An Analysis of Dual‐Kanban Just‐In‐Time Systems in a Non‐Repetitive Environment

Recent advances in approaches and production technologies for the production of goods and services have made just‐in‐time (JIT) a strong alternative for use in intermittent and small batch production systems, especially when time‐based competition is the norm and a low inventory is a must. However, the conventional JIT system is designed for mass production with a stable master production schedule. This paper suggests supplementing the information provided by production kanbans with information about customer waiting lines to be used by operators to schedule production in each work‐station of intermittent and small batch production systems. This paper uses simulation to analyze the effect of four scheduling policy variables—number of kanbans, length of the withdrawal cycle, information about customer waiting lines, and priority rules on two performance measures—customer wait‐time and inventory. The results show that using information about customer waiting lines reduces customer wait‐time by about 30% while also reducing inventory by about 2%. In addition, the effect of information about customer waiting lines overshadows the effect of priority rules on customer wait‐time and inventory.     

An Evaluation of the NERJIT Priority Rule in a Kanban‐Controlled Flowshop

Significant progress in production and information technologies and innovations in management of operations during the last couple of decades have made the production of small lots and deployment of Just‐In‐Time (JIT) concepts in flowshops possible. As a result, some researchers and practitioners have been seeking to improve the performance of non‐repetitive systems using JIT concepts. In this process, the JIT concepts that were originally designed for mass production have been modified to adapt JIT to non‐repetitive systems. This article uses a priority rule that is based on real‐time demand and production information for sequencing jobs in a kanban‐controlled flowshop. The analysis of the effect of this priority rule; the number of kanbans; the length of the withdrawal cycle; First‐Come, First‐Served (FCFS); and Shortest Processing Time (SPT) on four performance measures—customer wait time, total inventory, input stock‐point inventory, and output stock‐point inventory, shows that the use of this priority rule results in a significant reduction of customer wait time and a slight decrease in inventory.     

A Simulation Study of Sequencing Rules in a Kanban-Controlled Flow Shop*

This paper addresses the problem of sequencing in decentralized kanban-controlled flow shops. The kanban production control system considered uses two card types and a constant withdrawal period. The flow shops are decentralized in the sense that sequencing decisions are made at the local workstation level rather than by a centralized scheduling system. Further, there are no material requirements planning (MRP)-generated due dates available to drive dispatching rules such as earliest due date, slack, and critical ratio. Local sequencing rules suitable for the decentralized kanban production-control environment are proposed and tested in a simulation experiment. These rules are designed so that they can be implemented with only the information available at the workstation level. Example sequencing problems are used to show why the shortest processing time rule minimizes neither average work-in-process inventory nor average finished-goods withdrawal kanban waiting time. Further, it is shown how work station supervisors can use the withdrawal period, in addition to the number of kanbans, to manage work-in-process inventories.     

MANAGING A FLOW LINE WITH SINGLE‐KANBAN,DUAL‐KANBAN OR CONWIP

To control the production of different parts on a single flow line, managers can choose between the Single‐kanban, Dual‐kanban, and Conwip. This paper therefore compares the three different systems. The results show that Conwip consistently produces the shortest mean customer wait time and lowest total work‐in‐process. Our results also contradict the finding of a previous study, which showed that Dual‐kanban performed better than Single‐kanban. The different findings can, however, be attributed to the use of a material transfer policy, which favors the Dual‐kanban modeled in the previous study. Our study shows that transferring replenished containers immediately to downstream stations, increasing the number of cards, and reducing the withdrawal cycle reduce the mean customer wait time significantly.     

A Decomposition Approximation for Periodic Kanban-Controlled Flow Shops*

The kanban system is a pull method of production control in which the material-handling operation between two stations is initiated by the downstream station. Most often, because of limited transportation resources, the physical distance separating workstations, or other factors, the material-handling operation is performed periodically. The number of withdrawal kanbans must be set large enough to satisfy production requirements over the period between occurrences of the material-handling operation-the withdrawal cycle time. This paper presents a decomposition approximation for kanban-controlled flow shops that explicitly considers the withdrawal cycle time. Several examples are given to show how the approximation method can be used to determine the required number of kanbans, the required withdrawal cycle time, or both.     

How Long Should a Customer Wait for Service?

A major concern for service managers is the determination of how long a customer should wait to be served. Services, due to the customer's direct interaction with the process, must face a trade-off between minimizing the cost of having a customer wait and the cost of providing good service. A total cost model is presented for determining how long a customer should wait when these two conflicting cost components are considered. An integral part of this model includes a measure of customer satisfaction with waiting time which is used to develop a waiting cost function. The model is then applied to a major fast food chain, using data collected at several locations. Analysis of the data reveals that the “ideal” waiting time for this firm is significantly less than the current corporate waiting time policy. Thus, as indicated by the model, a corporate policy change is recommended to provide much faster service. The adoption of such a policy would result in increased labor costs, and would simultaneously increase the firm's overall profits. Although appearing contradictory, increases in current labor costs and long-term profits are both possible when management takes the long-range perspective suggested in this paper.     

Analysis and Approximation of a JIT Production Line: A Comment

A recent Decision Sciences article by Jordan [9] presented a Markov-chain model of a just-in-time (JIT) production line. This model was used to estimate average inventories and production rates to find the optimal number of kanbans. Results for expected production rate were found to be consistently lower than those obtained by Huang, Rees, and Taylor [8] in a previous Decision Sciences article. Jordan attributed this unexpected outcome to some procedural problems in Huang et al.'s simulation methodology. In this paper, Markov-numerical analysis is used to compare the performance of Jordan's and Huang et al.'s methods of production control. Simulation analysis is then used to determine the effects of finite withdrawal cycle times. Results show that, for equal numbers of kanbans, Huang et al.'s two-card method of production control provides substantially greater expected production rates than Jordan's method. These results suggest that the Jordan model should not be applied to the problem of setting kanban numbers on manual JIT lines. Finally, we comment on the efficiency of Jordan's iterative method to obtain performance measures of tandem queues.     

A REVIEW OF THE KANBAN PRODUCTION CONTROL RESEARCH LITERATURE

Station interdependence, blocking caused by finite buffer capacities, and periodic material handling make modeling and analysis of kanban-controlled lines challenging. Also, one must consider flows of material as well as flows of kanbans. The many models given in the literature contribute to the confusion and debate that often characterize kanban research. The only element common to all kanban systems appears to be finite buffer capacities. I describe blocking by total queue size, blocking by part type, and the single-card and twocard systems. I review the kanban literature and organize it by type of system and decision area. First, I discuss elements of system design, including setting kanban numbers, performance measures, material-handling frequencies, and container sizes. Then I cover the production control topics of sequencing and batch-sizing. I conclude with a comparison of kanban and conventional methods of production control and with suggestions for future research.     

基于系统柔性的MTS-MTO混合生产决策

研究生产商采用MTS、MTO混合作业的方式为不同客户提供产品和服务的策略。计划利用一组可灵活控制的动态设备处理那些不同需求的MTS和MTO生产业务,为此,我们开发了一个多服务台的排队模型,利用拟生灭过程和相位型分布得到了MTS、MTO排队系统平衡条件和稳态概率矩阵几何解。通过求解分块矩阵方程组,给出了系统队列长度、平均等待队长、顾客服务水平等绩效测度指标。建立了系统运作成本最优化的数学模型,采用搜索算法,确定了关键参数的边界值,找到了混合系统运作的最优策略。数值模拟和系统绩效比较分析结果显示：（1）动态切换策略能够更快速的帮助MTS恢复目标库存量,控制系统缺货风险,降低库存持有成本;（2）找到了满足顾客服务水平的最少的设备配置数量和库存成本最低的生产切换时间,且动态系统的平均队列长度低于静态系统;（3）混合运作策略减少了约2/3的静态系统平均队列长度,企业在队列长度减小的窗口期内可以接受更多订单和缩短MTO订单交货时间。     

Revenue Management with End‐of‐Period Discounts in the Presence of Customer Learning

Consider a firm that sells identical products over a series of selling periods (e.g., weekly all‐inclusive vacations at the same resort). To stimulate demand and enhance revenue, in some periods, the firm may choose to offer a part of its available inventory at a discount. As customers learn to expect such discounts, a fraction may wait rather than purchase at a regular price. A problem the firm faces is how to incorporate this waiting and learning into its revenue management decisions. To address this problem we summarize two types of learning behaviors and propose a general model that allows for both stochastic consumer demand and stochastic waiting. For the case with two customer classes, we develop a novel solution approach to the resulting dynamic program. We then examine two simplified models, where either the demand or the waiting behavior are deterministic, and present the solution in a closed form. We extend the model to incorporate three customer classes and discuss the effects of overselling the capacity and bumping customers. Through numerical simulations we study the value of offering end‐of‐period deals optimally and analyze how this value changes under different consumer behavior and demand scenarios.     

基于异质性顾客心理期望等待时间的优先权服务定价研究

本文以非抢占式M/M/1排队系统为背景,以企业收益最大化为目标,基于顾客异质性(单位时间等待成本不同)将顾客分为两类,针对顾客的心理期望等待时间对服务提供商最优定价策略的影响进行研究。首先研究优先权顾客心理期望等待时间对企业收益的影响以及相应的优先权定价,然后研究优先权顾客和普通顾客同时存在心理期望等待时间对企业收益的影响和相应的优先权定价。研究表明:仅考虑优先权顾客的心理期望等待时间,企业应通过提高优先权定价来获得最优收益;当优先权顾客和普通顾客同时存在心理期望等待时间时,企业仍然采取提高优先权定价的策略,若普通顾客的价值大(获取服务的基本费用大),企业应对普通顾客提供一定的折扣来消除其心理期望等待时间增加企业收益;如果普通顾客的价值较小,企业应"有意"流失部分普通顾客,吸引更多顾客到优先权队列获取服务来获得更多收益。本文研究对于服务提供商在考虑顾客心理期望等待时间基础上设置最合理的队列机制有一定的指导意义和实际应用价值。     

Single‐Period Two‐Product Assemble‐to‐Order Systems with a Common Component and Uncertain Demand Patterns

We consider a single‐period assemble‐to‐order system that produces two types of end products to satisfy two independent and stochastic customer orders. Each type of product is used to fulfill a particular customer order and these two products share a common component. Furthermore, one customer may confirm her order before the other one, and the manufacturer needs to make a commitment immediately upon the receipt of each customer order on how many products to be delivered. We propose a model for optimizing the inventory and production decisions under the above ATO environment. We also extend our model to the situation where the manufacturer can fulfill the unsatisfied low‐priority demand using the left‐over inventories after fulfilling the high‐priority demand, in case the low‐priority customer arrives first. Numerical experiments are conducted, which provide some interesting insights on the impact of uncertain demand pattern.     

Competition and The Operational Performance of Hospitals: The Role of Hospital Objectives

We examine the effect of a hospital's objective (i.e., non‐profit vs. for‐profit) in hospital markets for elective care. Using game‐theoretic analysis and queueing models to capture the operational performance of hospitals, we compare the equilibrium behavior of three market settings in terms of such criteria as waiting times and patient costs from waiting and hospital payments. In the first setting, a monopoly, patients are served exclusively by a single non‐profit hospital; in the second, a homogeneous duopoly, patients are served by two competing non‐profit hospitals. In our third setting, a heterogeneous duopoly, the market is served by one non‐profit hospital and one for‐profit hospital. A non‐profit hospital provides free care to patients, although they may have to wait; for‐profit hospitals charge a fee to provide care with minimal waiting. A comparison between the monopolistic and each of the duopolistic settings reveals that the introduction of competition can hamper a hospital's ability to attain economies of scale and can also increase waiting times. Moreover, the presence of a for‐profit sector may be desirable only when the hospital market is sufficiently competitive. A comparison across the duopolistic settings indicates that the choice between homogeneous and heterogeneous competition depends on the patients' willingness to wait before receiving care and the reimbursement level of the non‐profit sector. When the public funder is not financially constrained, the presence of a for‐profit sector may allow the funder to lower both the financial costs of providing coverage and the total costs to patients. Finally, our analysis suggests that the public funder should exercise caution when using policy tools that support the for‐profit sector—for example, patient subsidies—because such tools may increase patient costs in the long run; it might be preferable to raise the non‐profit sector's level of reimbursement.     

基于顾客不公平规避的服务定价研究

设计合理的服务机制和定价策略对于企业运营至关重要。由于顾客异质性（等待时间成本不同）企业通常对顾客进行分类服务,然而分类服务会引发顾客的不公平心理,并带来负效用,从而引起顾客流动与转移,进而影响企业收益与社会成本。本文针对垄断型服务系统中,顾客不公平规避心理（用参数α表示）对于企业优化目标的影响进行分析,在此基础之上,研究企业是否对顾客采取分类服务以及如何合理定价。结果表明,当顾客不公平规避偏好心理较弱时,从社会成本最小化和企业收益最大化的角度都应该对顾客进行分类服务并收取优先服务费用。当顾客不公规避心理较强时,从企业收益最大化的角度应仅保留优先权顾客并收取优先服务费用,从社会成本最小化的角度则应取消优先服务费用仅保留普通顾客。最后,通过数值模拟和理论分析对上述结论进行验证。     

The Impact of Revenue‐Maximizing Priority Pricing on Customer Delay Costs

Speed is an increasingly important determinant of which suppliers will be given customers' business and is defined as the time between when an order is placed by the customer and when the product is delivered, or as the amount of time customers must wait before they receive their desired service. In either case, the speed a customer experiences can be enhanced by giving priority to that particular customer. Such a prioritization scheme will necessarily reduce the speed experienced by lower‐priority customers, but this can lead to a better outcome when different customers place different values on speed. We model a single resource (e.g., a manufacturer) that processes jobs from customers who have heterogeneous waiting costs. We analyze the price that maximizes priority revenue for the resource owner (i.e., supplier, manufacturer) under different assumptions regarding customer behavior. We discover that a revenue‐maximizing supplier facing self‐interested customers (i.e., those that independently minimize their own expected costs) charges a price that also minimizes the expected total delay costs across all customers and that this outcome does not result when customers coordinate to submit priority orders at a level that seeks to minimize their aggregate costs of priority fees and delays. Thus, the customers are better off collectively (as is the supplier) when the supplier and customers act independently in their own best interests. Finally, as the number of priority classes increases, both the priority revenues and the overall customer delay costs improve, but at a decreasing rate.     

基于顾客公平偏好的服务机制与定价研究

由于顾客异质性（单位时间等待成本不同），服务提供商通常对顾客采取分类服务策略，然而分类服务会引起服务系统中不同类型顾客之间等待时间和服务价值的差异性，从而给顾客带来心理上的不公平感，进而引起顾客在服务系统中的流动和转移，进一步影响企业收益和社会福利。本文针对非抢占M/M/1服务系统顾客分类情形为背景，由两种顾客之间期望等待时间的不同和公平偏好参数相结合构建普通顾客的公平心理效用模型，以垄断型服务系统为背景，分别从企业收益、社会福利与顾客效用三个视角进行分析。研究表明，服务提供商应对顾客采取可观测型的分类服务机制来获得最大收益；从社会福利视角，服务提供商应对顾客采取不可观测型的分类服务机制；从顾客效用视角，服务提供商应取消顾客分类服务，仅保留普通顾客。最后同现有结论进行比较分析，并进行拓展研究。本文研究对服务提供商采取合理的服务机制及相应的服务定价具有重要参考价值和指导意义。     

An Approximate Solution to Deterministic Kanban Systems

This paper presents a simple heuristic for computing the number of kanbans in a kanban system. The production systems under consideration have a multistage, uncapacitated, assembly tree structure, with every stage producing only one item at a time. The experimental results show that this method generates very good solutions. In more realistic problems where the master production schedule incorporates a smoothed demand, the solution found under the proposed method is identical to that of the linear programming approximation. This simple heuristic can be used in the real world to quickly determine the number of kanbans for daily just-in-time operations.     

Optimum common cycle for scheduling a single-machine multiproduct system with a budgetary constraint

This paper deals with the single machine multi-product lot size scheduling problem, and has two objectives. The first objective is to minimize the maximum aggregate inventory for the common cycle (CC) scheduling policy. A simple and easy-to-apply rule has been developed which determines the optimal production sequence that achieves this objective. The second objective is to find an optimal common cycle for minimizing the average production and inventory costs per unit time, subject to a given budgetary constraint. A method has been presented that achieves this objective     

Equilibrium Joining Strategies and Optimal Control of a Make‐to‐Stock Queue

We consider a make‐to‐stock, finite‐capacity production system with setup cost and delay‐sensitive customers. To balance the setup and inventory related costs, the production manager adopts a two‐critical‐number control policy, where the production starts when the number of waiting customers reaches a certain level and shuts down when a certain quantity of inventory has accumulated. Once the production is set up, the unit production time follows an exponential distribution. Potential customers arrive according to a Poisson process. Customers are strategic, i.e., they make decisions on whether to stay for the product or to leave without purchase based on their utility values, which depend on the production manager's control decisions. We formulate the problem as a Stackelberg game between the production manager and the customers, where the former is the game leader. We first derive the equilibrium customer purchasing strategy and system performance. We then formulate the expected cost rate function for the production system and present a search algorithm for obtaining the optimal values of the two control variables. We further analyze the characteristics of the optimal solution numerically and compare them with the situation where the customers are non‐strategic.     

INVENTORY RATIONING AND SHIPMENT FLEXIBILITY ALTERNATIVES FOR DIRECT MARKET FIRMS

This paper investigates inventory‐rationing policies of interest to firms operating in a direct market channel. We model a single product with two demand classes, where one class requests a lower order fulfillment lead time but pays a higher price. Demand for each class follows a Poisson process. Inventory is fed by a production system with exponentially distributed build times. We study rationing policies in which the firm either blocks or backlogs orders for the lower priority customers when inventory drops below a certain level. We compare the performance of these rationing policies with a pure first‐come, first‐serve policy under various scenarios for customer response to delay: lost sales, backlog, and a combination of lost sales and backlog.