A survey of simulation modeling techniques in production planning and control (PPC)

The manufacturing sector as a whole has undergone remarkable changes in terms of scale, complexity and technology over the past decades and this applies across most modern high-technology manufacturing such as electronics, semiconductor, aerospace and automotive industries. In order to remain competitive, manufacturers have to produce high-quality products at low cost, and at the same time retain sufficient flexibility and to meet rapidly changing customer demands. Production planning and control (PPC) is a key role which enables the manufacturer to gain visibility and control over all aspects of manufacturing activities. PPC in itself forms a subject of study, within which simulation techniques have proven themselves to be one of the most practical methodologies available to investigate and evaluate manufacturing issues. In this review paper, we focus on state-of-the art applications of simulation techniques in PPC to demonstrate their applicability to modern manufacturing issues. The review reports on academic publications on simulation applications in manufacturing from 2002 to 2014, incorporating surveys of peer-reviewed literature. The review covers three types of simulation techniques (system dynamic, discrete event simulation and agent-based simulation) and eight PPC issues (facility resource planning, capacity planning, job planning, process planning, scheduling, inventory management, production and process design, purchase and supply management). Literature survey is analysed on the basis of simulation application to PPC problems which can give a guideline for simulation technique selection and also can help for simulation modelling in PPC problemsWould you consider changing the term “modeling” to “modelling” in the title. Please check, and correct if necessary.     

基于新产品的供应链最优生产策略

商业竞争与技术进步导致产品生命周期的缩短,要求企业能不断地推出新产品。而新产品的生产与需求是一个逐步适应和熟悉的过程,具有明显的学习效应。本文运用Bass模型来描述新产品的需求扩散效应,建立了新产品供、产、销三级供应链的生产存储优化模型,并通过算例,计算机模拟出最优生产批量。该研究改进了传统的一般产品的生产存储计划,对面向市场需求的供应链的新产品投产具有重要的指导意义。     

Production planning and control for remanufacturing: literature review and analysis

This article reviews the literature on production planning and control (PPC) for remanufacturing. The objectives are threefold: to determine whether the gaps identified by Guide (Guide Jr, V.D.R., 2000. Production planning and control for remanufacturing: industry practice and research needs. Journal of Operations Management, 18, 467–483) on the subject with respect to the main complicating characteristics of remanufacturing have been fulfilled; to classify the literature based on an appropriate structure to obtain a better understanding of the subject identifying sources of future research and to provide a useful source for scholars and practitioners. Seventy-six papers were examined and classified. It was found that none of the studies deals simultaneously with all of the complicating characteristics, and that more practical research is needed. In addition it was found that we lack studies regarding forecasting and aggregate planning considering disassembly of returned products, material matching restrictions or stochastic routings, master production scheduling considering material matching restrictions or stochastic routings, ordering system and capacity planning considering material matching restrictions and inventory control and management considering stochastic routings.     

Integrated long range planning at Nestlé

Nestlé's long-term planning system, which in its present form reflects the Company's philosophy of decentralized decision-making, consists of annually presented 6-year plans for the operating companies. They comprise the areas: Marketing, New Products, Production & Distribution, Investments, Organization, and Finance.     

Design requirements for health care production control systems

This paper addresses the issue of determining design requirements for production control in health care organizations, with a restriction to the internal production control of hospitals. Hospital management has limited possibilities to control hospital production, as hospital production processes are driven by medical specialists who, however, do not manage that process. We consider therefore the hospital as a virtual organization, consisting of a number of relatively independent businesses in a common framework. Each business unit functions as a focused factory for a range of more or less homogeneous products. Production control principles can be applied to each of these businesses, but not to the system as a whole. A number of elements from classical production control theory can be also applied to health care, i.e. the use of decoupling points, the bottleneck-oriented approach, and the operational control between production and market. However, important factors that need to be considered in health production control are that often specifications on quality are not available at the start of the process, and that there is strong interaction between the patient and the process. Our conclusion is that a dedicated framework for approaching hospital production control is necessary. The specific characteristics of hospital care and its state of production control development are the main arguments for this dedicated framework.     

Integration of process planning and production planning and control in cellular manufacturing

Organisations willing to succeed in global competition have to integrate their internal and external processes. This especially includes planning and production control (PPC) processes. Optimised allocation of the production resources and quick response to demand changes result in lower cost and improvement of production performance. Practitioners and researchers have been trying to achieve these goals using production planning techniques. Although the results are significant, it seems necessary to integrate production operations in order to improve the production performance. The goals, information and decisions taken in production planning and control and process planning are often very different and difficult to integrate in Cellular Manufacturing (CM) environments. Designing an efficient PPC system and integrating it with process planning in a cellular environment is of the same importance. The following paper proposes first a comprehensive framework of integrated process planning and production planning and control in CM. Then, with respect to this framework and utilising the domain knowledge in the area of CM systems, an integrated model based on Integrated Definition Modeling Language is developed. The application of the models has been considered as a case study for a production system in electronics and telecommunication sector in a plant in Iran. The validity and completeness of the proposed model is tested by a panel of experts in the areas of production planning and control in CM environments.     

Selection and implementation of a PPC system

There are many computer-aided production planning and control (PPC) systems available on the market which can provide a solution to the complex task of production planning and control. However, the question remains, how can a company find an optimal system from the vast amount of available systems? This article proposes that a company, having decided to buy one of the available systems, starts a project for selection and implementation of the PPC system.     

A modularised typology for flow design based on decoupling points – a holistic view on process industries and discrete manufacturing industries

Management of production activities covers a wide range of decisions. In this paper, a modularised approach is suggested that, through configuration, generates a case-specific flow design. The approach is based on identification of decision categories that are generic and fundamental in the flow design, covering both discrete manufacturing industries and process industries. Each decision category identifies a unique property of the flow which changes at a particular point: this is termed a ‘decoupling point’. A three-dimensional modularised typology is developed by combining three different decision categories. Cases from the steel industry and the tooling industry are used to illustrate how the typology can be applied. The modularised approach provides a typology for the application of both qualitative and quantitative methods for flow management, including planning, control and performance management.     

The generalized process manufacturing systems package

Process manufacturing systems should not be considered a simple variation to a discrete manufacturing control system. The change is often quite complex and generally it becomes easier to create a new package customized for the process manufacturer rather than try to change an existing M RP-based-discrete package. This article discusses why a discrete-to-process conversion can be an ineffective way to create a production control system. It describes the types of changes that will be necessary for process manufacturing systems.     

The new marketing—Developing long-term interactive relationships

This article places emphasis on relationships and interaction in marketing, an emphasis which has developed out of new theories of services marketing and industrial marketing and also out of practical experience. Building and maintaining relationships have significant long-term implications and therefore affect the strategic and long-range planning of the firm's marketing. In the author's view, the present Marketing Concept, as it appears in research, textbooks and seminars, is unrealistic and needs to be replaced. One reason is its inability to absorb new developments in marketing and its rigid attachment to traditional consumer goods marketing. The conclusions can be seen as part of a progress report from an ongoing research project which aims at developing a New Marketing Concept, that draws both on theory and on the views of practitioners.     

THE USE OF INDUSTRIAL SOFTWARE TO CREATE EXPERIENTIAL LEARNING ACTIVITIES IN OPERATIONS MANAGEMENT COURSES

Computer-based manufacturing planning and control (MPC) systems are widely used in industry to gain competitive advantage through integration and coordination of managerial activities. In collegiate business schools, important operations management activities are taught and studied, often by sequential examination of discrete topics such as aggregate production planning, master production scheduling, capacity planning, material planning, and production activity control. This paper explores the potential use of industrial MPC software in the classroom to create experiential learning activities that address the dynamic and integrative nature of operations management. Experiences with this pedagogical approach over the past decade are reported.     

Alternate Routing Strategies in Batch Manufacturing: An Evaluation

Batch manufacturing firms are experiencing significant changes because of technological developments in work center design, such as flexible manufacturing systems (FMS) and planning/control tools like computer-aided process planning (CAPP). These new developments provide production managers with some solutions to a number of complex problems. For example, numerical-controlled (NC) machine center installations are effective in providing quality parts because of tight tolerance specifications built into the equipment. However, these highly efficient centers create bottlenecks that constrain shop throughput, since production planners tend to rely too much on them. To help improve manufacturing planning, we introduce an important element to the batch production scheduling component of CAPP's mission—evaluating possible alternate routes. Production scheduling encompasses job route selection as well as machine center assignment (loading), job releasing, and setting due dates. In this paper, three routing strategies requiring different levels of shop floor information are tested and evaluated using computer simulation. Shop performance is measured by total cost and traditional measures of job flow time, lateness, and tardiness.     

Strategic planning—Which style do you need?

Strategic planning is now a large and diverse activity practised in many different kinds of organizations. This article provides an overview of the field with a summary of the five main schools of thought each with its own business philosophy and a range of practical approaches and techniques. These basic styles are concerned with planning as a central control system, a framework for innovation, an organizational change process, a political activity, and a way of exploring the future. Most planning systems have a dominant style or focus and this emphasis needs to be adjusted in response to changes which are occurring continually in the organization and in the external environment. The article is designed to help the senior manager or corporate planner to assess the state of planning in his organization and to see where there are important gaps in the enterprise's capability for planning which might be filled by the launching of new initiatives. The article also offers an agenda of approaches for consideration by the executive who wishes to move his enterprise from a conventional 5-year planning and budgeting system towards a more comprehensive process of managing organizational change and development.     

REQUIREMENTS PLANNING FOR CONTROL OF INFORMATION RESOURCES

Producing reports assembled from files, records, and raw data is a major function of the computer in modern organizations. Transaction processing, records management, file organization, and data-base management are aspects of the information production function that have received a good deal of attention. But planning, scheduling, and controlling the production of information products have been neglected. For complex applications involving assembly of reports from multilevel information sources, the requirements planning model is suggested as an effective alternative to present methods. Thus, our suggestion is that the computer be used to plan, schedule, and control computer production of information products. Presently available material requirements planning software may be employed with minor modifications that depend on the given information system characteristics. In this paper an example of requirements planning as applied to production of information in a satellite control system is presented.     

Integration of CAD/CAM and production control in sheet metal manufacturing — an application area of operations research

Abstract

This paper describes a process planning system for sheet metal parts. This system has capabilities to deliver process planning data just in time. The change of tools, processes and even machines for manufacturing of the parts is possible at the shop door after design has been finished.

The sequence of the production planning steps carried out can be changed. In this way the system can be adapted to the requirements of different sheet metal manufacturing companies.

More detailed information is given about the methods used for nesting of the workpieces on the sheets to be produced.     

Production planning of mixed-model assembly lines: a heuristic mixed integer programming based approach

Process technology capabilities are becoming increasingly important as flexible manufacturing continues to be more prevalent, and as competition compels companies to provide expanded variety, at ever lower cost, so introducing plant and processes technological constraints. Model flexibility can also benefit from an appropriate production planning process, especially concerning mixed-model assembly lines, since it can facilitate master scheduling and line balancing activities, which are essential aspects of flexibility. Robust and practical planning approaches have to take into account two different aspects: the first consists in ensuring that the elaborated aggregate plan can be disaggregated into at least one detailed feasible plan for the realised demand, whereas the second in ensuring that this detailed plan is feasible at the operational level. This article faces the model flexibility challenge, reviewing and discussing the planning problem of a real world assembly manufacturing system, producing high volume and a variety of agricultural tractors and machines, analysing and resolving some important issues related to technological, organisational and managerial constraints. This article illustrates the implementation of an Advanced Planning System integrated with a mixed integer-programming model, which is solved by a new iterative heuristic approach capable of achieving interesting planning improvements for model-flexibility management.     

A diagnostic analysis of the impact of forecast errors on production planning via MRP system nervousness

Abstract. The purpose of this paper is to examine the impact of forecast errors on the performance of a multi-product, multilevel production planning system via MRP system nervousness. The accuracy of forecasting methods was at one time a major concern of production scheduling and inventory control. However, with the advent of material requirements planning (MRP) systems, the significance of selecting an accurate forecasting method has diminished. Inaccurate forecast results are taken as a fact of life in production planning. Instead of attempting to develop an accurate forecasting method, efforts have been devoted towards providing an appropriate buffering method ai the master production schedule level or on the shop floor level to counteract fluctuations in demand. MRP is capable of rescheduling planned orders as well as open orders to restore the priority integrity after the disruptive changes of forecast errors occur. Nevertheless, excessive rescheduling may lead to a problem, generally referred to as system nervousness. This study investigates this problem by means of a computer simulation model. The results show that the presence of forecasi     

CIM implementation for job-shop environments

Abstract

Abstract. The small to medium-sized job-shop manufacturing industry can benefit most from the implementation of computer integrated manufacturing (CIM) technology, to meet the increasing demand for high-quality and economically priced products. The injection mould making industry is a typical representative for this group, where a manufacturer would generally produce moulds which consist of parts that are standard to every mould type or very similar. Thus, manufacturing techniques, such as group technology (GT), and production planning and control (information) management systems could make significant contributions in improving the efficiency of design and production operations.

The objective of the project, presented in this paper, was the development of a GT-based classification and coding (C/C) system for injection mould parts especially for the design and process planning phases, and the development of a production planning and shop-floor control (SFC) information management system.

An extensive investigation was carried out on existing GT-based C/C systems. This investigation, followed by a thorough examination of many injection mould parts for determining geometric similarities, led to the development of part families (classes) required for GT implementation. An OPITZ-type GT system was developed, thereafter, for the C/C of the manufactured parts of the target company.

The production planning and control software that has been developed for the target company utilizes a relational data base management system. It consists of 13 application programs, which provide a tool of organizing information for efficient production planning and SFC. The programs are designed to cover all manufacturing operations of a job from the proposal to the final testing stage. Shop orders and dispatch lists are created using this software for effective and prioritized SFC. Shop status and job status reports are generated based on feedback information received through time card entries.     

The effects of the warranty cost on the imperfect EMQ model with general discrete shift distribution

In this paper, we investigate the effect of the warranty cost on optimization of the economic manufacturing quality (EMQ). This is done for a deteriorating process where the production process shifts from the in-control state to the out-of-control state following a general discrete probability distribution. Once the production process goes out of control, the production process produces some defective items. The defective item cost includes reworking and warranty costs. Thus, in order to economically operate a production-inventory system with products sold under warranty, the tradeoffs among the production setup, inventory, and defective item cost, including the reworked cost before sale and the warranty cost after sale, needed to be analysed. This objective in this paper is to determine the production lot size while minimizing the total cost per unit of time per unit of time. Various special cases are presented. Two of them are extensions of results obtained previously in the literature. Finally, a numerical example is given which uses a discrete Weibull probability distribution. Sensitivity analysis of the model with respect to cost and time parameters is also performed.