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.     

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.     

REALIZATION OF THE VIRTUAL ENTERPRISE PARADIGM IN THE CLOTHING INDUSTRY THROUGH E‐BUSINESS TECHNOLOGY

This paper presents a methodology and a case study for supply chain management in the clothing industry that makes extensive use of the virtual enterprise paradigm. The main research goal was to design and implement a prototype e‐business software component and carry out tests in several industrial users. The research effort resulted in the extended production data management system (epms), which supported the business processes of customer order management, subcontractor selection, and multi‐site/multi‐firm production orders release. The enablers of this software application were business‐to‐business (b2b) e‐commerce technologies in the operating context of application service providers (asps).     

Planning a computer network: The octopus experience

The author of this article is engaged in software design and implementation for the decade-old Octopus computer network. This network remains in a continual state of growth and change in a constant effort to take advantage of the most advanced hardware and software available from an ever-developing technology. Those planning a computer network or other complex computer system should benefit by considering the Octopus experience with regard to the needs of computer users, methods of design, network and operating system structure, security and privacy, the management of limited resources, and the advantages of locally generated hardware and software.     

A decision-based approach: application to the automatic design of process planning

The notion of centre of decision presented in this article defines a conceptual and generic model enabling us to represent and use expert knowledge. It is suitable when the problem to be solved can be broken down into a sum of interdependent subproblems. Actions can be planned progressively and previous decisions can he modified by a backtrack mechanism. This principle is iterative. The structure is made up of many independent rules and an action plan. The customization of the application is possible even if the software evolves with future updates. This model has been applied in the LURPA-TOUR software which is a computer-aided process planning system for rotational parts.     

Retail category management: State-of-the-art review of quantitative research and software applications in assortment and shelf space management

Retail requires efficient decision support to manage increasing product proliferation and various consumer choice effects with limited shelf space. Our goal is to identify, describe and compare decision support systems for category planning. This research analyzes quantitative models and software applications in assortment and shelf space management and contributes to a more integrated modeling approach. There are difficulties commonly involved in the use of commercial software and the implementation and transfer of scientific models. Scientific decision models either focus on space-dependent demand or substitution effects, whereas software applications use simplistic rules of thumb. We show that retail assortment planning models neglect space-elastic demand and largely also ignore constraints of limited shelf space. Shelf space management streams on the other hand, mostly omit substitution effects between products when products are delisted orout-of-stock, which is the focus of consumer choice models in assortment planning. Also, the problem sizes of the models are often not relevant for realistic category sizes. Addressing these issues, this paper provides a state-of-the-art overview and research framework for integrated assortment and shelf space planning.     

Experimental push/pull production planning and control system

We introduce an experimental push/ pull production planning and control software system which is designed as an alternative to a MRP-II system for mass manufacturing enterprises in China. It has the following distinguishing features: (1) putting the philosophy of JIT into the master production scheduling of MRP-II via the earliness/ tardiness production planning method; (2) controlling material input by push and processing/ assembly by pull; and (3) adjusting the parameters of the production line by the‘ suggestion for improvement of production line’ module. Simulation results have shown that the proposed system can achieve better planning and control performance than existing systems.     

THE ROLE OF TRANSACTION COSTS FOR FINANCIAL VOLATILITY: EVIDENCE FROM THE PARIS BOURSE

This paper analyzes the causal linkage between transaction costs and financial volatility under two methodological improvements over the existing literature. First, we use panel data in which exogenous transaction cost differences in the French stock market are induced by price level dependent minimum price variation rules (tick size rules). Unlike in previous studies based on one‐time regulatory tick size changes (like the U.S. decimalization), we can separately identify and control for marketwide volatility changes. Second, we avoid the pitfalls of biased volatility measurement across regimes by using the range as a tick size robust volatility metric. Panel regressions controlling for marketwide volatility effects show at high levels of statistical significance that the hourly range volatility of individual stocks increases by more than 30% for a 20% exogenous increase in transaction costs due to tick size variations in the French trading system. In the light of this evidence, higher transaction costs in general, and security transaction taxes in particular, should be considered as volatility increasing. (JEL: F3, G1, G14)     

Experimental earliness/tardiness production planning with the due window system

In order to use the philosophy of JIT to improve the production planning method of MRP-II, we propose the experimental software system of the earliness/tardiness produc tion planning problem with due window. By means of the approaches and model reported in this paper, the optimal production planning can be achieved. The recommended model extends the problem of due window from the shop scheduling level into the aggregated planning level of mass manufacturing systems. Simulation results have demonstrated that the experimental software is a useful tool for the production management of repetitive manufacturing enterprises.     

Minimum cost network design in strategic alliances

Strategic alliances are established between firms to improve their competitiveness in markets and generally appear in the form of joint ventures. Such collaborative efforts require centralized planning, and the survival of the alliance largely depends on the success of joint planning processes. In this regard, we investigate the opportunities that centralized collaboration can offer to firms when designing their service networks. Apart from the classical fixed and variable costs associated with the network design, we also consider transaction costs induced by the formation of the alliance, which can broadly be defined as cost components related to the coordination and monitoring of the people, efforts and resources. We concentrate on bilateral alliances and develop alternative models for solving their associated network design problem. We also adopt a state-of-the-art heuristic to solve large-scale instances. Our findings confirm that accounting for the transaction cost in network design is vital for the alliance. These transaction costs can be high enough to even render the collaboration unattractive. Hence, careful data collection and model treatment are required before deciding whether to form an alliance.     

Engineering of a decision support system for underground coal mine planning and production scheduling

This paper reports on the development of a computer-based management information system at Datong Coal Company, the largest subsidiary of China National Coal Corporation. Particularly presented is the development methodology of a decision support system for underground coal mine planning and production scheduling, including an integration of computer graphics, database management, mathematical modelling and knowledge engineering techniques and a coupling of life cycle and prototyping software engineering processes to support systems quality assurance.     

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.     

A statistical analysis of yield loss in material requirements planning systems

In most of the research done on material requirements planning (MRP) systems it has been assumed that production and assembly operations incur no yield loss. This assumption has been dropped and performance of popular lot-size adjustment rules borrowed from the single-stage reject allowance problem has been tested in an MRP environment. Both the effect of the rules on the component inventory, and their ability to meet the master production schedule requirements have been analysed. An appropriate statistical design has been presented.     

Reference model for implementing an MRP system in a highly diverse component and seasonal lean production environment

Companies are currently choosing to integrate logics and systems to achieve better solutions. These combinations also include companies striving to join the logic of material requirement planning (MRP) system with the systems of lean production. The purpose of this article was to design an MRP as part of the implementation of an enterprise resource planning (ERP) in a company that produces agricultural implements, which has used the lean production system since 1998. This proposal is based on the innovation theory, theory networks, lean production systems, ERP systems and the hybrid production systems, which use both components and MRP systems, as concepts of lean production systems. The analytical approach of innovation networks enables verification of the links and relationships among the companies and departments of the same corporation. The analysis begins with the MRP implementation project carried out in a Brazilian metallurgical company and follows through the operationalisation of the MRP project, until its production stabilisation. The main point is that the MRP system should help the company's operations with regard to its effective agility to respond in time to demand fluctuations, facilitating the creation process and controlling the branch offices in other countries that use components produced in the matrix, hence ensuring more accurate estimates of stockpiles. Consequently, it presents the enterprise knowledge development organisational modelling methodology in order to represent further models (goals, actors and resources, business rules, business process and concepts) that should be included in this MRP implementation process for the new configuration of the production system.     

Simple systems for computer-aided production management

Future production concepts where workshop employees responsibly carry through planning and scheduling tasks call for new principles ofcomputer-aided production management (CAPM). With the aid of a critical analysis ofdifferent planning and scheduling mechanisms it will first be laid down why the field of computer-aided production management is suited for a dialogue-oriented planning support based on simple models rather than for the objective of automation with the aid of refined optimization algorithms. Consequently, an alternative design is proposed. This is a prototypically realized concept aiming at computer-aided support of production management of production teams.     

Development of simulation-based production execution system in a shipyard: a case study for a panel block assembly shop

The management of a panel block shop in a shipyard is a complex process that entails the largest amount of work and in which many decisions are involved. Shipbuilders have considered the process as a bottleneck since every panel for every ship must be processed through the shop. The objective of this research is to carry out a materials flow analysis to maximise process productivity and to place simulation optimisation technology in the hands of decision makers, such as production planners and supervisors. In this article, a production execution planning system is proposed for panel block operations utilising discrete-event simulation and simulated annealing. The simulation model was validated using a real production scenario and the comparison showed a very favourable agreement between the actual panel shop and the simulation model. The proposed system supports production planners by general dispatching rules and optimisation to make better scheduling decisions on the shop floor. The system will provide a complete schedule that is at least as clear and accurate as any schedule currently obtained.     

An intelligent workstation controller for integrated planning and scheduling of FMS cell

This paper presents an experimental design developed to determine a combination of robust planning and scheduling rules for an intelligent workstation controller (IWC). The IWC is used as part of the control system for an automated flexible manufacturing system. A three-level hierarchical control structure (shop, workstation and equipment)is adopted in order effectively to control a shop-floor. At the top level is a shop controller which receives orders and their associated manufacturing information, and manages interactions among workstations. The IWC defines and resolves the production control activities necessary to coordinate a group of equipment controllers so as to ensure the completion of orders. Specifically, the IWC is responsible for selecting a specific process routeing for each part, allocating resources, scheduling and coordinating the activities across the equipment, monitoring the progress of activities, detecting and recovering from errors, and preparing reports. These activities are accomplished using planning, scheduling, and execution functions. In order to demonstrate the effectiveness and robustness of the IWC, all the controllable and uncontrollable factors need to be identified and detailed. Controllable factors are those which are set by the controller and cannot be directly affected by the production environment. Uncontrollable factors are those which vary with the production environment and cannot be directly changed by the controller developer. The objective of the paper is to illustrate how a good set of controllable factors that dictate the IWC's effectiveness and robustness over various uncontrollable factors can be determined. Due to the number of possible combinations of all the factors, a complete validation of the effectiveness and robustness of the IWC is extremely time consuming and far beyond the scope of this paper. Therefore, a few planning and scheduling strategies are selected and a formal experiment is conducted. The experiment illustrates how significant performance dependencies for various planning and scheduling strategies can be identified.     

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.     

Reliability: Its implications in production systems design

Research on production systems design has in recent years tended to concentrate on ‘software’ factors such as organisational aspects, work design, and the planning of the production operations. In contrast, relatively little attention has been paid to maximising the contributions made by fixed assets, particularly machines and equipment. However, as the cost of unproductive machine time has increased, reliability, particularly of machine tools, has become ever more important. Reliability theory and research has traditionally been based in the main on electrical and electronic equipment whereas mechanical devices, especially machine tools, have not received sufficiently objective treatment. A recently completed research project has considered the reliability of machine tools by taking sample surveys of purchasers, maintainers and manufacturers. Breakdown data were also collected from a number of engineering companies and analysed using both manual and computer techniques. Results obtained have provided an indication of those factors most likely to influence reliability and which in turn could lead to improved design and selection of machine tool systems. Statistical analysis of long-term field data has revealed patterns of trends of failure which could help in the design of more meaningful maintenance schemes.     

Annualized hours as a capacity planning tool in make-to-order or assemble-to-order environment: An agricultural implements company case

Capacity planning is one of the most important elements for an efficient production planning and control system. It is even more important when the main strategies to fulfil sales requirements are make-to-order (MTO) or assemble-to-order (ATO). Neither MTO or ATO companies keep finished products in stock which means that production level is driven by actual sales figures. Therefore, it is very important to have an available capacity as flexible as possible to meet sales requirements. Annualized hours (AH) is a work time control system that helps in increasing the flexibility of available capacity. The main rule of the AH system is to hire employees to work a certain number of hours on a yearly basis. Following some other pre-defined rules and limits, the AH system allows a company to adjust weekly available time in order to reduce idle capacity or to fulfil requirements that could mean overtime. This paper proposes a linear programming model to plan the operations using AH. This model has been implemented in a company that produces agricultural implements, showing that it is very simple to use. It is producing excellent practical results.