Scheduling of non-repetitive lean manufacturing systems under uncertainty using intelligent agent simulation

World-class manufacturing paradigms emerge from specific types of manufacturing systems with which they remain associated until they are obsolete. Since its introduction the lean paradigm is almost exclusively implemented in repetitive manufacturing systems employing flow-shop layout configurations. Due to its inherent complexity and combinatorial nature, scheduling is one application domain whereby the implementation of manufacturing philosophies and best practices is particularly challenging. The study of the limited reported attempts to extend leanness into the scheduling of non-repetitive manufacturing systems with functional shop-floor configurations confirms that these works have adopted a similar approach which aims to transform the system mainly through reconfiguration in order to increase the degree of manufacturing repetitiveness and thus facilitate the adoption of leanness. This research proposes the use of leading edge intelligent agent simulation to extend the lean principles and techniques to the scheduling of non-repetitive production environments with functional layouts and no prior reconfiguration of any form. The simulated system is a dynamic job-shop with stochastic order arrivals and processing times operating under a variety of dispatching rules. The modelled job-shop is subject to uncertainty expressed in the form of high priority orders unexpectedly arriving at the system, order cancellations and machine breakdowns. The effect of the various forms of the stochastic disruptions considered in this study on system performance prior and post the introduction of leanness is analysed in terms of a number of time, due date and work-in-progress related performance metrics

Production planning systems for cellular manufacturing

New product development is one of the most powerful but difficult activities in business. It is also a very important factor affecting final product quality. There are many techniques available for new product development. Experimental design is now regarded as one of the most significant techniques. In this article, we will discuss how to use the technique of experimental design in developing a new product - an extrusion press. In order to provide a better understanding of this specific process, a brief description of the extrusion press is presented. To ensure the successful development of the extrusion press, customer requirements and expectations were obtained by detailed market research. The critical and non-critical factors affecting the performance of the extrusion press were identified in preliminary experiments. Through conducting single factorial experiments, the critical factorial levels were determined. The relationships between the performance indexes of the extrusion press and the four critical factors were determined on the basis of multi-factorial experiments. The mathematical models for the performance of the extrusion press were established according to a central composite rotatable design. The best combination of the four critical factors and the optimum performance indexes were determined by optimum design. The results were verified by conducting a confirmatory experiment. Finally, a number of conclusions became evident.

Short-Term Robustness of Production Management Systems: New Methodology

This paper investigates the short-term robustness of production planning and control systems. This robustness is defined here as the systems ability to maintain short-term service probabilities (i.e., the probability that the fill rate remains within a prespecified range), in a variety of environments (scenarios). For this investigation, the paper introduces a heuristic, stagewise methodology that combines the techniques of discrete-event simulation, heuristic optimization, risk or uncertainty analysis, and bootstrapping. This methodology compares production control systems, subject to a short-term fill-rate constraint while minimizing long- term work-in-process (WIP). This provides a new tool for performance analysis in operations management. The methodology is illustrated via the example of a production line with four stations and a single product; it compares Kanban, Conwip, Hybrid, and Generic production control schemes.manufacturing;inventory;risk analysis;robustness and sensitivity analysis;scenarios

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

Optimization Versus Robustness in Simulation: A Practical Methodology, With a Production-Management Case-Study

Whereas Operations Research has always paid much attention to optimization, practitioners judge the robustness of the 'optimum' solution to be of greater importance.Therefore this paper proposes a practical methodology that is a stagewise combination of the following four proven techniques: (1) discrete-event simulation, (2) heuristic optimization, (3) risk or uncertainty analysis, and (4) bootstrapping.This methodology is illustrated through a case study on production control systems.That study defines robustness as the system's capability to maintain a short-term service measure, in a variety of environments (scenarios).More precisely, this measure is the probability of the short-term fill rate remaining within a prespecified range.Besides satisfying this probabilistic constraint, the system should minimize long-term work-in-process.Actually, the case study compares four systems: Kanban, Conwip, Hybrid, and Generic.These systems are studied for a well-known example, namely a production line with four stations and a single product.The conclusion of this case study is that Hybrid is best when risk is not ignored, but otherwise Generic is best: risk considerations do make a difference.simulation;experimental design;statistical methods;optimization;risk analysis;bootstrap;production control;robustness

Control of Supply Chain Systems by Kanban Mechanism.

This research studies the control mechanism of a supply chain system to operate it efficiently and economically under the just-in-time (JIT) philosophy. To implement a JIT system, kanbans are employed to link different plants\u27 production processes in a supply pipeline. Supply chain models may be categorized into single-stage, multi-stage, and assembly-line types of production systems. In order to operate efficiently and economically, the number of kanbans, the manufacturing batch size, the number of batches, and the total quantity over one period are determined optimally for these types of supply chains. The kanban operation at each stage is scheduled to minimize the total cost in the synchronized logistics of the supply chain. It is difficult to develop a generalized mathematical model for a supply chain system that incorporates all its salient features. This research employs two basic models to describe the supply chain system: a mathematical programming model to minimize the supply chain inventory system cost and a queuing model to configure the kanban logistic operations in the supply pipeline. A supply chain inventory system is modeled as a mixed-integer nonlinear programming (MINLP) that is difficult to solve optimally for a large instance. A branch-and-bound (B&B) method is devised for all versions of it to solve the MINLP problems. From the solution of MINLP, the number of batches in each stage and the total quantity of products are obtained. Next, the number of kanbans that are needed to deliver the batches between two adjacent stages is determined from the results of the MINLP, and kanban operations are fixed to efficiently schedule the dispatches of work-in-process. The new solutions result in a new line configuration as to the number and size of kanbans that led to simpler dispatch schedules, better material handling, reduction in WIP and delivery time, and enhancement of the overall productivity. These models can help a manager respond quickly to consumers\u27 need, determine the right policies to order the raw material and deliver the finished goods, and manage the operations efficiently both within and between the plants

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

A multi-echelon supply chain model for strategic inventory assessment through the deployment of kanbans

Thesis (M. Eng. in Logistics)--Massachusetts Institute of Technology, Engineering Systems Division, 2008.Includes bibliographical references (leaves 100-102).As global competition in the manufacturing space grows, so do corporations' needs for sophisticated and optimized management systems to enable continuous flows of information and materials across the many tiers within their supply chains. With the complexities introduced by the variability in the demand for finished goods as well as by the variability in lead-time of transportation, procurement, production and administrative activities, corporations have turned to quantitative modeling of their supply chains to address these issues. Based on the data of a heavy machinery manufacturer headquartered in the US, this research introduces a robust model for the deployment of strategic inventory buffers across a multi-echelon manufacturing system. Specifically, this study establishes a replenishment policy for inventory using a multiple bin, or Kanban, system for each part number in the assembly of products from our sponsors tractor line. We employ a numerical simulation to evaluate and optimize the various inventory deployment scenarios. Utilizing several thousand runs of the simulation, we derive a generalized treatment for each part number based on an econometric function of the parameters associated with lead-time, order frequency, inventory value and order costing. The pilot for the simulation focuses on the parts data for three earthmoving products across eight echelons, but scales to n products across m echelons. Our results show that this approach predicted the optimal quantities of Kanbans for 95% of parts to a level of accuracy +/- 3 bins.by Philip J. Hodge and Joshua D. Lemaitre.M.Eng.in Logistic