Interfacing aggregate plans and master production schedules via a rolling horizon feedback procedure

Aggregate planning and master scheduling are two important levels of a hierarchical production planning process. They serve as the front end of production and operations planning and control systems. It is imperative to have the front end well planned and coordinated. In this study, we demonstrate that a rolling horizon feedback procedure can be an effective coordination mechanism for interfacing aggregate planning and master scheduling. Each time the schedule is rolled ahead, the feedback of performance results from master scheduling provides the aggregate planning subsystem useful information for improving its planning activities. Our experiments show that there are at least three factors that make a rolling horizon procedure attractive: (i) the use of a horizon with a fractional portion of a seasonal cycle, (ii) high smoothing costs, and (iii) high setup costs. Using rolling horizons reduces the total aggregate costs in these situations relative to not using rolling horizons. The potential impacts of the rolling-horizon strategy are greater under some circumstances than others.     

Order Promising and the Master Production Schedule*

Previous research on material requirements planning (MRP) systems has rarely considered the impact of the master production scheduling method used to promise customer orders and to allocate production capacity. Based on a simulation study of an MRP environment, we show that the correct selection of a master production schedule (MPS) method depends on the variance of end-item demand. In addition, we find evidence that the effectiveness of a particular MPS method can be enhanced by holding buffer inventory at the same level in the product structure as in the MPS.     

Establishing safety stocks for master production schedules

The basic master production scheduling problem assumes that periodic demands are known with certainty. Uncertainty in the forecasts arc typically accommodated afterwards by adding safety stocks to a schedule. Two popular methods for establishing safety stocks are: (1) the constant cycle service level method; and (2) the constant safety stock method. This paper outlines these methods and then develops a third method which results in optimal safety stocks. The paper includes an experimental investigation aimed at comparing performances of the three safety stock methods. The constant safety stock method is shown to perform within one or two per cent of optimal, while the constant cycle service level method performs worse under most conditions. Shorter lead times, variable order interval lengths, and time-dependent forecast errors all adversely affect the performances of the non-optimal methods. An operations manager could use these results to evaluate the appropriateness of the methods for his master production scheduling environment.     

MRP system performance under lumpy demand environments

Material requirements planning (MRP) systems are deemed to deal with master schedules with lumpy demand patterns better than any other production scheduling system. Past studies have advocated important advantages of using MRP systems. The objective of this paper is to look into the impact of patterns of demand lumpiness on the performance of MRP systems by a simulation study. Results show that there is an important threshold point in terms of degree of lumpiness at which MRP system performance starts to deteriorate in the operating conditions considered. If master production schedules (MPS) can be controlled by manufacturers, MRP users should exercise caution to introduce demand lumpiness in MPS to improve system performance. If not, MRP users should then examine the given lumpiness and choose an appropriate lot-sizing rule that has been shown to take advantage of the effect of demand lumpiness.     

Production scheduling in SMT electronic boards assembly

This paper tackles the problem of scheduling in the assembly of SMT electronic boards. In particular, it focuses on a new scheduling method developed within the framework of an industry-university joint research project. The scheduling system aims at minimizing the makespan; this goal is achieved by reducing setup times and idle times of the machines. As an example, the outcome of a test carried out on a production mix made up of 10 board types is presented and analyzed in a summarized form.     

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.     

Real-time scheduling and control of one-of-a kind production

Due to the great diversity of product types in one-of-a-kind production (OKP), the production scheduling and control in OKP is much more difficult than production scheduling and control of other production systems, e.g. mass production and batch production. Hence, the production efficiency in OKP companies is relatively lower. To improve productivity in OKP, a dynamic hierarchy production control system is presented. Using this control structure, a production system in an OKP company can be flexibly organized or re-organized according to the structure of a customized product (or an OKP product). Production synchronizing and scheduling algorithms for OKP shop floor production control are presented. Using these algorithms, a cybernetic model can be developed for shop floor control in OKP. The algorithms are applied to two alternate production scheduling goals in OKP, namely ASAP (as soon as possible) production and JIT (just in time) production.     

A Comparative Analysis of Master Production Scheduling Techniques for Assemble-To-Order Products

This paper studies the master production scheduling (MPS) activity of manufacturing firms that produce assemble-to-order (ATO) products. It describes four techniques for master scheduling ATO products: end-product bills, modular bills, super bills, and percentage bills. These procedures are compared in terms of the percentage of customer orders delivered late, the mean tardiness of customer order deliveries, and the total cost of inventory using simulation analysis. The results indicate that the performance of an MPS technique is affected by the level of uncertainty of the end products' demands and the degree of component commonality in the product structure. In particular, modular bills produce the highest customer service level and super bills produce the lowest total inventory cost under most operating conditions. The conclusions also suggest that the choice of a particular MPS technique is often a compromise between the benefits of improved MPS performance and the costs of implementing and executing the MPS system.     

Evaluation of safety stock methods in multilevel material requirements planning (MRP) systems

This paper evaluates alternative methods of establishing the safety stock level taking into consideration of historical measures of forecasting accuracy and the needs for master production scheduling and material requirement planning under a rolling time horizon. A computer model is used to simulate the forecasting, master production scheduling and material planning activities in a company that produces to stock and the production activities are managed by multilevel MRP systems. The simulation output is analysed to evaluate the impact of safety stock methods on MRP system performance. The result of the study shows that using safety stock can help to reduce total cost, schedule instability and improve service level in the MRP systems. Guidelines are developed to help managers select methods to determine safety stock in MRP system operations.     

The Integration of Cost and Capacity Considerations in Material Requirements Planning Systems

Within the sequential framework of material requirements planning (MRP), a master production schedule (MPS) of end-item production is prepared and a bill-of-material processor is used to convert the MPS into a plan for needed subassemblies, parts, and materials. This study examines the impact of different procedures for considering inventory-related costs and capacity limitations in the two phases of planning: master production scheduling and bill-of-material (BOM) processing. A total of nine procedures are considered for integrating the two phases of planning. The results indicate that the integrated procedures have a significant effect on the trade-offs among inventory-related costs, work load variations, over/under time costs, and excess work loads. Further, the results suggest that the method used to develop the MPS has the primary influence on these trade-offs, but the method used by the BOM processor can sometimes have a moderating effect.     

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.     

A SIMULATION ANALYSIS OF THE JAPANESE JUST-IN-TIME TECHNIQUE (WITH KANBANS) FOR A MULTILINE,MULTISTAGE PRODUCTION SYSTEM

The Japanese “just-in-time with kanban” technique reduces in-process inventory to absolute minimal levels, in concert with the Japanese belief that inventory is an unnecessary evil. Due to the success of Japanese firms that employ this type of system, American firms would like to import this technique and emulate Japanese successes. But this Japanese success may be attributable not only to the just-in-time with kanban technique but also to the production environment in which the technique is employed. This paper simulates the just-in-time with kanban technique for a multiline, multistage production system in order to determine its adaptability to an American production environment that might include such characteristics as variable processing times, variable master production scheduling, and imbalances between production stages. The results have practical implications for those firms considering adoption of the Japanese technique.     

A Model for Master Production Scheduling in Uncertain Environments

In uncertain environments, the master production schedule (MPS) is usually developed using a rolling schedule. When utilizing a rolling schedule, the MPS is replanned periodically and a portion of the MPS is frozen in each planning cycle. The cost performance of a rolling schedule depends on three decisions: the choice of the replanning interval (R), which determines how often the MPS should be replanned; the choice of the frozen interval (F), which determines how many periods the MPS should be frozen in each planning cycle; and the choice of the forecast window (T), which is the time interval over which the MPS is determined using newly updated forecast data. This paper uses an analytical approach to study the master production scheduling process in uncertain environments without capacity constraints, where the MPS is developed using a rolling schedule. It focuses on the choices of F, R, and T for the MPS. A conceptual framework that includes all important MPS time intervals is described. The effects of F, R, and T on system costs, which include the forecast error, MPS change, setup, and inventory holding costs, are also explored. Finally, a mathematical model for the MPS is presented. This model approximates the average system cost as a function of F, R, T, and several environmental factors. It can be used to estimate the associated system costs for any combination of F, R, and T.     

A COMPARISON OF PRODUCTION SCHEDULING POLICIES ON COSTS,SERVICE LEVEL,AND SCHEDULE CHANGES

We consider a single product, single level, stochastic master production scheduling (Mps ) model where decisions are made under rolling planning horizons. Outcomes of interest are cost, service level, and schedule stability. The subject of this research is the Mps control system: the method used in determining the amount of stock planned for production in each time period. Typically, Mps control systems utilize a single buffer stock. Here, two Mps dual-buffer stock systems are developed and tested by simulation. We extend the data envelopment analysis (dea ) methodology to aid in the evaluation of the simulation results, where Dea serves to increase the scope of the experimental design. Results indicate that the dual-buffer control systems outperform existing policies.     

面向并行制造的多生产单元协同调度研究

为提升多生产单元制造系统整体效率，在其系统内开展面向并行制造的协同调度研究，在考虑运输、换线等时间的基础上，构建多生产单元并行协同调度模型，采用并行分段协同遗传算法求解；在此基础上，将所研究协同调度方法应用于某复杂机电产品多生产单元制造车间，并与变批量调度与等批量调度比较。研究表明，所提的并行协同调度方法可以显著提升生产单元效率，提高生产单元设备和人员利用率。     

A closed loop automatic scheduling system (CLASS)

Abstract

CLASS is a production scheduling system, that is designed to function in either a stand-alone manner, or in conjunction with an MRP system. MRP systems innately do not have 'closed loop’ capability in the sense of being able to produce master schedules and order releases that are consistent and that respect capacity constraints. True closed loop performance requires detailed scheduling. In addition to interfacing with MRP systems, CLASS is designed to produce schedules that can be used in conventional shops or can be downloaded to automated facilities. The design goals for the system, its internal architecture, and its role in manufacturing control systems are described. The modelling and decision capabilities     

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     

Product mix in the TFT-LCD industry

As operational costs and equipment depreciation in the TFT-LCD (thin film transistor-liquid crystal display) industry are a high percentage of the total cost, most manufacturers usually fully utilise their production capacity to reduce the average unit cost. However, when the market demand is less than the supply the stock of panels increases; this forces manufacturers to instigate a price war to reduce levels of stock and results in a wide fluctuation in panel prices. Inventory stocks of panels could be decreased by optimising the product mix. This will help manufacturers to reduce the risk of holding stocks, increase profit, and improve competitive advantage. This study uses mixed integer linear programming (MILP) to construct a product mix for the TFT-LCD industry given the conditions of profit, productivity, raw materials supply, and market demand. A case study shows that this model is proven to be effective in generating product mix for the TFT-LCD industry while improving profit. The product mix generated by this model can provide a reference for the sales department for orders and shipping, for the production department for the order quantity, and for master production scheduling for each product.     

Guest Editorial Production Planning and Control in other Industries

This paper provides an excursion into various scheduling problems arising in the manufacturing environment and possible approaches that can be taken to solve them. It reviews the research in production scheduling from the perspective of designing and operating a production system and examines the research strategies adopted to find the solution of the practical problems. This review is in the form of the paradigms that evolved during the twentieth century and shows the transition in theory and practice of each paradigm. It covers the fundamental frameworks of scheduling theory, outlining various approaches that can be taken to solve (optimally or approximately) such problems, and the difficulties arising in their practical use. Subsequently, an iterative scheduling process is suggested as an extension of existing paradigms to solve practical production scheduling problems and to bridge the gap between theory and practice in production scheduling and control.     

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.