The use of period batch control (PBC) in the implosive industries

Period batch control (PBC) is a just-in-time (JIT) production control system of the flow control, single cycle type. It was developed in the UK before the Second World War, by the late R. J. Gigli, who installed it in 30 different factories and used it to regulate the manufacture of Spitfire fighter aircraft for the Battle of Britain. Implosive industries are those—such as foundries, glass works, spinning mills and potteries, among others—which produce a wide variety of different products from a very small number of material items. The paper shows how PBC is used in implosive industries, and explains why it is normally the best method to adopt in such factories.     

Manufacturing feature-based cost management system: a case study in Brazil

Feature costing is a topic of recent discussion related to cost management systems (CMSs) aimed at understanding how product features influence production process costs. It raises as a key issue in mass customisation environments where a single product model can present hundreds of menu options. In this study, we explore the concept of feature costing beyond the use of activity-based costing (ABC). We propose a CMS based on features and common elements as costing objects instead of products. In our model, we use the unit of production effort method to organise the direct manufacturing costs, ABC method to address the indirect cost and the standard methods to compute raw materials costs. We illustrate the method in the production of bus seats in a Brazilian manufacturing company. This study gives different perspectives to the international academic community on the use of a different CMS used by many Brazilian companies.     

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.     

The shape of protective capacity in unbalanced production systems with unplanned machine downtime

Several studies have shown that when both statistical fluctuations and dependent events exist, unbalanced production lines out-perform balanced lines. By definition, unbalanced lines have some amount of protective capacity built into them; however, little research exists to address the question of quantity and position of protective capacity necessary to counteract the impact of variation on system performance. This research seeks to improve our understanding concerning the shape of protective capacity in unbalanced lines when faced with variation in the form of unplanned machine downtime. Both Kanban and drum-buffer-rope (DBR) controlled lines are investigated. Results show that balancing the protective capacity yields superior results over both increasing and decreasing protective capacity shapes (holding average protective capacity equal). Results also show that Kanban lines behave differently than DBR lines.     

Reference model for implementing an MRP system in a highly diverse component and seasonal lean production environment

Companies are currently choosing to integrate logics and systems to achieve better solutions. These combinations also include companies striving to join the logic of material requirement planning (MRP) system with the systems of lean production. The purpose of this article was to design an MRP as part of the implementation of an enterprise resource planning (ERP) in a company that produces agricultural implements, which has used the lean production system since 1998. This proposal is based on the innovation theory, theory networks, lean production systems, ERP systems and the hybrid production systems, which use both components and MRP systems, as concepts of lean production systems. The analytical approach of innovation networks enables verification of the links and relationships among the companies and departments of the same corporation. The analysis begins with the MRP implementation project carried out in a Brazilian metallurgical company and follows through the operationalisation of the MRP project, until its production stabilisation. The main point is that the MRP system should help the company's operations with regard to its effective agility to respond in time to demand fluctuations, facilitating the creation process and controlling the branch offices in other countries that use components produced in the matrix, hence ensuring more accurate estimates of stockpiles. Consequently, it presents the enterprise knowledge development organisational modelling methodology in order to represent further models (goals, actors and resources, business rules, business process and concepts) that should be included in this MRP implementation process for the new configuration of the production system.     

Development of supplier relationship including cost of defectives in the cyclic production

In the supply chain situation, a decision regarding supplier relationship is of high importance. This usually happens on the basis of supplier company parameters. In order to satisfy the demands, a buyer company often expects the supplier company to expedite their operations, i.e., to enhance the related production rate. In this context, presently the focus of this article is on the cyclic production environment at the supplier company premises. Any practical production process is expected to generate defective products also along with the normal usable products. After an estimation of this and the costs concerning defectives, it needs to be modelled in the cyclic manufacturing. This article incorporates specifically the cost of defectives along with the other relevant costs. After developing an interest in the inclusion of these costs, the supplier company is categorised. A contribution of this article is the development of supplier relationship in the discussed environment.     

A simulation testing and analysis of aggregate production planning strategies

In this study, a hybrid discrete event simulation (DES) and system dynamics (SD) methodology is applied to model and simulate aggregate production planning (APP) problem for the first time. DES is used to simulate operational-level and shop-floor activities incorporated into APP and estimate critical time-based control parameters used in SD model of APP and SD is used to simulate APP as a collection of aggregate-level strategic decisions. The main objective of this study is to determine and analyse the effectiveness of APP strategies regarding the Total Profit criterion by developing a hybrid DES–SD simulation model for APP in a real-world manufacturing company. The simulation results demonstrated that the priority of APP strategies with regards to Total Profit criterion is: (1) the pure chase strategy, (2) the modified chase strategy, (3) the pure level strategy, (4) the modified level strategy, (5) the mixed strategy and (6) the demand management strategy, respectively. The APP system is first simulated under mixed strategy (basic scenario) conditions to include all APP capacity and demand options in constructed SD simulation model to show a comprehensive view of APP components and their interdependent interactions. Then, the obtained results will be used as Total Profit measure to compare with system's performance under some experimental scenarios applying different APP strategies.     

Literature review of material flow control mechanisms

We review mechanisms which control the flow or material into and within a manufacturing line. These material flow control (MFC) mechanisms address the problem of when to release material into a manufacturing line and when workcentres should be authorized to produce. The MFC mechanisms reviewed include: Kanban, CONWIP, workload regulating, starvation avoidance, BORA, maximum load limit, MRP, the base stock system, workload control, and production authorization cards.     

A hierarchical production plan for a make-to-order steel fabrication plant

A three-tiered hierarchical production plan (HPP) for a strictly make-to-order steel fabrication plant with the objective of developing a production plan and master schedule for a set of product archetypes is implemented. Data are collected from an actual steel fabrication plant located in the Midwestern section of the US. An aggregate linear programming model, a non-linear disaggregate model and a master production schedule comprise the respective tiers. Appropriate models provide the forecasts needed in the first two tiers. A production plan and master schedule based on data collected at the plant, benefits expected for its implementation and practical limitations are reported.     

The Effects of a Combined Goal Setting,Feedback and Incentive Intervention on Job Performance in a Manufacturing Environment

Abstract

Baked anodes are used in finished aluminum production. Employees of a large multinational aluminum smelter were responsible for the production of more than 3500 baked anodes per week. During a 74 week long baseline (A) condition, production of unusable anodes exceeded 300 per week or 8.6 percent of their nominal 3500 anode production requirement. A problem analysis suggested that this high rate of defective anodes might have been due to weak antecedents, inefficient work procedures and weak performance contingencies. An intervention package that included a combination of goal setting, performance feedback, and tangible rewards was designed to strengthen antecedents and consequences of job performance. A performance feedback system was introduced with and remained constant across the three types of performance contingent rewards and three successively higher goal levels. The three reward and goal combinations were introduced to “strengthen” antecedents and performance contingencies within an A-B1-B2-B3-A with reversal to baseline conditions design. Anode reject rates were lower (better performance) during the three intervention phases compared to both the pre- and post-intervention baseline phase data. A dramatic performance improvement (lowered rate of rejects) was observed during the B3 phase that included the highest performance goal. These data demonstrate that a treatment combination of specific goal setting, feedback and tangible rewards can “strengthen” antecedents and performance contingencies resulting in improved objective performance in a manufacturing environment.