for production. They must minimize the work in progress while ensuring no stock-outstock-out occurs. While these twin opposing goals are achievable when demand is stable, they are difficult to realize under an erratic demand pattern. This dissertation aims to develop a production system that can meet erratic demands with minimal costs or errors. After a detailed introduction to the problem considered, we review the relevant literature. We then conduct a numerical analysis of current production systems, identify their deficiencies, and then present our solution to address these deficiencies via the ARK (Automated Replenishment System) technique. This technique is applied to a real-world problem at Methode Engineering ©. We conclude by detailing the scientific benefit of our technique and proposing ideas for future research

Card-based systems: systematic literature review of new systems and proposal of a list of soft factors for systems implementation

Although Production Control Systems are considered a mature topic in literature, up to now, the focus of literature has been on optimizing the operating parameters of each system, assigning little importance to factors related to human influence (soft factors). Implementation, however, remains a complex problem. This paper aims to reduce this gap by proposing, through a combination of research methods, a list of soft factors critical to success in implementing card-based systems, which which are the most studied and implemented and which share as a characteristic a strong human influence on their functioning. However, to achieve this goal, it was initially necessary to identify which systems are based on cards. Although for systems such as Kanban and CONWIP there is a large literature available, systems developed after POLCA proposal in 1998 were little explored. Therefore, this dissertation initially performs a systematic literature review identifying 13 systems developed between 1999 and 2018, such as COBACABANA, DDMRP, Redutex, B-CONWIP, BK-CONWIP, among others. Briefly, it presents how each system works, its characteristics, current research stage and environments in which it has been proved to be useful, aiming to increase researches about them. The systems are also compared in relation to six variables defined in the literature, identifying that many of the new systems are card-based. The soft factors proposed for the implementation of card-based systems are based on the analysis of problems cited in the literature as well as difficulties identified through a longitudinal case study. This list was validated by experts as well as a group of employees from the focus company that participated in the implementation of kanban. This dissertation also proposes a soft factor house for the implementation of card-based systems, in which the factors are classified as exclusive to this theme or classic management factors, as well as in relation to the organizational level in which it operates (organization, implementation group, or individual). This house aims to assist managers in implementing card-based systems, increasing success rates in this process. In addition, by reviewing recent production control systems, this dissertation aims to increase the repertoire of managers on existing systems, enabling the implementation of more appropriate options for the productive environment in which they are located.Não recebi financiamentoEmbora os Sistemas de Coordenação de Ordens sejam considerado um tópico maduro na literatura, o foco da literatura até o momento recaiu especialmente sobre a otimização dos parâmetros de funcionamento de cada sistema, atribuindo pouca importância aos fatores relacionados a influência humana (soft factors). A implementação, contudo, continua a ser um problema complexo. Esse trabalho visa reduzir essa lacuna, propondo, através de uma combinação de métodos de pesquisa, uma lista de fatores soft críticos para o sucesso na implementação de sistemas baseado em cartão, os quais são os mais estudados e implementados e que compartilham como característica uma forte influência humana em seu funcionamento. Contudo, para realização desse objetivo, inicialmente foi necessário identificar quais são os sistemas baseados em cartão. Embora para sistemas como o Kanban e o CONWIP exista uma grande literatura disponível, sistemas desenvolvidos após a proposta do POLCA em 1998 foram pouco explorados. Assim, essa dissertação inicialmente realiza uma revisão sistemática de literatura identificando 13 sistemas desenvolvidos entre 1999 e 2018, tais como COBACABANA, DDMRP, Redutex, B-CONWIP, BK-CONWIP, dentre outros. Brevemente, é apresentado o funcionamento, características, estágio atual de pesquisa e ambientes propícios para cada sistema, visando aumentar as pesquisas sobre eles. Os sistemas são também comparados em relação a seis variáveis, identificando-se que muitos dos novos sistemas são baseados em cartão. Os fatores soft propostos para a implementação de sistemas baseado em cartão se baseiam na análise de problemas citados na literatura bem como de dificuldades identificadas através de um estudo de caso longitudinal. Essa lista foi validada por especialistas assim como por um grupo de colaboradores da empresa foco que participou da implementação do kanban. Nessa dissertação é proposta também uma casa de fatores soft para a implementação de sistemas baseados em cartão, nas quais os fatores são classificados como exclusivos dessa temática ou fatores clássicos de administração, bem como em relação ao nível organizacional em que atua. (organização, grupo de implementação ou indivíduo). Essa casa tem como objetivo auxiliar os gerentes na implementação de sistemas baseados em cartão, aumentando as taxas de sucesso nesse processo. Além disso, através da revisão de sistemas de coordenação de ordens recentes, essa dissertação visa aumentar o repertório dos gerentes sobre os sistemas existentes, possibilitando a implementação de opções mais adequadas para o ambiente produtivo em que se encontram

Multiproduct supplye chain analysis through by simulation with kanban and EOQ system

This work reviews lean literature on the supply chain focused on the operational approach, from the lean management to the Kanban system. But, the main issue of this work is to analyze the behavior of a lean supply chain using a Kanban system managing the planning in two different ways. The difference between both is related to the production order or sequence to follow: the product with fewer inventories in stock (the most critical to run out) or the one which requires less set-up time to optimize unproductive times. The study the behavior of the supply chain, it would be done through simulation with many different scenarios: 5 different demands, each one with two coefficients of variance, 4 different batch sizes, 4 different compositions of production and process saturation and ensuring different service levels between 92% and 98%. To compare these supply chain models, an approach of the supply chain using the EOQ (Economic Order Quantity) system will be also simulated in the same conditions but with one batch size, the most economic one