Integrative Cycle Scheduling Approach for a Capacitated Flexible Assembly System*

This study revisits the traditional single stage, multi-item, capacitated lot-sizing problem (CLSP) with a new integrative focus on problem structuring. Unlike past research, we develop integrative cycle scheduling approaches which simultaneously address lot-sizing, capacity, and sequencing issues. Our purposes are to (1) explore the effect of sequencing on inventory levels, (2) examine the problem of infeasibility in the economic lot scheduling problem (ELSP), and (3) provide a simple methodology of generating low-cost cycle schedules in an environment with discrete shipping, dynamic demands, limited capacity, zero setup cost, and sequence-independent setup times. Our procedures are compared to benchmark cycle scheduling approaches in terms of both inventory cost and computation time under different demand scenarios, using the operating data from a flexible assembly system (FAS) at the Ford Motor Company's Sandusky, Ohio plant.     

An Evaluation of Capacity Sensitive Order Review and Release Procedures in Job Shops

We investigate the performance of capacity-sensitive order review and release (ORR) procedures in job shop environments that have not been previously explored. Previous research has ignored the case of job shops which must perform to very tight due-dates because of time-sensitive customers. We propose and test a new capacity sensitive ORR procedure called path based bottleneck (PBB) in such environments, along with the modified infinite loading (MIL) procedure which has been shown to work well in several studies. We compare the performance of these two controlled release rules with that of immediate release rule under different conditions of capacity utilization and customer specified exogenous duedates. Our results indicate that PBB performs well in lowering total costs when due-dates are tight, while MIL is a better procedure with relatively loose to medium due-dates. We also show that in many cases, the shortest processing time (SPT) dispatching rule is a superior performer than a due-date based rule like critical ratio (CR); a conclusion which is contrary to the existing research in this area. In addition, the shop floor control policies recommended are shown to be sensitive to the cost structure of the firm. The managerial implications of this research in providing effective shop floor control in job shops operating under tight due-date conditions are also discussed.     

Scheduling in a Management Context: Uncertain Processing Times and Non-Regular Performance Measures*

Decision makers often face scheduling problems in which processing times are not known with certainty. Non-regular performance measures, in which both earliness and tardiness are penalized, are also becoming more common in both manufacturing and service operations. We model a managerial environment with task processing times (which include sequenceindependent set-up times) prescribed by three-parameter lognormal distributions. Upon completion, each task derives a reward given by a particular piecewise-linear reward function. The objective is to select a sequence of tasks maximizing the expected total reward. The relative generality of the problem renders many enumerative methods inapplicable or computationally intractable. To overcome such difficulties we develop efficient priorityinduced construction (PIC) heuristics which build up a complete schedule by inserting tasks (singly from a list) into a partial sequence of tasks. In each partial and complete sequence a period of idle time is permitted prior to the first task. Performance on realistic-sized problems is very encouraging, with cost penalties averaging less than one percent.     

Redesigning a Cellular Manufacturing System to Handle Long-Term Demand Changes: A Methodology and Investigation*

Cellular manufacturing systems have been proposed as an alternative to the job shop since they provide some of the operational benefits of a flow line production process, while retaining to some extent the flexibility of job shops. However, this must be balanced against the possibility of additional initial investments in equipment to form the cells and a certain loss in manufacturing flexibility, particularly in terms of the ability to deal with long-term demand changes. This paper presents a model-based heuristic cell system redesign methodology to deal with such demand changes. The methodology is validated and applied to system designs generated from several data sets published in the literature. Results show that different kinds of demand changes incur distinct kinds of costs. Further, characteristics of cell designs that can handle long-term demand changes at least cost are identified.     

The Impact of Learning and Labor Attrition on Worker Flexibility in Dual Resource Constrained Job Shops

This study investigates the impact of worker learning, worker flexibility, and labor attrition on the system performance of a dual resource constrained (DRC) job-shop. The effects of learning and labor attrition have not been previously addressed in DRC literature. Results from the study, consistent with previous literature, show that the greatest benefits are achieved when inter-departmental worker flexibility is incrementally introduced into the system. In addition, the learning environment, which depends on the initial processing time of jobs and the learning rates of workers, is shown to impact the acquisition of flexibility. The study also shows that the impact of labor attrition on system performance under certain shop conditions may be significant.     

Distinguishing Features of Just-in-Time Systems in the Make-to-Order/Assemble-to-Order Environment*

Few studies of just-in-time (JIT) implementation examine their significance in make-to-order manufacturing environments. This study examines the relative importance of several operating variables that are characteristic features of JIT systems within such environments in North America. The results suggest that the most salient features of JIT for make-to-order and assemble-to-order firms are the elimination of waste (in the form of time and defects), reduced setup time, reduced lotsize, and a smaller pool of suppliers. In addition, the results suggest that the use of non-domestic suppliers can possibly hinder efforts at JIT implementation of materials procurement.     

Vendor Selection with Bundling*

Product bundling has become increasingly prevalent not only in consumer goods but also in the industrial sector. We study a purchasing problem in which a buyer must obtain necessary numbers of various stock items from a variety of vendors who charge different prices, have limited capacities and different levels of quality, and offer bundled products at discounted prices. We examine relationships among different bundling scenarios and show that the most general scenario is one in which free items are given to the buyer when sufficient quantities are purchased. We develop a mixed integer linear program that finds the purchasing strategy for the buyer that minimizes the total purchase cost. We present computational results which indicate that the problem is very tractable to solve optimally on a personal computer with standard optimization software. Finally, three extensions of the model are discussed.     

A Decision Model for the Robot Selection Problem Using Robust Regression*

Industrial robots are increasingly used by many manufacturing firms. The number of robot manufacturers has also increased with many of these firms now offering a wide range of models. A potential user is thus faced with many options in both performance and cost. This paper proposes a decision model for the robot selection problem. The proposed model uses robust regression to identify, based on manufacturers' specifications, the robots that are the better performers for a given cost. Robust regression is used because it identifies and is resistant to the effects of outlying observations, key components in the proposed model. The robots selected by the model become candidates for testing to verify manufacturers' specifications. The model is tested on a real data set and an example is presented.     

Standard Container Size Discounts and the Single-Period Inventory Problem*

This paper analyzes the problem of choosing the optimal order quantity and its associated number of standard containers making up the order for single-period inventory models under standard container size discounts. A range is determined that contains the optimal order quantity. Two algorithms are presented. The first algorithm solves the general case in which there is no restriction on the types of containers included in an order. The second algorithm solves a more restricted policy that requires the buyer to accept the order with successively smaller container sizes.     

Graphical Presentations of Data Envelopment Analyses: Management Implications from Parallel Axes Representations*

The conversion of multivariate data analysis into information that managers can readily use in their decision making has always been a challenging task. In this paper we provide a parallel axis representation of multivariate data and demonstrate how this representation may be used as a tool for implementing the results of data envelopment analysis. We use an analysis of the efficiency of electricity generating plants to illustrate the technique.