Production planning and control as a tool for eco-efficency improvement and environmental impact reduction

The environmental impacts of industrial activity are an increasing concern amongst firms and their stakeholders. As a result, companies around the world have been exploring new tools to diminish the adverse impact of their activities on the environment. Eco-efficiency has played an essential role in this scenario, as companies are continuously seeking to produce more while utilizsing fewer resources and minimising adverse effects on the environment. The literature includes several initiatives to improve eco-efficiency and to reduce the environmental impact of manufacturing operations, but the use of production planning and control (PPC) activities to accomplish these goals has rarely been considered. Therefore, to contribute to the assessment of this issue, this paper proposes to integrate environmental concepts and actions as part of the PPC execution; therefore, they could also be applied to minimise environmental impacts, resulting in an increase in the eco-efficiency level of a company. The practical utilisation of the suggested procedure was confirmed using a case study where the procedure was successfully applied to a make-to-order firm, where a simplified version of a workload control (WLC) form of PPC was in use. As a result, incorporating environmental considerations into the WLC practices enabled the eco-efficiency level of the designated production area to increase by 42%, while the environmental impact of production was reduced by 13%.     

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.     

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.     

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.     

A general approach to disassembly planning and control

Closing product and material cycles have emerged as a paradigm for industry in the 21st century, and are directed towards an economical and responsible use of our limited resources. Disassembly plays a key role in recycling. It enables the recovery of functioning components for re-use of pure materials for re-utilization and the separation of harmful substances. Major challenges are presented by the enormous variety of products to be disassembled, by uncertainty as to quantity and by their unknown properties. An appropriate planning and control of disassembly processes is essential for an economic disassembly. Based on an investigation of the suitability of common production planning and control (PPC) methods for disassembly, a specific disassembly planning and control concept (DPC) is outlined.     

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.     

Consumers,clothing retailers and production planning and control in the smart city

Abstract

Though there has been much talk of smart cities, it is still unclear what the concept means and what the role of their inhabitants might be in the development of such cities. There is a tendency to focus on technology and infrastructure and forget that cities are places for people to live. To counter this, smart city planners need to recognise that people’s needs can and should influence and shape their environment, rather than concentrating too much on technology or the built environment. In order to understand how smart cities can serve the needs of their inhabitants, we will examine the specific example of the fashion clothing industry and its development of omni-channel retailing. This will show that retailers, driven by technology-smart and fashion-conscious consumers, are reshaping the clothing supply chain to achieve greater integration, flexibility and speed. Central to this process is the manufacturers’ ability to create production planning and control (PPC) systems capable of operating effectively in an omni-channel environment. The paper presents a Composite Model of Enterprise Planning which can aid the development of such PPC systems. The paper concludes that changes within the fashion clothing industry indicate how smart cities can develop and are developing, and that although these changes are facilitated by technology, they are driven by the necessity to meet consumers’ needs.     

A reference activity model for smart factory design and improvement

Smart manufacturing systems (SMSs) are envisioned to contain highly automated and IT-driven production systems. To address the complexity that arises in such systems, a standard and holistic model for describing its activities and their interrelationships is needed. This paper introduces a factory design and improvement (FDI) activity model and illustrates a case study of FDI in an electromechanical component factory. In essence, FDI is a reference activity model that encompasses a range of manufacturing system activities for designing and improving a factory during its initial development and also its operational phases. The FDI model shows not only the dependency between activities and manufacturing control levels but also the pieces of information and software functions each activity relies on. We envision that the availability of these pieces of information in digital form to integrate across the software functions will increase the agility of factory design and improvement projects. Therefore, our future work lies in contributing to standards for exchanging such information.     

Sustainable supply chain management in the fast fashion industry: An analysis of corporate reports

In recent decades, the fast fashion industry has been characterized by widespread operations across both developing and developed countries. Due to the economic, social and environmental problems in developing countries, companies increasingly focus on sustainability and try to ensure the same quality and standards in working and production conditions throughout their supply chains. Although the tension in the exchange of resources between developing and developed countries lies at the heart of current sustainability activities, what these companies are actually doing to manage their supply chain has not yet been explored in depth in the literature. Drawing on the theoretical framework of Seuring and Müller (2008), the current study attempts to fill this void by conceptually mapping the current situation of sustainable supply chain management (SSCM) in the fast fashion industry by analysing reports from 9 companies that use the same reporting guidelines. The results of the study reveal that these companies focus significantly on supplier compliance with their code of conduct, employing further monitoring and auditing activities to prevent production problems in developing countries, improve overall supply chain performance and set sustainability criteria for their suppliers.     

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.     

A structured procedure for materials planning during production transfer

This paper explores materials planning procedures to ensure the materials’ availability during production transfers. The paper defines a production transfer as the preparation, physical transfer and start-up of relocated production. A structured procedure of materials planning during production transfer is developed based on theory, and then validated and refined based on the analysis of four case studies. The paper shows that there is a need for a structured procedure of materials planning during production transfers. It also explains the importance of activities that create prerequisites for the materials’ availability during production transfer, such as updating and adapting documentation, planning and control systems, and describes the activities that ensure the materials’ availability, such as preventive and corrective actions. A valid estimation of the time needed to reach a steady state and a combination of several preventive actions improves the ability to ensure that materials are available. The cases showed differences across company size, because large companies took more and farther-reaching preventive actions.     

Can Management Accounting Be Helpful for Young and Small Companies? Systematic Review of a Paradox

While management accounting (MA) implies potential benefits for large established companies, its usefulness for young and small companies is less clear. This review analyzes and partially resolves the paradox and provides a structured overview of present knowledge. A systematic literature search yielded 67 empirical papers in 25 journals. Drawing on the results of a two‐step coding process, this study proposes 20 novel second‐level constructs expressing the types of MA, their antecedents and their consequences in young and small companies. The main results show that, in discussing MA, the literature refers mainly to business planning, accounting‐based management control activities and financial accounting. Most studies find MA to be helpful for young and small companies because it provides tools to overcome difficulties arising from company growth and reduces information asymmetry with external partners. Overall, however, the empirical literature on this topic is highly concentrated, offers theoretical construct definitions of poor quality, and lacks a clear statement of what MA really does in young and small companies. Therefore, future research and theory development are warranted.     

独立董事制度,真的有效吗?——基于上市公司行业数据的实证研究

本文运用随机前沿分析模型(SFA)分析了中国独立董事制度对企业效率的影响效应,发现当前的独立董事制度对企业效率的提高作用并不明显;研究结果表明必须完善独立董事的选拨制度和激励制度,吸引具有良好教育水平和丰富的相关工作经验、有良好声誉和国际视野的人士作为独立董事加入董事会,同时提高独立董事津贴,才能充分发挥独立董事的作用,促进企业效率的提高。     

Cloud manufacturing system for sheet metal processing

Abstract

Cloud computing is changing the way industries and enterprises run their businesses. Cloud manufacturing is emerging as an approach to transform the traditional manufacturing business model, while helping the manufacturer to align production efficiency with its business strategy, and creating intelligent factory networks that enable collaboration across the whole enterprise. Many production planning and control (PPC) problems are essentially optimisation problems, where the objective is to develop a plan that meets the demand at minimum cost or maximum profit. Because the underlying optimisation problem will vary in the different business and operation phases, it is important to think about optimisation in a dynamic mechanism and in a number of interlinked sub-problems at the same time. Cloud manufacturing has the potential to offer decision support as a service and medium of communication in PPC. To solve these problems and produce collaboration across the supply chain, this paper provides an overview of the state of the art in cloud manufacturing and presents a model of cloud-based production planning and production system for sheet metal processing.     

The myth of aggregate planning

Abstract

Abstract. An empirical study explores the business environment, the nature of manufacturing, and the planning cycle, using a sample of enterprises with seasonally-biased sales profiles for their products. This enables both the principles and the practicalities of aggregate planning to stand comparison with the observed rubric of manufacturing management. The conclusion is that neither is germane to industry, and that, in general, practitioners develop an effective (broad) manufacturing strategy with an appropriate resources-acquisition programme. The master production schedule then strikes an acceptable balance between productivity, flexibility, and financial risk.     

Lot sizing and scheduling: a survey of practices in Brazilian companies

The lot sizing and scheduling (LSS) problem has motivated much research in production planning and control. However, while there are many papers on modelling this problem, there is scant research on how it is addressed in the industry. We present a survey of Brazilian industry practices in LSS, intending to understand the problem faced by operations managers, drawing parallels with academic findings to identify gaps between theory and practice and opportunities for future research. We confirm that the main objective of practitioners in companies operating under MTS strategy is to maximise service level, followed by inventory reduction. Availability of raw material, demand uncertainty and safety stock levels, lack of decision support software and the impact of sequence-dependent set-up times are other major concerns highlighted by the practitioners. Lastly, we confirmed that despite the relevant body of research on this problem, there is still a large gap between theory and practice.     

Implementation of S-DBR in four manufacturing SMEs: a research case study

Production planning and control systems (PPCs) are tools that have a major effect on the performance of manufacturing companies. An inappropriate determination of the applicability of PPCs could seriously jeopardise the ability to achieve competitive priorities. This mistake can be expensive for any company, but proper implementation is particularly critical for small and medium enterprises (SMEs), which are characterised by limited access to financial resources. Simplified Drum–Buffer–Rope (S-DBR) is a PPC control approach that is characterised by minimum detail in the planning stage and a primary emphasis on the control of execution. Therefore, this approach is a suitable choice for the highly variable context of SMEs. This study aims to explore the practical issues related to S-DBR implementation in four Ecuadorian SMEs through case study research. The case analysis within this study first identifies the choices made in the implementation process design within the four companies according to process and product characteristics. We then conduct a cross-case analysis to explore the effects of the S-DBR implementation process designs on a group of performance measures. Our research findings provide new insights into the S-DBR implementation process in the context of SMEs, and the effects of this approach on performance measures.     

Corporate Planning and Control in German industry

This article records some important results of an extensive empirical investigation in GFR. In so doing the structure and the stage of development of Corporate Planning and Control Systems in 355 industrial companies were analyzed—in addition other systems were investigated. Within the context of the planning and Control Systems, the multi-echelon organization of the system, the time scale and the differentiation of the plans as regards content, co-ordinated planning between various management levels (multi-echelon co-ordination) as well as the harmonization, adaptation and formalization of the plans and the planning, were investigated. Furthermore the content of the planning— for example, objectives, programmes, resources, and budgets—, the various sectional plans of the company, the organizational units, information as well as the interrelationship between the different management levels as regards information and the instruments for planning and control, were surveyed. In relation to the other systems, the organization, information, and management development systems as well as the general management system were analyzed.Within the context of the empirical investigation the structure and developmental stage of Planning and Control Systems in 355 industrial companies in the GFR were analyzed. As the basis for the empirical study a technological concept for Planning and Control Systems was worked out, which is based on a comprehensive planning and control theory.     

Total quality control: Lessons European executives can learn from Japanese companies

This paper reports the finding of a Mission to Japan by 18 executives to study the total quality control activities of 8 companies from diverse industries. A number of the companies can be classified as world class. In the companies studied the dedication, vision and planning for total quality control, development of policy and setting of improvement objectives at each level in the organisation structure, and attention to detail in the production preparation stage is without equal in the majority of Western organisations. It is also pointed out that the housekeeping of Japanese companies is first class and all the companies studied said their greatest assets are employees.     

Production planning and control in automated manufacturing systems

Automated manufacturing systems (AMSs) have the potential for providing a high level of manufacturing performance. Owing to the high cost of capital investment, a high utilization level of AMSs with the help of suitable production planning and control (PPC) is feature of AMSs. Realizing the potential of PPC in AMSs, an attempt has been made to review the available techniques/methods for solving the problems of production planning, control and scheduling in AMSs. The need for further research on PPC of AMSs is brought to the fore along with future research directions.