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Workload control in flow shops with bottleneck shifting and process time variability

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Identyfikatory
Warianty tytułu
Języki publikacji
EN
Abstrakty
EN
Manufacturing industries struggle to devise precise planning and scheduling solutions due to unpredictable business situations. Additionally, uncertainties in production such as machine breakdowns, labour absenteeism, cycle time deviations, etc., would further deteriorate production plans and lead to uncertainty in decision-making processes. Flow shops with bottlenecks are particularly susceptible to these disturbances. Moreover, the random variations in cycle time variations can cause the bottleneck to shift between different stages. Literature indicates that conventional job release methods are ineffective in addressing these difficulties. In contrast, workload control methods would provide better solutions. Hence, a flow shop model has been developed and simulated using the variables like process time variations and bottleneck shifting on the discrete-event simulation software. The flow shop model incorporates realistic shop characteristics which are subjected to random process time variations, so as to assess the performance. The outcomes of the experimentation demonstrate that order release methods play a pivotal role in improving the performance of flow shops in more volatile situations.
Rocznik
Strony
48--56
Opis fizyczny
Bibliogr. 35 poz,. rys., tab.
Twórcy
autor
  • Mechanical and Industrial Engineering, Manipal Institute of Technology, Manipal Academy of Higher Education, Manipal, India
  • Mechanical and Industrial Engineering, Manipal Institute of Technology, Manipal Academy of Higher Education, Manipal, India
autor
  • Humanities and Management, Manipal Institute of Technology, Manipal Academy of Higher Education, Manipal, India
Bibliografia
  • 1. Bertrand, J. W. M., van Ooijen, H. P. G., 2002.Workload based order release and productivity: A missing link. Production Planning and Control, 13(7), 665–678. DOI: 10.1080/0953728021000026276
  • 2. Betterton, C. E., Cox, J. F., 2009. Espoused drum-buffer-rope flow control in serial lines: A comparative study of simulation models. International Journal of Production Economics, 117(1), 66-79. DOI: 10.1016/j.ijpe.2008.08.050
  • 3. Betterton, C. E., Silver, S. J., 2012. Detecting bottlenecks in serial production lines - A focus on interdeparture time variance. International Journal of Production Research, 50(15), 4158-4174. DOI: 10.1080/00207543. 2011.596847
  • 4. Breithaupt, J. W., Land, M., Nyhuis, P., 2002. The workload control concept: Theory and practical extensions of load oriented order release. Production Planning and Control, 13(7), 625-638. DOI: 10.1080/0953728021 000026230
  • 5. Bullington, S. F., 2001. Factory Physics: Foundations Of Manufacturing Management, 2 Nd Edition, Wallace J. Hopp and Mark L. Spearman, Irwin Mcgraw-Hill, 2001, 720 PP., ISBN 0-256-24795-1, LIST: $96. Journal of Design and Manufacturing Automation, 1(3), 230-231. DOI: 10.1080/15320370108500206
  • 6. Chakravorty, S. S., 2001. An evaluation of the DBR control mechanism in a job shop environment. OMEGA, 29, 335-342. DOI: 10.1016/s0305- 0483(01)00028-7
  • 7. Fernandes, N. O., Thürer, M., Silva, C., Carmo-Silva, S., 2017. Improving workload control order release: Incorporating a starvation avoidance trigger into continuous release. International Journal of Production Economics, 194, 181-189. DOI: 10.1016/j.ijpe.2016.12.029
  • 8. Francas, D., Löhndorf, N., Minner, S., 2011. Machine and labor flexibility in manufacturing networks. International Journal of Production Economics, 131(1), 165–174. DOI: 10.1016/j.ijpe.2010.03.014
  • 9. Fredendall, L. D., Ojha, D., Wayne Patterson, J., 2010. Concerning the theory of workload control. European Journal of Operational Research, 201(1), 99-111. DOI: 10.1016/j.ejor.2009.02.003
  • 10. Gilland, W. G., 2002. A simulation study comparing performance of CONWIP and bottleneck-based release rules. Production Planning and Control, 13(2), 211-219. DOI: 10.1080/09537280110069784
  • 11. Huang, Y., 2017. Information architecture for effective Workload Control: an insight from a successful implementation. Production Planning and Control, 28(5), 351-366. DOI: 10.1080/09537287.2017.12882
  • 12. Kadipasaoglu, S. N., Xiang, W., Hurley, S. F., Khumawala, B. M., 2000. A study on the effect of the extent and location of protective capacity in flow systems. International Journal of Production Economics, 63, 217- 228. DOI: 10.1016/S0925-5273(99)00020-1.
  • 13. Kamble, S., Gunasekaran, A., Dhone, N. C., 2020. Industry 4.0 and lean manufacturing practices for sustainable organisational performance in Indian manufacturing companies. International Journal of Production Research, 58(5), 1319-1337. DOI: 10.1080/00207543.2019.1630772
  • 14. Kim, S., Roscoe Davis, K., Cox, J. F., 2003. An investigation of output flow control, bottleneck flow control and dynamic flow control mechanisms in various simple lines scenarios. Production Planning and Control, 14(1), 15-32. DOI: 10.1080/0953728021000039416
  • 15. Land, M., Gaalman, G., 1996. Workload Control Concepts in Job Shops: A critical assessment. International Journal of Production Economics, 46- 47: 535–548, DOI: 10.1016/S0925-5273(96)00088-6
  • 16. Land, M. J., Gerard, Gaalman, J. C., 1998. The Performance of Workload Control Concepts in Job Shops: Improving the Release Method. International Journal of Production Economics, 56-57: 347-364. DOI: 10.1016/S0925-5273(98)00052-8
  • 17. Land, M. J., Stevenson, M., Thürer, M., Gaalman, G. J. C., 2015. Job shop control: In search of the key to delivery improvements. International Journal of Production Economics, 168, 257-266. DOI: 10.1016/j.ijpe. 2015.07.007
  • 18. Land, M., Stevenson, M., Thürer, M., 2014. Integrating load-based order release and priority dispatching. International Journal of Production Research, 52(4), 1059–1073. DOI: 10.1080/00207543.2013.836614
  • 19. Lödding, H., Yu, K. W., Wiendahl, H. P., 2003. Decentralized WIP-oriented manufacturing control (DEWIP). Production Planning and Control, 14(1), 42-54. DOI: 10.1080/0953728021000078701
  • 20. Lu, H. L., Huang, G. Q., Yang, H. D., 2011. Integrating order review/release and dispatching rules for assembly job shop scheduling using a simulation approach. International Journal of Production Research, 49(3), 647-669. DOI: 10.1080/00207540903524490
  • 21. Oosterman, B., Land, M., Gaalman, G., 2000. The Influence of Shop Characteristics on Workload Control. International Journal of Production Economics, 68 (1), 107-119. DOI: 10.1016/S0925-5273(99)00141-3.
  • 22. Prabhu, A., Raghunandana, K., Yogesh Pai, P., 2022. Bottleneck shifting in serial line production: An investigation with different order release methods. Materials Today: Proceedings, 52, 1714-1720. DOI: 10.1016/ j.matpr.2021.11.337
  • 23. Renna, P., 2022. Workload Control Order Release With Controllable Processing Time Policies: An Assessment by Simulation. International Journal of Industrial Engineering and Management, 13(3), 194–205. DOI: 10.24867/IJIEM-2022-3-312
  • 24. Riezebos, J., Korte, G. J., Land, M. J., 2003. Improving a practical DBR buffering approach using Workload Control. International Journal of Production Research, 41(4), 699-712. DOI: 10.1080/00207540310
  • 25. Soepenberg, G. D., Land, M. J., Gaalman, G. J. C., 2012. Workload control dynamics in practice. International Journal of Production Research, 50(2), 443-460. DOI: 10.1080/00207543.2010.539277
  • 26. Spearman, M. L., Woodruff, D. L., Hopp, W. J., 1990. CONWIP: A Pull Alternative to Kanban. International Journal of Production Research, 28(5), 879-894. DOI: 10.1080/00207549008942761
  • 27. Stevenson, M., Hendry, L. C., 2006. Aggregate load-oriented workload control: A review and a re-classification of a key approach. International Journal of Production Economics, 104(2), 676-693. DOI: 10.1016/ j.ijpe.2005.05.022
  • 28. Thürer, M., Fernandes, N. O., Stevenson, M., Qu, T., 2017. On the backlogsequencing decision for extending the applicability of ConWIP to highvariety contexts: an assessment by simulation. International Journal of Production Research, 55(16), 4695–4711. DOI: 10.1080/00207543.2017. 1281462
  • 29. Thürer, M., Qu, T., Stevenson, M., Li, C. D., Huang, G. Q., 2017. Deconstructing bottleneck shiftiness: the impact of bottleneck position on order release control in pure flow shops. Production Planning and Control, 28(15), 1223-1235. DOI: 10.1080/09537287.2017.1362486
  • 30. Thürer, M., Stevenson, M., 2018. Bottleneck-oriented order release with shifting bottlenecks: An assessment by simulation. International Journal of Production Economics, 197, 275-282. DOI: 10.1016/j.ijpe.2018.01.010
  • 31. Thürer, M., Stevenson, M., 2018. Bottleneck-oriented order release with shifting bottlenecks: An assessment by simulation. International Journal of Production Economics, 197, 275-282. DOI: 10.1016/j.ijpe.2018.01.010
  • 32. Thürer, M., Stevenson, M., Land, M. J., Fredendall, L. D., 2019. On the combined effect of due date setting, order release, and output control: an assessment by simulation. International Journal of Production Research, 57(6), 1741-1755. DOI: 10.1080/00207543.2018.1504250
  • 33. Thürer, M., Stevenson, M., Protzman, C. W., 2016. Card-based production control: a review of the control mechanisms underpinning Kanban, ConWIP, POLCA and COBACABANA systems. Production Planning and Control, 27(14), 1143-1157. DOI: 10.1080/09537287.2016.1188224
  • 34. Thürer, M., Stevenson, M., Silvaa, C., 2011. Three decades of workload control research: A systematic review of the literature. In International Journal of Production Research, 49(23), 6905-6935. DOI: 10.1080/ 00207543.2010.519000
  • 35. Thürer, M., Stevenson, M., Silva, C., Qu, T., 2017. Drum-buffer-rope and workload control in High-variety flow and job shops with bottlenecks: An assessment by simulation. International Journal of Production Economics, 188, 116-127. DOI: 10.1016/j.ijpe.2017.03.025
Uwagi
Opracowanie rekordu ze środków MNiSW, umowa nr SONP/SP/546092/2022 w ramach programu "Społeczna odpowiedzialność nauki" - moduł: Popularyzacja nauki i promocja sportu (2024).
Typ dokumentu
Bibliografia
Identyfikator YADDA
bwmeta1.element.baztech-26866798-bda9-4fe5-bfec-2d831b2a7a67
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