The ConWip Production Control System: a Literature Review

International audienceA growing body of literature dealing with ConWip has been observedduring the past decade. Considering the current industrial challengescharacterized by adaptability, product customization, shortened lead times andcustomer satisfaction, ConWip appears to be an effective and adaptedproduction control system for manufacturers. Given this context, this paper aimsto update the previous literature review about ConWip that was made in 2003and to provide an understanding key through an original classification method.This method allows the reader to distinguish papers that concentrate on ConWipsizing, ConWip performance, ConWip environment or on the comparison ofConWip with other PCS. It also provides a reading key about the researchapproach. Taking these criteria into account, this paper helps to answer thefollowing questions: how can ConWip be implemented? How can ConWip beoptimized? Why and when should ConWip be used? The paper then concludeswith some research avenues

Tricks and trucks: Ten years of organizational renewal at DAF?

Organizational Change;Lean Production;DAF;production

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

Milk Run Design: Definitions, Concepts and Solution Approaches

Efficient inbound networks in the European automotive industry rely on a set of different transport concepts including milk runs - understood as regularly scheduled pickup tours. The complexity of designing such a mixed network makes decision support necessary: In this thesis we provide definitions, mathematical models and a solution method for the Milk Run Design problem and introduce indicators assessing the performance of established milk runs in relation to alternative transport concepts

SIMULATION AND OPTIMIZATION OF A CROSSDOCKING OPERATION IN A JUST-IN-TIME ENVIRONMENT

In an ideal Just-in-Time (JIT) production environment, parts should be delivered to the workstationsat the exact time they are needed and in the exact quantity required. In reality, formost components/subassemblies this is neither practical nor economical. In this study, thematerial flow of the crossdocking operation at the Toyota Motor Manufacturing plant inGeorgetown, KY (TMMK) is simulated and analyzed.At the Georgetown plant between 80 and 120 trucks are unloaded every day, with approximately1300 different parts being handled in the crossdocking area. The crossdocking areaconsists of 12 lanes, each lane corresponding to one section of the assembly line. Whereassome pallets contain parts designated for only one lane, other parts are delivered in such smallquantities that they arrive as mixed pallets. These pallets have to be sorted/crossdocked intothe proper lanes before they can be delivered to the workstations at the assembly line. Thisprocedure is both time consuming and costly.In this study, the present layout of the crossdocking area at Toyota and a layout proposed byToyota are compared via simulation with three newly designed layouts. The simulation modelswill test the influence of two different volumes of incoming quantities, the actual volumeas it is now and one of 50% reduced volume. The models will also examine the effects ofcrossdocking on the performance of the system, simulating three different percentage levelsof pallets that have to be crossdocked.The objectives of the initial study are twofold. First, simulations of the current system,based on data provided by Toyota, will give insight into the dynamic behavior and the materialflow of the existing arrangement. These simulations will simultaneously serve to validateour modeling techniques. The second objective is to reduce the travel distances in the crossdockingarea; this will reduce the workload of the team members and decrease the lead timefrom unloading of the truck to delivery to the assembly line. In the second phase of theproject, the design will be further optimized. Starting with the best layouts from the simulationresults, the lanes will be rearranged using a genetic algorithm to allow the lanes withthe most crossdocking traffic to be closest together.The different crossdocking quantities and percentages of crossdocking pallets in the simulationsallow a generalization of the study and the development of guidelines for layouts ofother types of crossdocking operations. The simulation and optimization can be used as abasis for further studies of material flow in JIT and/or crossdocking environments

Agile and Lean Systems Engineering: Kanban in Systems Engineering

This is the 2nd of two reports that were created for research on this topic funded through SERC. The first report, SERC-TR-032-1 dated March 13, 2012, constituted the 2011-2012 Annual Technical Report and the Final Technical Report of the SERC Research Task RT-6: Software Intensive Systems Data Quality and Estimation Research In Support of Future Defense Cost Analysis. The overall objectives of RT-6 were to use data submitted to DoD in the Software Resources Data Report (SRDR) forms to provide guidance for DoD projects in estimating software costs for future DoD projects. In analyzing the data, the project found variances in productivity data that made such SRDR-based estimates highly variable. The project then performed additional analyses that provided better bases of estimate, but also identified ambiguities in the SRDR data definitions that enabled the project to help the DoD DCARC organization to develop better SRDR data definitions. In SERC-TR-2012-032-1, the resulting Manual provided the guidance elements for software cost estimation performers and users. Several appendices provide further related information on acronyms, sizing, nomograms, work breakdown structures, and references. SERC-TR-2013-032-2 (current report), included the “Software Cost Estimation Metrics Manual.” This constitutes the 2012-2013 Annual Technical Report and the Final Technical Report of the SERC Research Task Order 0024, RT-6: Software Intensive Systems Cost and Schedule Estimation Estimating the cost to develop a software application is different from almost any other manufacturing process. In other manufacturing disciplines, the product is developed once and replicated many times using physical processes. Replication improves physical process productivity (duplicate machines produce more items faster), reduces learning curve effects on people and spreads unit cost over many items. Whereas a software application is a single production item, i.e. every application is unique. The only physical processes are the documentation of ideas, their translation into computer instructions and their validation and verification. Production productivity reduces, not increases, when more people are employed to develop the software application. Savings through replication are only realized in the development processes and on the learning curve effects on the management and technical staff. Unit cost is not reduced by creating the software application over and over again. This manual helps analysts and decision makers develop accurate, easy and quick software cost estimates for different operating environments such as ground, shipboard, air and space. It was developed by the Air Force Cost Analysis Agency (AFCAA) in conjunction with DoD Service Cost Agencies, and assisted by the SERC through involving the University of Southern California and the Naval Postgraduate School. The intent is to improve quality and consistency of estimating methods across cost agencies and program offices through guidance, standardization, and knowledge sharing. The manual consists of chapters on metric definitions, e.g., what is meant by equivalent lines of code, examples of metric definitions from commercially available cost models, the data collection and repository form, guidelines for preparing the data for analysis, analysis results, cost estimating relationships found in the data, productivity benchmarks, future cost estimation challenges and a very large appendix.SERCU.S. Department of DefenseSystems Engineering Research Center (SERC)Systems Engineering Research Center (SERC) Contract H98230-08-D-0171

Agile Processes in Software Engineering and Extreme Programming: 18th International Conference, XP 2017, Cologne, Germany, May 22-26, 2017, Proceedings

agile software development; lean development; scrum; project management; software developmen

Variational optimization of probability measure spaces resolves the chain store paradox

In game theory, players have continuous expected payoff functions and can use fixed point theorems to locate equilibria. This optimization method requires that players adopt a particular type of probability measure space. Here, we introduce alternate probability measure spaces altering the dimensionality, continuity, and differentiability properties of what are now the game's expected payoff functionals. Optimizing such functionals requires generalized variational and functional optimization methods to locate novel equilibria. These variational methods can reconcile game theoretic prediction and observed human behaviours, as we illustrate by resolving the chain store paradox. Our generalized optimization analysis has significant implications for economics, artificial intelligence, complex system theory, neurobiology, and biological evolution and development.Comment: 11 pages, 5 figures. Replaced for minor notational correctio

International Logistics

In this study guide the essence, the basic conceptions and the role of international logistics in economic development, the international and organizational aspects of procurement logistics, international warehousing, conceptual foundations of distribution logistics and inernational transport logistics are examined. This study guide is intended for students of specialty “International Economic Relations”