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1

Analytical Research on Operational Issues of the Remanufacturing Process in India

Sinha Ajay Kumar, Rao Hanumantha

Management and Production Engineering Review

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2023

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Vol. 14, No. 4

19--27

EN

Environmental awareness among the masses compelled many companies to adopt sustainable practices in their business operations. Remanufacturing is a well-tested and successful business model practiced in many European countries. But in many African and Asian countries, it is still nascent, including India. This research study tries to identify the critical factors in the “Operational Management” area for the viability of remanufacturing business in India. For this purpose, a questionnaire was developed based on the important factors identified from the extensive literature review. An online questionnaire survey was conducted among Indian white goods appliance manufacturing companies and their suppliers. The responses were analyzed statistically and ranked based on their criticality in initiating remanufacturing business in India. The findings may help the Indian government and manufacturing firms to frame proper strategies related to the operational management issues of remanufacturing business in India.

2

The geological modelling of deposits, production designing and scheduling in the JSW SA Mining Group

Dyczko Artur

Gospodarka Surowcami Mineralnymi

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2023

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T. 39, z. 1

35--62

EN

The paper presents the analysis of IT tools selection to develop a system of deposits geological modelling as well as production designing and scheduling in a hard coal mine. The presented concept creates a subject-matter foundation of the solution supporting the decision making system in the field of production activities performance, with the use of IT solutions and monitoring of end product quality, implemented under the paradigm of so-called Intelligent Mine. A technological dialogue carried out by questionnaire surveys, supported with experts’ opinions, was applied to select the software for designing a system of deposit modelling, and for designing and scheduling of mining operations. Questionnaires originated based on presentations, covering the functionality in the field of geological data gathering, developing a geological spatial model of a bedded deposit, as well as designing and scheduling. The presented solutions were next evaluated, via questionnaires, by the employees of the company. In addition, 4 groups of criteria were prepared: technical (questionnaires), technical (experts), business, and IT, based on which the final evaluation was carried out. Ultimately, Solution 2 was selected as that, which to the highest degree satisfied technical, business, and IT requirements of the planned system. The indicated IT solution was implemented and became one of basic tools for modelling hard coal deposits, an also for designing and scheduling of the mining operations in the company.

PL

Rozwój informatyki, automatyki i robotyki umożliwia coraz większej liczbie podmiotów zwiększenie wykorzystania technik cyfrowych lub komputerowych. Dotyczy to również branży tradycyjnych, takich jak górnictwo, dla których stosowanie narzędzi informatycznych do gromadzenia, przechowywania i przetwarzania danych również powinno być jednym z priorytetów. Grupa Kapitałowa JSW SA, zajmująca się wydobyciem węgla kamiennego oraz produkcją koksu, przeprowadziła badania w zakresie opracowania i wdrożenia systemu do modelowania złoża oraz harmonogramowania produkcji górniczej. Celem stosowania wdrożonego systemu była realizacja nadrzędnego celu Programu Jakość Grupy Kapitałowej, czyli zwiększenia efektywności zarządzania jakością złoża i produktu handlowego. W artykule przedstawiono jeden z etapów badań, którym był wybór dedykowanych narzędzi informatycznych dla potrzeb modelowania geologicznego złóż oraz projektowania i harmonogramowania produkcji. Opracowane rozwiązanie pozwala na stałą aktualizację informacji w bazie danych, szybkie ich wykorzystanie i modyfikację oraz usprawnienie procesu projektowego (roboty udostępniające, przygotowawcze, jak i eksploatacyjne). System pozwala na planowanie (krótko- i długoterminowe) eksploatacji oraz projektowanie techniczne, projektowanie robót udostępniających, przygotowawczych i eksploatacyjnych oraz wykonanie harmonogramu projektowanych robót. Umożliwia automatyczne obliczanie ilości i jakości urobku oraz skały płonnej w wybranych przedziałach czasowych oraz przygotowanie prognozy dla wszystkich parametrów dotyczących wykonanego projektu wydobycia, takich jak: ilość urobku, ilość skały płonnej, parametry jakościowe itp.

3

Using Internet of Services to Stablish a Service-Oriented Manufacturing Architecture model in Industry 4.0

Reis Jacqueline Zonichenn, Goncalves Rodrigo Franco, Silva Marcia Terra

Management and Production Engineering Review

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2022

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Vol. 13, No. 4

137--151

EN

The manufacturing industry has been reshaping its operations using digital technologies for a smart production towards a more customized demand. Nevertheless, the flexibility to attend the production plan changes in real time is still challenging. Although the Internet of Services (IoS) has been addressed as a key element for Industry 4.0, there is still a lack of clarity about the IoS contribution for advanced manufacturing. Through a case study, the paper aims to validate the adherence of a theoretical model named Service-Oriented Manufacturing Architecture (SOMA) in two manufacturing companies that have been already engaged in Industry 4.0. As main results, it was concluded that IoS could suit in one case of Industry 4.0 flexible production process but not in a mass production one. Considering the scarcity of research that exemplifies the IoS contribution, the present paper brings an important assessment on a real manufacturing scenario.

4

The Pandemic-Type Demand Shocks in the Mean-Variance Newsvendor Problem

Bieniek Milena

Management and Production Engineering Review

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2022

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Vol. 13, No. 1

52--61

EN

The paper considers the negative pandemic-type demand shocks in the mean-variance newsvendor problem. It extends the previous results to investigate the case when the actual additive demand may attain negative values due to high prices or considerable, negative demand shocks. The results indicate that the general optimal solution may differ to the solution corresponding exclusively to the non-negative realizations of demand.

5

Scheduling of the Manufacturing Cell Work with the Use of a Genetic Algorithm on the Example of a Flexible Production System

Matuszny Marcin

Management and Production Engineering Review

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2022

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Vol. 13, No. 4

98--106

EN

The article is to present the application of genetic algorithm in production scheduling in a production company. In the research work the assumptions of the methodology were described and the operation of the proposed genetic algorithm was presented in details. Genetic algorithms are useful in complex large scale combinatorial optimisation tasks and in the engineering tasks with numerous limitations in the production engineering. Moreover, they are more reliable than the existing direct search algorithms. The research is focused on the effectivity improvement and on the methodology of scheduling of a manufacturing cell work. The genetic algorithm used in the work appeared to be robust and fast in finding accurate solutions. It was shown by experiment that using this method enables obtaining schedules suitable for a model. It gives a group of solutions that are at least as good as those created by the heuristic rules.

6

Prioritizing and Scheduling of Production Orders in Non-homogenous Production Systems

Skołud Bożena, Szopa Agnieszka, Kalinowski Krzysztof

Management and Production Engineering Review

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2022

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Vol. 13, No. 1

62--75

EN

The aim of the work was to develop a prioritizing and scheduling method to be followed in small and medium-sized companies operating under conditions of non-rhythmic and nonrepeatable production. A system in which make to stock, make to order and engineer to order (MTS, MTO and ETO) tasks are carried out concurrently, referred to as a non-homogenous system, has been considered. Particular types of tasks have different priority indicators. Processes involved in the implementation of these tasks are dependent processes, which compete for access to resources. The work is based on the assumption that the developed procedure should be a universal tool that can be easily used by planners. It should also eliminate the intuitive manner of prioritizing tasks while providing a fast and easy to calculate way of obtaining an answer, i.e. a ready plan or schedule. As orders enter the system on an ongoing basis, the created plan and schedule should enable fast analysis of the result and make it possible to implement subsequent orders appearing in the system. The investigations were based on data from the non-homogenous production system functioning at the Experimental Plant of the Łukasiewicz Research Network – Institute of Ceramics and Building Materials, Refractory Materials Division – ICIMB. The developed procedure includes the following steps: 1 – Initial estimation of resource availability, 2 – MTS tasks planning, 3 – Production system capacity analysis, 4 – ETO tasks planning, 5 – MTO orders planning, 6 – Evaluation of the obtained schedule. The scheduling procedure is supported by KbRS (Knowledge-based Rescheduling System), which has been modified in functional terms for the needs of this work assumption.

7

Extending Value Stream Mapping for Lean Production Planning and Control

van Landeghem Hendrik, Cottyn Johannes

Management and Production Engineering Review

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2022

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Vol. 13, No. 3

75--82

EN

Value Stream Mapping has been a key Lean tool since its publication in 1988, offering a strategic view on the reconfiguration of an organization’s processes to reduce overall lead time. It has since been used in many different domains beyond (car) manufacturing. However, the potential offered by its concise representation of both material flow and its controlling information flow seems to have been largely underused. Most literature reports on VSM in the context of waste detection and local improvements. VSM also supports redesigning the material flow (even on a supply chain level) towards (pure) pull systems. However, it fails to adequately give guidance on how to gradually evolve towards this ultimate ideal state. This paper wants to offer a significant contribution to practitioners on how to use VSM to bridge this gap. Another key challenge that remains largely unpublished is how to adapt the planning systems accordingly at each reconfiguration of the material flow. This paper presents extensions to the basic VSM tool to meet these challenges. It includes a more comprehensive 5-level hierarchy that allows to position most lean flow-related techniques. It also extends the basic “door-to-door” VSM with new symbols to accommodate these techniques into the map. Finally, it introduces a new set of 13 questions to support redesigning not only the material flow, but also the information flow. The resulting richer future state maps better support the gradual evolution towards a leaner future shop floor, as illustrated with an example.

8

Integrated maintenance, inventory and quality engineering decisions for multi-product systems

Salmasnia Ali, Hafezian Rahil, Maleki Mohammad Reza

Engineering Management in Production and Services

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2022

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Vol. 14, no. 4

94-113

EN

It is essential for manufacturers to consider the interrelation among quality, inventory, and maintenance decisions to detect imperfect quality products, keep the production system in good operating condition, and manage quality and inventory costs. Hence, this paper aims to develop an integrated model of inventory planning, quality engineering, and maintenance scheduling in which the expected total cost per time unit is minimised by determining the sample size, sampling interval, control limit coefficient, along with production cycle time. In this regard, an imperfect multi-product manufacturing system is considered, in which the inventory shortage in satisfying the demand for each product type and the idle time during the production cycle are not allowed. It is assumed that the process starts in an in-control condition where most produced units are conforming. However, due to the occurrence of an assignable cause (AC), the process mean moves to an out-of-control condition in which a significant fraction of non-conforming units is produced. The efficiency of the proposed mathematical model is evaluated by a numerical example, and then the sensitivity of the proposed model to important inputs is analysed. Finally, a comparative study based on the Taguchi design approach is given to confirm the capability of the proposed model to achieve remarkable cost savings.

9

Analytic optimization framework for resilient manufacturing production and supply planning in Industry 4.0 context-buffer stock allocation - case study

Laciuga Maria, Sęp Jarosław

Technologia i Automatyzacja Montażu

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2021

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nr 3

42--50

PL

Planowanie montażu zespołów i wynikające z niego planowanie i harmonogramowanie produkcji (PPS) oraz planowanie zakupu surowców są kluczowymi elementami odpowiedzialnymi za dostawy na czas oraz aspekt kosztowy poprzez odpowiednie obciążenie zasobów oraz nośnik zapasów. Systemy klasy Industry 4.0 poszerzają wiedzę i możliwości dla podniesienia wydajności systemu oraz usprawniają podejmowanie decyzji. Środowisko produkcyjne z uwagi na sieć strumieni wartości, mnogość zmiennych, wielopoziomowe struktury materiałowe staje się bardzo złożone co jest dodatkowo wzmacniane przez nacisk na doskonałość operacyjną. Niepewność zapotrzebowań wymaga dodatkowej atencji oraz integracji z łańcuchem dostaw. W pracy zaprezentowano rozbudowane środowisko dla rozwiązań analitycznych wspierających narzędzia planowania montażu, produkcji oraz zakupów. Ryzyko związane z zmiennymi planami klienta oraz zmiennością dostawców jest ograniczane poprzez zarządzanie buforami. Poziom bufora zależy od predykcji na bazie modelu symulacyjnego opartego na mechanizmach uczenia maszynowego z wykorzystaniem sieci neuronowych w celu zagwarantowania dostaw na czas oraz w oczekiwanym koszcie. Aktualne wyzwania i oczekiwania w obszarze inteligencji opartej na danych zostały zaprezentowane. Rezultaty zaproponowanego modelu zostały szczegółowo porównane ze stanem obecnym.

EN

Advanced components assembly planning and related manufacturing production planning and scheduling (PPS) and supply planningare key elements responsible for deliveries and cost aspects as a resources workload and inventory driver. Industry 4.0 systems broaden science for improving system performance and decision making.Industry site environment because of material flow network, interrelated multi-variable, multilevel production becomes very complex what is challenged by a strong focus on operational excellence. Demand uncertainty requires additional attention and integration with Supply Chain. This paper presents an extended framework for analytics solutions in assembly, production and supply planning for manufacturing company. Risk related to violable customers demand is mitigated by buffer management. Buffer levels relay on a prediction from simulation model using computational methods based on machine learning algorithm using Neutral Networks to guarantee on-time deliveries and rational costs. Actual challenges and requirements for new use cases in data-driven intelligence are presented. The proposed models and the actual state will be comparably discussed with results analyses.

10

Stochastic programming model for production planning with stochastic aggregate demand and spreadsheet-based solution heuristics

Saadouli Nasreddine

Operations Research and Decisions

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2021

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Vol. 31, No. 4

117--127

EN

By discretising the stochastic demand, a deterministic nonlinear programming formulation is developed. Then, a hybrid simulation-optimisation heuristic that capitalises on the nature of the problem is designed. The outcome is an evaluation problem that is efficiently solved using a spreadsheet model. The main contribution of the paper is providing production managers with a tractable formulation of the production planning problem in a stochastic environment and an efficient solution scheme. A key benefit of this approach is that it provides quick near-optimal solutions without requiring in-depth knowledge or significant investments in optimisation techniques and software.

11

The Way of ETO SMEs to Mass Customization – Overview from Real Production Systems

Ciesla Bartosz, Mleczko Janusz

Management and Production Engineering Review

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2021

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Vol. 13, No. 3

97--105

EN

In this article conclusions from nearly 10 years of collaboration with Polish and German Engineer-to-Order (ETO) small and medium-sized enterprises (SMEs) from mechanical sector was presented. Research objective was to highlight common organizational problems they are dealing with, which prevent them from transition to Mass Customizers. As a result, a concept of 5 foundations for robust process design was proposed: procedures, product selection, machining philosophy, planning and storage, cross-functional teams. More practical solutions from this field have to be published to fill the research gap.

12

A Method to Improve Planning of Product Placement on a Printing Sheet

Czerniachowska Kateryna, Żywicki Krzysztof, Wichniarek Radosław

Management and Production Engineering Review

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2021

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Vol. 12, No. 1

119--128

EN

Major manufactures are moving towards a sustainability goal. This paper introduces the results of collaboration with the leading company in the packaging and advertising industry in Germany and Poland. The problem addresses the manufacturing planning problem in terms of minimizing the total cost of production. The challenge was to bring a new production planning method into cardboard manufacturing and paper processing which minimizes waste, improves the return of expenses, and automates daily processes heavily dependent on the production planners’ experience. The authors developed a module that minimizes the total cost, which reduces the overproduction and is used by the company’s manufacturing planning team. The proposed approach incorporates planning allowances rules to compromise the manufacturing requirements and production cost minimization.

13

Artificial intelligence-based hybrid forecasting models for manufacturing systems

Rosienkiewicz Maria

Eksploatacja i Niezawodność

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2021

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Vol. 23, no. 2

263--277

EN

The paper addresses the problem of forecasting in manufacturing systems. The main aim of the research is to propose new hybrid forecasting models combining artificial intelligencebased methods with traditional techniques based on time series – namely: Hybrid econometric model, Hybrid artificial neural network model, Hybrid support vector machine model and Hybrid extreme learning machine model. The study focuses on solving the problem of limited access to independent variables. Empirical verification of the proposed models is built upon real data from the three manufacturing system areas – production planning, maintenance and quality control. Moreover, in the paper, an algorithm for the forecasting accuracy assessment and optimal method selection for industrial companies is introduced. It can serve not only as an efficient and costless tool for advanced manufacturing companies willing to select the right forecasting method for their particular needs but also as an approach supporting the initial steps of transformation towards smart factory and Industry 4.0 implementation.

14

Computer aided assembly planning using MS Excel software – a case study

Brzozowska Jolanta, Gola Arkadiusz

Applied Computer Science

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2021

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Vol. 17, no 2

70--89

EN

The issue of planning assembly operations remains crucial decision-making area for many of manufacturing companies. It becomes particularly significant in case of small and medium enterprises that perform unit or small-scale production, where the option of applying specialized software is often very limited – both due to high purchase price, but also due to its applicability to single unit manufacturing, that is executed based on individual customer orders. The present article describes the possibility of applying the MS Excel spreadsheet in the planning of machine assembly processes. It emphasises, in particular, the method for using the spreadsheet in subsequent stages of the process, and the identification of possible causes that have impact on problems with the planning process. We performed our analysis on the basis of actual data from one of the machine industry enterprises that manufactures in central Poland.

15

Production Scheduling for the Two Furnaces – One Casting Line System

Stawowy A., Duda J.

Archives of Foundry Engineering

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2020

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Vol. 20, iss. 1

43--48

EN

The paper presents a production scheduling problem in a foundry equipped with two furnaces and one casting line, where the line is a bottleneck and furnaces, of the same capacity, work in parallel. The amount of produced castings may not exceed the capacity of the line and the furnaces, and their loads determine metal type from which the products are manufactured on the casting line. The purpose of planning is to create the processing order of metal production to prevent delays in the delivery of the ordered products to the customers. The problem is a mix of a lot-sizing and scheduling problems on two machines (the furnaces) run in parallel. The article gives a mathematical model that defines the optimization problem, and its relaxed version based on the concept of a rolling-horizon planning. The proposed approaches, i.e. commercial solver and Iterated Local Search (ILS) heuristic, were tested on a sample data and different problem sizes. The tests have shown that rolling horizon approach gives the best results for most problems, however, developed ILS algorithm gives better results for the largest problem instances with tight furnace capacity.

16

Joint effect of forecasting and lot-sizing method on cost minimization objective of a manufacturer: a case study

Olesen Jack, Pedersen Carl-Emil Houmøller, Knudsen Markus Germann, Toft Sandra, Nedbailo Vladimir, Prisak Johan, Nielsen Izabela Ewa, Saha Subrata

Applied Computer Science

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2020

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Vol. 16, no 4

21--36

EN

Forecasting and lot-sizing problems are key for a variety of products manufactured in a plant of finite capacity. The plant manager needs to put special emphasis on the way of selecting the right forecasting methods with a higher level of accuracy and to conduct procurement planning based on specific lot-sizing methods and associated rolling horizon. The study is con-ducted using real case data form the Fibertex Personal Care, and has evalu-ated the joint influence of forecasting procedures such as ARIMA, exponen-tial smoothing methods; and deterministic lot-sizing methods such as the Wagner-Whitin method, modified Silver-Meal heuristic to draw insights on the effect of the appropriate method selection on minimization of operational cost. The objective is to explore their joint effect on the cost minimization goal. It is found that a proficient selection process has a considerable impact on performance. The proposed method can help a manager to save substantial operational costs.

17

Rozproszone systemy baz danych w planowaniu produkcji

Rojek Izabela, Królikowski Zbyszko, Marciniak Mariola

Studia i Materiały Informatyki Stosowanej

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2019

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nr 2

15--21

PL

We współczesnym globalnym świecie wiele przedsiębiorstw zmienia swoją strategię zarządzania przedsiębiorstwem opartym na scentralizowanej bazie danych na strategię opartą na rozproszonych systemach baz danych. W artykule scharakteryzowano rozproszone systemy baz danych w planowaniu produkcji. W szczególności omówiono cechy planowania produkcji oraz zdefiniowano rodzaje rozproszonych systemów baz danych. Jako przypadek szczególny omówiono możliwość zastosowania rozproszonych systemów baz danych w planowaniu produkcji w wybranym przedsiębiorstwie produkcyjnym.

EN

In the modern global world, many enterprises are changing their enterprise management strategy based on a centralized database to a strategy based on distributed database systems. The article characterizes distributed database systems in production planning. In particular, the features of production planning were discussed and the types of distributed database systems were defined. As a special case, the possibility of using distributed database systems in production planning in a selected enterprise was discussed.

18

Hurtownia danych w planowaniu produkcji

Rojek Izabela, Królikowski Zbyszko, Marciniak Mariola

Studia i Materiały Informatyki Stosowanej

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2019

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nr 1

8--12

PL

W artykule scharakteryzowano hurtownie danych w planowaniu produkcji. W szczególności omówiono cechy charakterystyczne planowania produkcji oraz przepływ informacji i decyzji w tym planowaniu. Zdefiniowano hurtownie danych oraz przedstawiono architektury systemów hurtowni danych. Jako przypadek szczególny omówiono możliwość zastosowania hurtowni danych w planowaniu produkcji w wybranym przedsiębiorstwie produkcyjnym. Artykuł ten jest pierwszym z cyklu, wprowadzającym do wybranej tematyki.

EN

The article describes data warehouses in production planning. In particular, the characteristics of production planning and the flow of information and decisions in this planning were discussed. Data warehouses were defined and the architecture of data warehouse systems was presented. As a special case, the possibility of using a data warehouse in production planning in a selected production company was discussed. This article is the first in the introductory cycle to the chosen topic.

19

Computer simulation of manual operated and robotized technological lines in FlexSim software

Maliszewski Daniel, Gołda Grzegorz

Selected Engineering Problems

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2019

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nr 8

49--52

EN

The article present current research realized during works on production planning and manufacturing system quality improving with use a methods of computer modelling and simulation techniques. Except that, the functional analysis of simulation software FlexSim are shown in context of manual operated and robotized technological lines. At realized tests, the possibility of the selected application were examined in the optimization of material flow through internal system, especially in the context of automated and robotized medium-series and high volume production. During research two models were created and compared, at the end some conclusions were presented. The article was created on the base of master thesis [1].

20

Selected elements of the management of production processes

Mitkow Szymon, Sterniczuk Ewa

Scientific Journal of Polish Naval Academy

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2019

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R. 60 nr 1 (216)

89--102

EN

The effectiveness and efficiency of production system is a guarantee of the company’s success, especially in times of dynamic growth of trade (including online trade), as well as increasing customers’ requirements, who want to have goods always available and delivered, preferably on the day of order. A modern customer of services raises the bar high not only for production systems, but also for transport systems. Therefore, IT tools supporting the management process of all areas of its activity are implemented in enterprises. This article describes selected of them, focusing primarily on the support of production planning process. As the use of IT systems should be preceded by deepening the knowledge of algorithms applied in them, first of all a calculation example of the use of material requirements planning procedure for complex products with a modular structure was presented, and then the characteristics of selected IT tools supporting the processes of material requirements planning and enterprise resource planning have been made.

PL

Skuteczność i sprawność systemu produkcyjnego są gwarancją powodzenia przedsiębiorstwa, szczególnie w czasach dynamicznego rozwoju handlu (w tym internetowego) i coraz wyższych wymagań klientów, którzy chcą mieć towar zawsze dostępny i dostarczony najlepiej w dniu zamówienia. Nowoczesny odbiorca usług podnosi wysoko poprzeczkę nie tylko systemom produkcyjnym,ale takżetransportowym. Dlatego w firmach wdrażane są narzędzia informatyczne wspierające proces zarządzania wszystkimi obszarami ich działalności. Wartykule scharakteryzowano wybrane sfery, skupiając się przede wszystkim na wsparciu procesu planowania produkcji.Korzystanie z systemów informatycznych warto poprzedzić zgłębieniem wiedzy dotyczącej zastosowanych w nich algorytmów. Wartykule przedstawiono więc przykład obliczeniowy wykorzystania procedury planowania zapotrzebowania materiałowego MRP dla złożonych wyrobów o strukturze modułowej, której celem jest wsparcie procesów planowania zapotrzebowania materiałowego i wykorzystania zasobów przedsiębiorstwa.