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

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).

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

Evaluation of Pull Production Control Strategies Under Uncertainty: An Integrated Fuzzy Ahp-Topsis Approach

Purpose: Just-In-Time (JIT) production has continuously been considered by industrial practitioners and researchers as a leading strategy for the yet popular Lean production. Pull Production Control Policies (PPCPs) are the major enablers of JIT that locally control the level of inventory by authorizing the production in each station. Aiming to improve the PPCPs, three authorization mechanisms: Kanban, constant-work-in-process (ConWIP), and a hybrid system, are evaluated by considering uncertainty. Design/methodology/approach: Multi-Criteria Decision Making (MCDM) methods are successful in evaluating alternatives with respect to several objectives. The proposed approach of this study applies the fuzzy set theory together with an integrated Analytical Hierarchy Process (AHP) and a Technique for Order Performance by Similarity to Ideal Solution (TOPSIS) method. Findings: The study finds that hybrid Kanban-ConWIP pull production control policies have a better performance in controlling the studied multi-layer multi-stage manufacturing and assembly system. Practical implications: To examine the approach a real case from automobile electro-mechanical part production industry is studied. The production system consists of multiple levels of manufacturing, feeding a multi-stage assembly line with stochastic processing times to satisfy the changing demand. Originality/value: This study proposes the integrated Kanban-ConWIP hybrid pull control policies and implements several alternatives on a multi-stage and multi-layer manufacturing and assembly production system. An integrated Fuzzy AHP TOPSIS method is developed to evaluate the alternatives with respect to several JIT criteriaPeer Reviewe

Stream Fusion, to Completeness

Stream processing is mainstream (again): Widely-used stream libraries are now available for virtually all modern OO and functional languages, from Java to C# to Scala to OCaml to Haskell. Yet expressivity and performance are still lacking. For instance, the popular, well-optimized Java 8 streams do not support the zip operator and are still an order of magnitude slower than hand-written loops. We present the first approach that represents the full generality of stream processing and eliminates overheads, via the use of staging. It is based on an unusually rich semantic model of stream interaction. We support any combination of zipping, nesting (or flat-mapping), sub-ranging, filtering, mapping-of finite or infinite streams. Our model captures idiosyncrasies that a programmer uses in optimizing stream pipelines, such as rate differences and the choice of a "for" vs. "while" loops. Our approach delivers hand-written-like code, but automatically. It explicitly avoids the reliance on black-box optimizers and sufficiently-smart compilers, offering highest, guaranteed and portable performance. Our approach relies on high-level concepts that are then readily mapped into an implementation. Accordingly, we have two distinct implementations: an OCaml stream library, staged via MetaOCaml, and a Scala library for the JVM, staged via LMS. In both cases, we derive libraries richer and simultaneously many tens of times faster than past work. We greatly exceed in performance the standard stream libraries available in Java, Scala and OCaml, including the well-optimized Java 8 streams

A comparative study of Just-In-Time (JIT) and Theory of Constraints (TOC) systems with varying constraint locations and operational characteristics

Various researchers have extolled the benefits of Theory of Constraints (TOC), Just-in-Time (JIT), and other manufacturing strategies. Some supporters of JIT argue it is the least costly, while others point to the overall benefits of TOC. There are conflicting claims as to the best manufacturing philosophies which is compounded by the fact that no one system is best in every situation. The success of a production system truly depends on the manufacturing environment rather than the philosophy being used. This study uses computer simulations of differing manufacturing environments to compare Just-in-Time (JIT) and Theory of Constraints (TOC) philosophies over two response variables, make span and work-in-process (WIP). Results showed significant differences favoring both TOC and JIT in different manufacturing environments with respect to both make span and work-in-process (WIP). The study showed evidence that both JIT and TOC are essentially the same when a production system has a bottleneck located at the last station. However, the performance of TOC could equal that of JIT with less inventory. This supports the concept of strategic inventory use for the constrained resource in TOC over the JIT concept of having at least two Kanban cards at each workstation. Different process structures showed different performance for the two strategies used. The study suggested that higher setup and process variation did not have much effect on WIP level, but they did have a significant effect on the make span variable. In conclusion, the study proved that not one system is best in every condition. Each manufacturing environment will be best served by a unique manufacturing strategy --Abstract, page iii

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