| 1. |
- Axsäter, Sven
(författare)
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A Capacity Constrained Production-Inventory System with Stochastic Demand and Production Times
- 2010
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Ingår i: International Journal of Production Research. - : Informa UK Limited. - 0020-7543 .- 1366-588X. ; 48:20, s. 6203-6209
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Tidskriftsartikel (refereegranskat)abstract
- This paper considers a simple model of a capacity constrained production-inventory system with Poisson demand. The system is controlled by an S policy. The production time for a unit is modelled as a gamma distributed stochastic variable. Using M/G/1 queuing theory it is very easy to evaluate holding and backorder costs and optimise the ordering policy. The suggested model may be useful when evaluating investments in production.
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| 2. |
- Berling, Peter, 1973-, et al.
(författare)
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Multi-echelon inventory control : an adjusted normal demand model for implementation in practice
- 2014
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Ingår i: International Journal of Production Research. - : Informa UK Limited. - 0020-7543 .- 1366-588X. ; 52:11, s. 3331-3347
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Tidskriftsartikel (refereegranskat)abstract
- This paper presents an approximation model for coordinated control of one-warehouse multiple-retailer inventory systems, where all locations use continuous review (R, nQ) policies. The motivation stems from close collaboration with a supply chain management software company, Syncron International, and one of their customers. A core objective has been to develop an accurate method for determining near-optimal reorder points that can be directly applied to real-life systems. The approach is based on decomposing the complex multi-echelon problem into N + 1 single-echelon problems, using a near-optimal-induced backorder cost at the central warehouse. Important extensions made compared to earlier work include the addition of procedures to adjust for lead-time variability, and for undershooting the reorder point when customers’ order sizes vary. The result is a flexible model that is computationally and conceptually simple enough to be implemented in practice. A numerical study, including real data from the case company, illustrates that the new model outperforms existing methods in the literature. Compared to the current methods used by the case company, it offers significant improvements in both service-level fulfilment and system-wide inventory holding costs. Implementations of the model into the Syncron software are in progress.
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| 3. |
- Bruch, Jessica, et al.
(författare)
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Characteristics affecting management of design information in the production system design process
- 2013
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Ingår i: International Journal of Production Research. - : Informa UK Limited. - 0020-7543 .- 1366-588X. ; 51:11, s. 3241-3251
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Tidskriftsartikel (övrigt vetenskapligt/konstnärligt)abstract
- Although it has been argued that the design of production systems is crucial, there is a general lack of empirical studies analysing and identifying resources and capabilities required for an efficient production system design process. One of these resources is the critical role attributed to design information and one such capability is how the design information is managed. To address this research gap, this paper reports the results from two in-depth case studies in the automotive industry focusing on the management of design information in the production system design process. Our results show that design information management needs to be understood as a multidimensional concept having three dimensions: acquiring, sharing and using design information. By focusing on the three dimensions, six characteristics affecting the management of design information when designing the production system are identified. The characteristics are information type, source of information, communication medium, formalisation, information quality and pragmatic information. © 2013 Copyright Taylor and Francis Group, LLC.
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| 4. |
- Buffington, John, et al.
(författare)
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Development of a product design and supply-chain fulfillment system for discontinuous innovation
- 2012
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Ingår i: International Journal of Production Research. - : Informa UK Limited. - 0020-7543 .- 1366-588X. ; 50:14, s. 3776-3785
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Tidskriftsartikel (refereegranskat)abstract
- Given the lengthy product development lifecycle process, high cost, and low success rate, many firms avoid considering discontinuous innovation strategies, in spite of their increase in frequency and importance in many markets. Even with advances in automation and technology, many of the techniques being utilised in product development are relatively unchanged, and the definition of discontinuous innovation itself lacks a structural component. To address this problem, the authors developed a methodology for generative customisation to implement discontinuous innovation. Using the emerging technologies of generative design and agent-based modelling, the authors developed a methodology to create product inventions and measure product innovations using a complex adaptive system (CAS) model. This appears to be the first model that represents a complex adaptive system environment to measure the success of discontinuous innovation in the development of a market equilibrium agent model.
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| 5. |
- Colledani, M., et al.
(författare)
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Analytical methods to support continuous improvements at Scania
- 2010
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Ingår i: International Journal of Production Research. - : Informa UK Limited. - 0020-7543 .- 1366-588X. ; 48:7, s. 1913-1945
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Tidskriftsartikel (refereegranskat)abstract
- Considerable effort is usually devoted by companies to ensure the competitiveness of their manufacturing systems. This makes continuous improvement a central topic in production management activities. Less attention is given to the methods that drive improvement and to the way actions are defined and selected. In the literature, analytical models and simulation are the most widely used tools for manufacturing systems' performance evaluation and improvement. In practice, simple approaches, mainly based on experience, seems to be the best compromise to face this problem. In a collaboration project between Politecnico di Milano ( Milano, Italy), Kungliga Tekniska hogskolan ( Stockholm, Sweden) and Scania CV AB (Sodertalje, Sweden) within the European Network of Excellence VRL-KCiP we proposed a new methodology, based on analytical methods, to support the company in manufacturing system productivity improvement through re-configuration. The application of this approach to the Scania six-cylinder engine-block machining line enabled a remarkable increment in throughput by selecting analytically the most suitable improvement actions.
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| 6. |
- Feldmann, Andreas, 1981-, et al.
(författare)
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Linking networks and plant roles : The impact of changing a plant role
- 2013
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Ingår i: International Journal of Production Research. - : Taylor & Francis. - 0020-7543 .- 1366-588X. ; 51:19, s. 5696-5710
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Tidskriftsartikel (refereegranskat)abstract
- Many manufacturing firms are expanding their global footprint to explore new opportunities for efficient and effective production. The strategic perspective on international manufacturing networks involves both the network level and the plant level. A key aspect is the relationship between the network and the role of plants. In this research, we investigate the relationship between the network and plant perspectives in international manufacturing networks. We use an embedded case study that includes five plants in two product networks over a period of three years. We analyse how changing the role of one plant affects the network as well as the roles of the other plants in the networks. We find that decisions on plant roles are, to a very high degree, network decisions and not decisions for individual plants. Based on the insights into the case study, we also develop a framework for mapping manufacturing networks, including market coverage, plant location and site competence.
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| 7. |
- Finnsgård, Christian, 1974, et al.
(författare)
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Factors impacting manual picking on assembly lines: An experiment in the automotive industry
- 2013
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Ingår i: International Journal of Production Research. - : Informa UK Limited. - 0020-7543 .- 1366-588X. ; 51:6, s. 1789-1798
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Tidskriftsartikel (refereegranskat)abstract
- Manual picking on assembly lines is an important part of the assembly operator’s work. In the automotive industry, alternative material exposure strategies are continually evaluated in order to facilitate the assembler’s work and minimize non-value-adding time, resulting in increased use of smaller bins or containers at workstations, instead of large pallets. The assembly operator’s retrieval of components from bins, containers or pallets is known as manual picking. Previous work in this area has focused on picking from pallets placed on the floor; therefore, there is a need to include other forms of materials exposure. The purpose of this paper is to explain what materials exposure factors have an impact on manual picking times on assembly lines. A full factorial experiment, testing seven factors in 128 experiments, was conducted in an automotive assembly line setting. The factors with the greatest impact on manual picking time were packaging type; angle of exposure; height of exposure; and part size. This study contributes by addressing the importance of six factors influencing manual picking times, enhancing knowledge derived from MTM and elsewhere. The results from this study can be useful for designing manual picking operations, not just at assembly lines but also other situations were discrete manual picking occurs such as workstations or bench assembly. Managerial contributions are evident in the examination of factors important in designing new production systems, including materials supply processes and assembly processes. A further managerial application is use of the results in managing assembly lines.
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| 8. |
- Finnsgård, Christian, 1974, et al.
(författare)
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Impact of materials exposure on assembly workstation performance
- 2011
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Ingår i: International Journal of Production Research. - : Informa UK Limited. - 0020-7543 .- 1366-588X. ; 49:24, s. 7253-7274
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Tidskriftsartikel (refereegranskat)abstract
- This paper examines how the choice of materials exposure impacts workstation performance, in terms of non-value-adding work, space requirements and ergonomics. In a typical Swedish automotive setting, components are exposed in wooden pallets with frames beside the assembly line and supplied by forklift truck. In a case study, three workstations on an assembly line were studied and redesigned following the principles of lean production, using smaller plastic containers for the materials exposure. After the redesign, the space required for materials was reduced by 67%, non-value-adding work decreased by 20%, and walking distance was reduced by 52%. Furthermore, the ergonomics for the assembly operator improved greatly, with a 92% reduction of potentially harmful picking activities, thereby almost eliminating potentially harmful body movements. The theoretical contribution of this paper is firstly the development of an analysis model describing the impact of material exposure on workstation performance and secondly development of the existing categorization of work operations to include different materials handling activities. The most important managerial implication is an increased understanding of the relationship between space, ergonomics, non-value-adding work and materials exposure. These findings have direct implications on workstation design in industry.
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| 9. |
- Grubbström, Robert W
(författare)
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The time-averaged L4L solution - a condition for long-run stability applying MRP theory
- 2012
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Ingår i: International Journal of Production Research. - : Taylor and Francis. - 0020-7543 .- 1366-588X. ; 50:21, s. 6099-6110
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Tidskriftsartikel (refereegranskat)abstract
- MRP theory provides a theoretical background for multi-level, multi-stage production-inventory systems (material requirements planning in a general sense) together with their economic evaluation, in particular applying the net present value principle. The theory combines the use of input-output analysis and Laplace transforms, the former for capturing product structures, and the latter for incorporating timing, including time lags, lead times, and output delays. In this paper, we consider any production policy, when given any external demand as a vector-valued function of time. It is shown that in order for available inventory to be kept at finite levels at any time, the lot-for-lot (L4L) solution must be valid for the time averages of production and deliveries, irrespective of the policy followed. This analysis is carried out using properties the Laurent expansions of the transforms involved.
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| 10. |
- Hanson, Robin, 1981, et al.
(författare)
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A comparison of kitting and continuous supply in in-plant materials supply
- 2013
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Ingår i: International Journal of Production Research. - : Informa UK Limited. - 0020-7543 .- 1366-588X. ; 51:4, s. 979-992
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Tidskriftsartikel (refereegranskat)abstract
- In the context of in-plant materials supply, the materials feeding principle of kitting is often discussed as an alternative to the more common continuous supply (also known as line stocking). However, there are few detailed studies describing the relative effects of kitting and continuous supply. The current paper identifies the relative effects of kitting and continuous supply, and provides insight into how these effects arise. The paper draws on empirical data from two case studies in the Swedish automotive assembly industry. In each of the cases, continuous supply has been replaced by kitting, enabling comparison of kitting and continuous supply in the same production environment. The performance areas studied include man-hour consumption, product quality, flexibility, inventory levels, and space requirements. Interviews with production engineers, assemblers, and operators responsible for kit preparation at each company contribute to a broad yet detailed view of the relative effects of the two materials feeding principles.
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| 11. |
- Hanson, Robin, 1981, et al.
(författare)
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Kitting and time efficiency in manual assembly
- 2012
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Ingår i: International Journal of Production Research. - : Informa UK Limited. - 0020-7543 .- 1366-588X. ; 50:4, s. 1115-1125
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Tidskriftsartikel (refereegranskat)abstract
- The present paper focuses on parts presentation in manual assembly. Its aim is to determine how kitting affects the time spent by the assembler fetching parts and, more specifically, what is the impact of the proportion of parts included in the kit. The present paper is based on four case studies of automobile assembly, in which parts presentation by kitting is compared with parts presentation in component racks. In the case studies, kitting enabled shorter distances between parts presentation and assembly object and thereby a potential reduction in the time spent fetching parts. However, when only a proportion of parts were kitted, the time spent fetching parts was not always reduced, in spite of this potential. The present paper finds that when deciding which parts should be kitted, attention should be paid to how and in what order assembly operations are performed.
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| 12. |
- Holmbom, Martin, et al.
(författare)
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A solution procedure for Economic Lot Scheduling Problems even in high utilisation facilities
- 2013
-
Ingår i: International Journal of Production Research. - : Informa UK Limited. - 0020-7543 .- 1366-588X. ; 51:12, s. 3765-3777
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Tidskriftsartikel (refereegranskat)abstract
- Economic lot scheduling problem (ELSP) handles the problem of deciding what order quantities to use when different products/items are produced in the same capacity constrained production facility. It has previously been shown, and it is shown in this article, that it is possible to find a feasible solution fulfilling true feasibility conditions. However, if the utilisation of the production facility is high the production often has to start before the inventory reaches zero to avoid future shortages. Such ‘early starts’ creates an extra inventory holding cost that the traditional approximation for the inventory holding cost does not account for. This article presents an iterative solution procedure that computes the true inventory holding cost and minimises the total costs. Contrary to previous solution procedures, this procedure requires that the production is scheduled in detail. The heuristic solution procedure is illustrated by a numerical example, it is programmed in MATLAB and variants of the problem are presented.
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| 13. |
- Li, Lin, et al.
(författare)
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A hybrid flowshop scheduling problem for a cold treating process in seamless steel tube production
- 2011
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Ingår i: International Journal of Production Research. - : Taylor and Francis. - 0020-7543 .- 1366-588X. ; 49:15, s. 4679-4700
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Tidskriftsartikel (refereegranskat)abstract
- Seamless steel tubes often have various categories and specifications, which further require complicated operations in production, especially in the cold treating process (CTP). This paper investigates the scheduling problem using the seamless tube plant of Baoshan Iron and Steel Complex as a study background. By considering the practical production constraints such as sequence-dependent setup times, maintenance schedule, intermediate material buffers, job-machine matches, we formulate the hybrid flowshop scheduling problem with a non-linear mixed integer programming model (NMIP). In addition, our model provides a flexibility to remove the permutation assumption, which is often a limitation in early studies. In order to obtain the solution of the above NMIP problem, a two-stage heuristic algorithm is proposed and it combines a modified genetic algorithm and a local search method. With real production instances, our computation experiments indicate that the proposed algorithm is efficient and it outperforms several other approaches. Industrial implementation also shows that such a scheduling tool brings a cost saving of more than 10% and it substantially reduces the computation time. Our study also illustrates the need of relaxing permutation assumption in such a scheduling problem with complicated operation sequences.
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| 14. |
- Liu, Yang
(författare)
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Sustainable competitive advantage in turbulent business environments
- 2013
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Ingår i: International Journal of Production Research. - : Taylor & Francis. - 0020-7543 .- 1366-588X. ; 51:10, s. 2821-2841
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Tidskriftsartikel (refereegranskat)abstract
- The future competitiveness of manufacturing operations under dynamic and complex business environments relies on forward-thinking strategies. The objective of this paper is to identify and develop the operational competitiveness in a sustainable manner by implementing a unique sustainable competitive advantage (SCA) for managing dynamic business situations. This paper develops a theoretical approach to integrating the core factors which affect operational competitiveness performance, that is to say manufacturing strategy and transformational leadership with technology level, into conceptual analytical models to evaluate overall competitiveness, and utilises sense and respond (S&R) for dynamic decision-making to optimise resource allocations and adjust strategies in order to develop competitiveness potential in a sustainable manner. From the empirical research, the adjustments in manufacturing strategy and transformation leadership by implementing SCA through fast strategy with proposed models are found to be effective and successful in managing turbulent business environments such as the economic crisis. Such proactive operations are proposed as the unique SCA with empirical research carried out in a global context, which provides both theoretical significance and also practical benefit to conclude the experience of managing operations in turbulent business environments.
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| 15. |
- Mahmood Reza, Khabbazi, 1972-, et al.
(författare)
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Lot-based traceability requirements and functionality evaluation for Small-to-medium size enterprises
- 2011
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Ingår i: International Journal of Production Research. - : Informa UK Limited. - 0020-7543 .- 1366-588X. ; 49:3, s. 731-746
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Tidskriftsartikel (refereegranskat)abstract
- This paper addressed a data modelling and functionality evaluation of traceability system requirements and its implementation for small- to medium-sized enterprises (SMEs). The major idea is to convert the data structure and system behaviour arising from traceability requirement into modelling using data modelling techniques in a user-friendly and economical way. Then, based on a case study the paper expounds the methodology by implementing the model to a computerised traceability information system. The system can manipulate operation data as well as quality data dynamically to keep the traceability information up to date and useful. The solution responds to all traceability requirements of integrity, data collecting, linking, and guarantees different types of lists and reports in the support of quick decision making with minimal human efforts.
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| 16. |
- Ng, Amos H. C., et al.
(författare)
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A comparative study of production control mechanisms using simulation-based multi-objective optimisation
- 2012
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Ingår i: International Journal of Production Research. - : Taylor & Francis. - 0020-7543 .- 1366-588X. ; 50:2, s. 359-377
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Tidskriftsartikel (refereegranskat)abstract
- There exist many studies conducted to compare the performance of different production control mechanisms (PCMs) in order to determine which one performs the best under different conditions. Nonetheless, most of these studies suffer from the problems that the PCMs are not compared with their optimal parameter settings in a truly multi-objective context. This paper describes how different PCMs can be compared under their optimal settings through generating the Pareto-optimal frontiers, in the form of optimal trade-off curves in the performance space, by applying evolutionary multi-objective optimisation to simulation models. This concept is illustrated with a bi-objective comparative study of the four most popular PCMs in the literature, namely Push, Kanban, CONWIP and DBR, on an unbalanced serial flow line in which both control parameters and buffer capacities are to be optimised. Additionally, it introduces the use of normalised hyper-volume as the quantitative metric and confidence-based significant dominance as the statistical analysis method to verify the differences of the PCMs in the performance space. While the results from this unbalanced flow line cannot be generalised, it indicates clearly that a PCM may be preferable in certain regions of the performance space, but not others, which supports the argument that PCM comparative studies have to be performed within a Pareto-based multi-objective context.
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| 17. |
- Olhager, Jan
(författare)
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Evolution of operations planning and control: from production to supply chains
- 2013
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Ingår i: International Journal of Production Research. - : Informa UK Limited. - 0020-7543 .- 1366-588X. ; 51:23-24, s. 6836-6843
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Tidskriftsartikel (refereegranskat)abstract
- The focus of operations planning and control for manufacturing firms has expanded successively over the last 50 years. New principles, techniques, and systems have emerged that have allowed for new approaches. The perspective for planning and control has expanded from internal production operations to supply chain operations linking suppliers, manufacturers, and customers. In this paper, we take a historical perspective identifying the key trends and focus shifts in the evolution of planning and control, from shop floor control through material requirements planning (MRP), master production scheduling (MPS), and sales and operations planning (S&OP) to supply chain planning (SCP).
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| 18. |
- Pettersen, Jan-Arne, et al.
(författare)
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Three-dimensional performance surfaces : a tool for analysing and estimation of production system performances
- 2010
-
Ingår i: International Journal of Production Research. - : Informa UK Limited. - 0020-7543 .- 1366-588X. ; 48:17, s. 4937-4948
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Tidskriftsartikel (refereegranskat)abstract
- This paper presents a new method to describe, analyse and estimate production system performances. Work-in-process (units), lead time (number of time units spent in the production system for each unit) and throughput (number of produced units per time unit) are basic performance measures, also used in this article. It is essential for industry to know about relations between system parameters and system performances in existing systems, and in not yet implemented system alternatives. Different performances are achieved by adjusting system parameters. Trade-offs between system parameters and its different performances are necessary to stay efficient and competitive in today's market. Queuing theory and simulation can help the decision makers to estimate system performances of existing and not yet implemented systems. When the complexity increases queuing theory becomes cumbersome, very difficult and eventually impossible to use. A single simulation presents limited information. Multiple simulations are necessary to ensure that the best alternative is chosen. A high number of simulations demand a lot of computer time and resources. Reduction of runs is desirable even with cheaper computer equipment. Currently, traditional two-dimensional charts are the only tools to present and analyse system performances. This article presents a new surrogate model for easier estimation and presentation of system performances, their internal relations, and relations to the system parameters. With the new surrogate model, system performances based on simulations are presented as positions in a three-dimensional environment. Parametric curves and surfaces of Bezier type are generated and adapted to these positions. System performances of other system alternatives can then be estimated without explicit simulation. The number of simulation calculations can thereby be moderated. The method is illustrated with a small production line system
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| 19. |
- Spiegler, Virginia L M, et al.
(författare)
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A control engineering approach to the assessment of supply chain resilience
- 2012
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Ingår i: International Journal of Production Research. - : Taylor and Francis. - 0020-7543 .- 1366-588X. ; 50:21, s. 6162-6187
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Tidskriftsartikel (refereegranskat)abstract
- There is no consensus on the supply chain management definition of resilience. To aid in evaluating the dynamic behaviour of such systems we need to establish clearly elucidated performance criteria that encapsulate the attributes of resilience. A literature review establishes the latter as readiness, responsiveness and recovery. We also identify robustness as a necessary condition that would complement resilience. We find that the Integral of the Time Absolute Error (ITAE) is an appropriate control engineering measure of resilience when it is applied to inventory levels and shipment rates. We use the ITAE to evaluate an often used benchmark model of make-to-stock supply chains consisting of three decision parameters. We use both linear and nonlinear forms of the model in our evaluation. Our findings suggest that optimum solutions for resilience do not yield a system that is robust to uncertainties in lead-time. Hence supply chains will experience drastic changes in their resilience performance when lead-time changes.
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| 20. |
- Storck, Joakim
(författare)
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Exploring improvement trajectories with dynamic process cost modelling : a case from the steel industry
- 2010
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Ingår i: International Journal of Production Research. - : Informa UK Limited. - 0020-7543 .- 1366-588X. ; 48:12, s. 3493-3511
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Tidskriftsartikel (refereegranskat)abstract
- Improvement trajectories are sequential managed chains of improvement initiatives required to handle changes in competition and market. This paper presents a five-step framework, based on dynamic process cost modelling, which was developed during a four-year research project at a major stainless steel producer, to support the selection of an improvement trajectory based on strategic requirements to combine high product diversity with cost reduction. The framework aims to develop insight into what manufacturing capabilities are required to reach the strategic goals by combining system dynamics simulation with process cost modelling and visual exploratory data analysis in an iterative modelling procedure. The applicability of the five-step framework is demonstrated through a case study from the steel industry, in which a goal driven analysis is used to assess process requirements based on performance and market considerations.
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| 21. |
- Wang, Lihui, et al.
(författare)
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A function block based approach for increasing adaptability of assembly planning and control
- 2011
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Ingår i: International Journal of Production Research. - : Taylor & Francis. - 0020-7543 .- 1366-588X. ; 49:16, s. 4903-4924
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Tidskriftsartikel (refereegranskat)abstract
- Today's market turbulences cause frequent changes in manufacturing environments. Products diversity, small batch sizes and short life cycles have increased production uncertainties and created a highly dynamic shop floor environment. One essential requirement of such an environment is an adaptive planning and control system that is sufficiently agile to respond to the variety of production requirements and enable easy system reconfiguration at run-time. When developing a product, assembly is a key area that impacts the manufacturing system's responsiveness to the changes. In this research, a framework and a new methodology are introduced to increase the adaptability and autonomy of job-shop assembly process planning and control using function blocks (FBs). A function block is a reusable functional module with an explicit event-driven model, and provides for data flow and finite state automata based control. Event-driven and FB-enabled decision-making is unique in adaptive assembly planning and control. It is explained through an example of a two-robot assembly work cell, where the result of the adaptive planning is wrapped in FBs for execution. The proposed approach has been implemented and simulated using Matlab Simulink in the case study. The simulation demonstrates how this approach would increase the adaptability and responsiveness to changes that may occur regularly in dynamic job-shop assembly operations.
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| 22. |
- Zeltzer, Luiza, et al.
(författare)
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Measuring complexity in mixed-model assembly workstations
- 2013
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Ingår i: International Journal of Production Research. - : Informa UK Limited. - 0020-7543 .- 1366-588X. ; 51:15, s. 4630-4643
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Tidskriftsartikel (refereegranskat)abstract
- In an effort to maintain or increase their market share and at the same time prevent costs from escalating, manufacturing organisations are increasingly using their current manufacturing system to produce custom output. As a consequence, the large number of product variants increases significantly the complexity of manufacturing systems, both for the operators as for the support services. This is especially true in automotive industry, where customisation is increasing at a rapid pace. To counter the ensuing loss of productivity, a more fundamental approach to dealing with this complexity in manufacturing processes is required. In order to investigate the impact of complexity on production performance, one must first delineate the concept and then identify as unambiguously as possible highly complex workstations. This article defines complexity at the workstation level and proposes a complexity measure for mixed-model assembly workstations. Based on data from several leading automotive companies from Belgium and Sweden, some statistical models are proposed to characterise workstations complexity. The models are described and their validity and accuracy are discussed.
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| 23. |
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