Information architecture for effective Workload Control: an insight from a successful implementation

The implementation of Workload Control (WLC), a Production Planning and Control concept uniquely designed for Make-To-Order companies, has been a constant challenge. Scholars argued that WLC is largely developed through simulations of well-defined environments while much more complex circumstances (e.g. information availability) have emerged in field research. A recent trend of WLC research is to improve the practical applicability of the concept, where empirical evidence is essential. However, success in WLC implementation remains impeded. The availability of data has been a significant area that frustrates the implementation process. While there is a tendency to simplify data requirements in recent WLC theory development, it is important to understand and maintain the information that is essential for the concept to be effective. For the first time in the field, this paper details the information architecture for WLC. Key informational entities of relevance to the input/output control functions in WLC as well as performance measurement are discussed based on evidence from a successful implementation. The paper not only sheds light for practitioners on how to construct an information system that facilitates successful WLC implementation but also has implications for future development of WLC mechanisms coping with information uncertainties in practice.     

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.     

Integration of the information systems in the production process: a case study

This paper evaluates the execution of an ERP – enterprise resource planning in a production process. The changes that were made to processes to make them compatible with ERP modules and adaptations that were required by the ERP implementation are presented. The presented study is different from the normal patterns of a vertical implementation, since its application is not direct. In order to use the standard modules of the ERP system, the internal processes were embellished and the data collection steps were integrated into the production process (production orders, inventory, production, daily consumption, daily output). The case study shows that the ERP implementation caused an improvement of the processes in the areas adjacent to production (purchasing, logistics, distribution, supply and sales). In conclusion, this paper presents the main advantages and disadvantages of the ERP system implementation, as well as some considerations and recommendations for the future ERP implementations.     

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.     

Shop floor characteristics influencing the use of advanced planning and scheduling systems

The purpose of this article is to investigate how the manufacturing process, the shop type and the data quality, i.e. the shop floor characteristics, influence the use of advanced planning and scheduling (APS) systems in production activity and control (PAC). The methodology implemented is a multiple case study at three case companies. Each company has different shop floor characteristics, but all use a scheduling module in an APS system, which supports production scheduling. A theoretical framework is developed suggesting how APS system are used in the PAC activities, and which major aspect to consider. The case analysis shows that the scheduling module in APS system, foremost supports sequencing and dispatching. In particular, the shop type is influenced by the decision of how often the APS runs and what freedom is given to the shop floor. The manufacturing process influences how the dispatch list is created. Contrary to the literature presuming that APS systems are most suitable in job shop processes, it is found that the manufacturing process is not a crucial factor when deciding whether APS systems are an appropriate investment. It is found that the level of data quality needed in the APS system depends to a large extent on how the dispatch list is used. For example, is the dispatch list used as a guideline, not a regulation, the need for accurate data in the module is reduced. This article extends the previous literature concerning APS systems by analysing how APS systems influence PAC as a whole and increase the understanding of the challenges of using APS systems in PAC.     

A column generation heuristic for dynamic capacitated lot sizing with random demand under a fill rate constraint

This paper deals with the dynamic multi-item capacitated lot-sizing problem under random period demands (SCLSP). Unfilled demands are backordered and a fill rate constraint is in effect. It is assumed that, according to the static-uncertainty strategy of Bookbinder and Tan [1], all decisions concerning the time and the production quantities are made in advance for the entire planning horizon regardless of the realization of the demands. The problem is approximated with the set partitioning model and a heuristic solution procedure that combines column generation and the recently developed _ABCβ${\mathit{ABC}}_{\beta }$ heuristic is proposed.     

Development and analysis of mathematical and simulation models of decision-making tools for remanufacturing

This article presents decision-making tools for remanufacturing. The first decision-making tool was used to address inventory lot-sizing problems in a hybrid remanufacturing–manufacturing system with varying remanufacturing fraction. In this article, the new inventory lot-sizing model with variable remanufacturing lot sizes has been shown to exhibit better performance than the benchmark model with fixed remanufacturing lot sizes. The new inventory lot-sizing model is anticipated to become a valuable decision-making tool in companies that are planning to adopt remanufacturing. The second decision-making tool was applied to address a production and inventory planning problem in a remanufacturing system considering different remanufacturing policies for a given remanufacturing strategy. For a remanufacture-to-stock system with two quality remanufacturables groups four alternative policies were examined, a policy which specifies simultaneous processing utilising dedicated resources was shown to be the best policy to achieve a shorter remanufacturing cycle time. For a remanufacture-to-order system with two quality remanufacturables groups, the three relevant policies of the four alternative policies were examined, a policy which specifies sequential processing and switching between various quality remanufacturables groups was shown to be the best policy to achieve a shorter remanufacturing cycle time. The production and inventory planning simulation models in a remanufacturing system are expected to become significant decision-making tools in remanufacturing operations.     

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%.     

Tactical production and distribution planning with dependency issues on the production process

Tactical production-distribution planning models have attracted a great deal of attention in the past decades. In these models, production and distribution decisions are considered simultaneously such that the combined plans are more advantageous than the plans resolved in a hierarchical planning process. We consider a two-stage production process, where in the first stage raw materials are transformed into continuous resources that feed the discrete production of end products in the second stage. Moreover, the setup times and costs of resources depend on the sequence in which they are processed in the first stage. The minimum scheduling unit is the product family which consists of products sharing common resources and manufacturing processes. Based on different mathematical modelling approaches to the production in the first stage, we develop a sequence-oriented formulation and a product-oriented formulation, and propose decomposition-based heuristics to solve this problem efficiently. By considering these dependencies arising in practical production processes, our model can be applied to various industrial cases, such as the beverage industry or the steel industry. Computation tests on instances from an industrial application are provided at the end of the paper.     

A framework for production rescheduling in sociotechnical manufacturing environments

No plan survives contact with reality. Despite the rich research base regarding handling uncertainty in production planning and control systems, there is an intellectual gap between theory and practice with regard to handling unforeseen events generated by internal and external factors, such as unforeseen machine downtimes and changes in demand. Motivated by longitudinal observations in two industrial settings and an analysis of the relevant literature, a framework for rescheduling decision-making in the face of unforeseen production events is proposed. In practical settings, the effectiveness of decisions depends on a set of situational factors. The findings of this research can be utilised further to provide guidelines for developing effective decision support principles and systems, addressing the needs of organisational decision-makers.     

规避农副产品原材料产出不确定风险的商业保险策略

为了保证产品质量、降低生产成本,许多农副产品制造商选择自己种植原材料以满足农副产品的加工生产。然而,农作物的产出易受不利事件（如各种自然灾害）的影响而具有不确定性。这种不确定性可能导致最终产品产出不足,严重时甚至引发财务危机。为了应对潜在风险,农副产品制造商可向金融机构购买商业保险。本文建立了单周期农副产品制造商的计划产量决策模型,通过研究制造商购买商业保险的边界条件及最优商业保险策略,分析商业保险策略在制造商规避原材料产出不确定风险时所具有的价值。研究结果表明：（1）只有保费的安全因子低于外部融资的单位惩罚成本时,制造商才会购买商业保险;（2）最优商业保险策略与计划产量无关;（3）最终产品单位净收益越低,商业保险的价值反而越高。     

Engineer-to-order (ETO) production planning and control: an empirical framework for machinery-building companies

This paper illustrates the results of an empirical study involving 21 engineer-to-order (ETO) companies, operating in the machinery-building industry. The study investigates the needs and requirements of such companies in terms of software support for governing the businesses, with particular emphasis on production planning and control (PPC) processes. An empirical analysis investigated two main aspects: (i) the set of business activities performed by the companies in the analysed industry and (ii) the relevant, high-level software functionalities required for the execution of such activities. As an answer to the observed compelling need for reviewing the general approaches to PPC in machinery-building companies, we develop an empirical, high-level production planning and scheduling reference framework, encompassing all the activities involved in the order fulfilment process.     

Uncertainty,flexibility and buffers in the management of the firm operating system

The role that buffers can assume in the management of uncertain situations that can occur in industrial firms is demonstrated. An outline is provided of the various types of buffers with regard to different types of uncertainty faced and to the characteristics of the production system. Although the prevalent scholarly trend is to evaluate buffers as factors which uselessly increase the complexity of the firms operating systems, this work tries to analyse the contributions they offer to the management process. Buffers are considered as alternative and complementary factors to technological flexibility. Technological flexibility is often considered the only competitive means able to face both external and internal uncertainties. The choice to use or not use buffers as a complementary resource or as an alternative to technological flexibility, depends on a comparison of the cost-benefits of the two solutions     

Production and changeover control policies of a class of failure prone buffered flow-shops

This article deals with a stochastic optimal control problem for a class of buffered multi-parts flow-shops manufacturing system. The involved machines are subject to random breakdowns and repairs. The flow-shop under consideration is not completely flexible and hence requires setup time and cost in order to switch the production from a part type to another, this changeover is carried on the whole line. Our objective is to find the production plan and the sequence of setups that minimise the cost function, which penalises inventories/backlogs and setups. A continuous dynamic programming formulation of the problem is presented. Then, a numerical scheme is adopted to solve the obtained optimality conditions equations for a two buffered serial machines two parts case. A complete heuristic policy, based on the numerical observations which describe the optimal policies in system states, is developed. It will be shown that the obtained policy is a combination of a KANBAN/CONWIP and a modified hedging corridor policy. Moreover, based on our observations and existent research studies extension to cover more complex flow-shops is henceforth possible. The robustness of such a policy is illustrated through sensitivity analysis.     

Building dynamic capabilities for digital transformation: An ongoing process of strategic renewal

In this qualitative study, we explore how incumbent firms in traditional industries build dynamic capabilities for digital transformation. Digital transformation has been defined as the use of new digital technologies, such as mobile, artificial intelligence, cloud, blockchain, and the Internet of things (IoT) technologies, to enable major business improvements to augment customer experience, streamline operations, or create new business models. In making sense of digital transformation, we discovered that leaders in various industry circles use the term inconsistently to describe various strategizing and organizing activities; in addition, the term has gained limited scholarly attention as a context for study of strategic change. Drawing on senior executives' experiences with leading digitalization projects at incumbent firms, we propose a process model comprising of nine microfoundations to reveal the generic contingency factors that trigger, enable, and hinder the building of dynamic capabilities for digital transformation. Our findings reveal that digital transformation is an ongoing process of using new digital technologies in everyday organizational life, which recognizes agility as the core mechanism for the strategic renewal of an organization's (1) business model, (2) collaborative approach, and eventually the (3) culture.     

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.     

Supply chain configuration for diffusion of new products: An integrated optimization approach

We develop an integrated/hybrid optimization model for configuring new products’ supply chains while explicitly considering the impact of demand dynamics during new products’ diffusion. The hybrid model simultaneously determines optimal production/sales plan and supply chain configuration. The production and sales plan provides decisions on the optimal timing to launch a new product, as well as the production and sales quantity in each planning period. The supply chain configuration provides optimal selection of options and safety stock level kept at each supply chain function. Extensive computational experiments on randomly generated testbed problems indicate that the hybrid modeling and solution approach significantly outperforms non-hybrid alternative modeling and solution approaches under various diffusion and supply chain topologies. We provide insights on optimal production/sales plan and supply chain configuration for new products during their diffusion process. Also, managerial implications relevant to effectiveness of the hybrid approach are discussed.     

Pricing decisions in a multi-criteria setting for product recovery facilities

Unpredictability in the arrival time and quantity of discarded products at product recovery facilities (PRFs) and varying demand for recovered components contribute to the volatility in their inventory levels. Achieving profit under such capricious inventory levels and stringent environmental legislations remains a challenge to many PRFs. This paper presents a multi-criteria decision model to determine a pricing policy that can simultaneously address two issues: stabilize inventory fluctuations and boost profits. The model considers that PRFs passively accepts discarded products as well as acquires them proactively if necessary. Under a multi-criteria setting, the current work determines prices of reusable and recyclable components to maximize revenue and minimize product recovery costs. A genetic algorithm is employed to solve the multi-criteria decision making problem. Sensitivity analysis is performed to investigate the effect of sorting yield, disassembly yield, and reusable component yield on the profits, prices, inventory levels, and disposal quantities.     

风险投资入股、首次过会概率与IPO耗时——来自我国中小板和创业板的经验证据

近年来,我国拟上市公司引入风险投资的现象日益普遍,但已有文献很少基于制度背景研究风险投资的引入动机.基于我国股票发行核准制的特殊背景,首次从风险投资提高IPO成功率和进程效率的角度揭示了我国拟上市公司有别于成熟市场中企业的风险投资引入动机.研究发现,风险投资入股不仅提高了被投资公司IPO首次申报的过会概率,而且缩短了其IPO进程的总耗时和过会时间;风险投资对IPO过会概率和耗时的影响主要由高声誉风险投资引起,而风险投资的持股比例、所有权性质和是否联合入股对过会概率、IPO进程时间未产生影响或影响一致.     

Coordination of teams,meetings, and managerial processes in construction projects: using a lean and complex adaptive mechanism

In a construction project, the ‘production planning and control’ function drives the deployment of construction operations. A reliable function is therefore essential. Currently, this function is supplied using economic/contractual and production processes. This approach, however, disregards the explicit regulation of teams, meetings, and the linkages between the function’s elements. Using Lean Management and Complexity theories, we studied a mechanism to address this issue. Using data from an 18-storey building construction project in a case study, this paper analyses a prototype system for driving the function using their linkages. A questionable behaviour beyond the function’s capability was found. This behaviour involves complex, flexible, and push features, focused on execution, where the linkages driven by teams, meetings and processes cause variation from 10% up to 54% in the failure reasons, the progress, and the reliability. These findings suggest a function driven by its complexity level. These new insights require further study.