Design and control of food job-shop processing systems

2017 ◽  
Vol 28 (3) ◽  
pp. 782-797 ◽  
Author(s):  
Stefano Penazzi ◽  
Riccardo Accorsi ◽  
Emilio Ferrari ◽  
Riccardo Manzini ◽  
Simon Dunstall
Keyword(s):  
Food Processing ◽  
Job Shop ◽  
Discrete Event ◽  
Cost Optimization ◽  
Job Shops ◽  
Content Type ◽  
Processing Equipment ◽  
Catering Industry ◽  
High Flexibility ◽  
Capacity Constrained

Purpose The food processing industry is growing with retail and catering supply chains. With the rising complexity of food products and the need to address food customization expectations, food processing systems are progressively shifting from production line to job-shops that are characterized by high flexibility and high complexity. A food job-shop system processes multiple items (i.e. raw ingredients, toppings, dressings) according to their working cycles in a typical resource and capacity constrained environment. Given the complexity of such systems, there are divergent goals of process cost optimization and of food quality and safety preservation. These goals deserve integration at both an operational and a strategic decisional perspective. The twofold purpose of this paper is to design a simulation model for food job-shop processing and to build understanding of the extant relationships between food flows and processing equipment through a real case study from the catering industry. Design/methodology/approach The authors designed a simulation tool enabling the analysis of food job-shop processing systems. A methodology based on discrete event simulation is developed to study the dynamics and behaviour of the processing systems according to an event-driven approach. The proposed conceptual model builds upon a comprehensive set of variables and key performance indicators (KPIs) that describe and measure the dynamics of the food job-shop according to a multi-disciplinary perspective. Findings This simulation identifies the job-shop bottlenecks and investigates the utilization of the working centres and product queuing through the system. This approach helps to characterize how costs are allocated in a flow-driven approach and identifies the trade-off between investments in equipment and operative costs. Originality/value The primary purpose of the proposed model relies on the definition of standard resources and operating patterns that can meet the behaviour of a wide variety of food processing equipment and tasks, thereby addressing the complexity of a food job-shop. The proposed methodology enables the integration of strategic and operative decisions between several company departments. The KPIs enable identification of the benchmark system, tracking the system performance via multi-scenario what-if simulations, and suggesting improvements through short-term (e.g. tasks scheduling, dispatching rules), mid-term (e.g. recipes review), or long-term (e.g. re-layout, working centres number) levers.

A new approach for performance assessment of parallel and non-bottleneck machines in a dynamic job shop environment

2019 ◽  
Vol 13 (4) ◽  
pp. 787-803
Author(s):  
Maurizio Faccio ◽  
Mojtaba Nedaei ◽  
Francesco Pilati
Keyword(s):  
Completion Time ◽  
Job Shop ◽  
Primary Objective ◽  
Design Parameters ◽  
Job Shops ◽  
Objective Functions ◽  
New Approach ◽  
Content Type ◽  
Decision Variables ◽  
Dynamic Job Shop

Purpose The current study aims to propose a new analytical approach by considering energy consumption (EC), maximum tardiness and completion time as the primary objective functions to assess the performance of parallel, non-bottleneck and multitasking machines operating in dynamic job shops. Design/methodology/approach An analytical and iterative method is presented to optimize a novel dynamic job shop under technical constraints. The machine’s performance is analyzed by considering the setup energy. An optimization model from initial processing until scheduling and planning is proposed, and data sets consisting of design parameters are fed into the model. Findings Significant variations of EC and tardiness are observed. The minimum EC was calculated to be 141.5 hp.s when the defined decision variables were constantly increasing. Analysis of the optimum completion time has shown that among all studied methods, first come first served (FCFS), earliest due date (EDD) and shortest processing time (SPT) have resulted in the least completion time with a value of 20 s. Originality/value Considerable amount of energy can be dissipated when parallel, non-bottleneck and multitasking machines operate in lower-power modes. Additionally, in a dynamic job shop, adjusting the trend and arrangement of decision variables plays a crucial role in enhancing the system’s reliability. Such issues have never caught the attention of scientists for addressing the aforementioned problems. Therefore, with these underlying goals, this paper presents a new approach for evaluating and optimizing the system’s performance, considering different objective functions and technical constraints.

Application of Petri nets towards improved utilization of machines in job shop manufacturing environments

2017 ◽  
Vol 28 (2) ◽  
pp. 169-188 ◽  
Author(s):  
Pravin S. Pachpor ◽  
R.L. Shrivastava ◽  
Dinesh Seth ◽  
Shaligram Pokharel
Keyword(s):  
Petri Nets ◽  
Material Handling ◽  
Job Shop ◽  
Work Force ◽  
General Purpose ◽  
The Body ◽  
Scheduling Problems ◽  
Job Shops ◽  
Content Type ◽  
Machine Utilization

Purpose The purpose of this paper is to demonstrate the use of Petri nets in a job shop setup for the improvement in the utilization of machines. Design/methodology/approach The study discusses concepts such as reachable state, token and matrix equations set, and demonstrates the improvements in machines’ utilization in a job shop. It makes use of algorithms to generate reachable markings to obtain utilization. The study not only describes the application of theory, but also extends the body of knowledge on Petri nets and job shops. Findings In this study, machines’ utilization has been studied in a job shop with six machines and eight products. The study finds that substantial utilization improvement in job shop set up can be obtained through the application of Petri nets. The study also exposes that Petri nets are mostly used for machines, jobs and tools scheduling problems, but its use in machines’ utilization is neglected. The framework and application presented here along with generalizable findings, is the first to report about machine utilization improvement in job shop manufacturing environment. Practical implications Job shops are characterized by high unit production cost, low investments, low volume and high variety, complex flows, flexible and skilled work force, general purpose machines, high material handling; resulting in poor utilization of machines. Therefore, the findings of this study can help in reducing such costs through better machine utilization. This can help in increasing the competitiveness of the companies. Originality/value The contribution of study lies in investigating and improving stage wise utilization in a job shop setup. It has never been reported before.

Integrated quality environmental management implementation in food processing SMEs

2019 ◽  
Vol 31 (5) ◽  
pp. 740-757 ◽  
Author(s):  
Syed Ali Raza Shah ◽  
Khairur Rijal Jamaludin ◽  
Hayati Habibah Abdul Talib ◽  
Sha’ri Mohd Yusof
Keyword(s):  
Environmental Management ◽  
Food Processing ◽  
Success Factors ◽  
Process Management ◽  
Empirical Studies ◽  
Sampling Technique ◽  
Developed Countries ◽  
Operational Performance ◽  
Snowball Sampling ◽  
Content Type

Purpose The purpose of this paper is to identify the critical success factors (CSFs) of integrated quality environmental management (IQEM) and analyze their impact on operational performance (OP) and environmental performance (EP) in food processing Small and medium-sized enterprises (SMEs) in Pakistan. Design/methodology/approach The study is based on collecting data using a survey questionnaire through snowball sampling technique. A total of 302 food processing SMEs operating in Punjab, Pakistan, responded to the survey. SPSS version-23 and SmartPLS-3 were used for data analysis. Findings The literature review identified leadership (LS), employee management (EM), strategic planning (SP), information management (IM), process management (PM), supplier management (SM) and customer focus (CF) as CSFs of IQEM. The results of this study found a significant relationship of all identified CSFs with operational performance in food processing SMEs whereas EM, IM, PM and SM were insignificant with the EP in the food processing SMEs. Research limitations/implications Although this study has collected data from one province, the Punjab province, it still relevant in identifying the CSFs for IQEM implementation within food processing SMEs to improve performance. Originality/value Despite the wide spread of integrated systems practices in the developed countries, little attention has been placed to implement and assess the IQEM initiatives by organizations in the developing countries. Thus, this study identified CSFs of IQEM based on empirical studies and analyzed their impact on OP and EP of food processing SMEs.

scholarly journals Assessing asset monitoring levels for maintenance operations

2015 ◽  
Vol 26 (5) ◽  
pp. 632-659 ◽  
Author(s):  
Abdullah A Alabdulkarim ◽  
Peter Ball ◽  
Ashutosh Tiwari
Keyword(s):  
Asset Management ◽  
Business Models ◽  
Discrete Event ◽  
Dynamic Modelling ◽  
Simulation Models ◽  
Content Type ◽  
Event Simulation ◽  
Product Service ◽  
Asset Monitoring ◽  
The Impact

Purpose – Asset management has recently gained significance due to emerging business models such as Product Service Systems where the sale of asset use, rather than the sale of the asset itself, is applied. This leaves the responsibility of the maintenance tasks to fall on the shoulders of the manufacturer/supplier to provide high asset availability. The use of asset monitoring assists in providing high availability but the level of monitoring and maintenance needs to be assessed for cost effectiveness. There is a lack of available tools and understanding of their value in assessing monitoring levels. The paper aims to discuss these issues. Design/methodology/approach – This research aims to develop a dynamic modelling approach using Discrete Event Simulation (DES) to assess such maintenance systems in order to provide a better understanding of the behaviour of complex maintenance operations. Interviews were conducted and literature was analysed to gather modelling requirements. Generic models were created, followed by simulation models, to examine how maintenance operation systems behave regarding different levels of asset monitoring. Findings – This research indicates that DES discerns varying levels of complexity of maintenance operations but that more sophisticated asset monitoring levels will not necessarily result in a higher asset performance. The paper shows that it is possible to assess the impact of monitoring levels as well as make other changes to system operation that may be more or less effective. Practical implications – The proposed tool supports the maintenance operations decision makers to select the appropriate asset monitoring level that suits their operational needs. Originality/value – A novel DES approach was developed to assess asset monitoring levels for maintenance operations. In applying this quantitative approach, it was demonstrated that higher asset monitoring levels do not necessarily result in higher asset availability. The work provides a means of evaluating the constraints in the system that an asset is part of rather than focusing on the asset in isolation.

Application of lean practices in small and medium-sized food enterprises

2013 ◽  
Vol 116 (1) ◽  
pp. 125-141 ◽  
Author(s):  
Manoj Dora ◽  
Dirk Van Goubergen ◽  
Maneesh Kumar ◽  
Adrienn Molnar ◽  
Xavier Gellynck
Keyword(s):  
Food Processing ◽  
Lean Manufacturing ◽  
Raw Materials ◽  
Current Status ◽  
Food Sector ◽  
Statistical Process ◽  
Content Type ◽  
Lean Practices ◽  
The Status ◽  
Manufacturing Techniques

Purpose – Recent literature emphasizes the application of lean manufacturing practices to food processing industries in order to improve operational efficiency and productivity. Only a very limited number of studies have focused on the implementation of lean manufacturing practices within small and medium-sized enterprises (SMEs) operating in the food sector. The majority of these studies used the case study method and concentrated on individual lean manufacturing techniques geared towards resolving efficiency issues. This paper aims to analyze the status of the lean manufacturing practices and their benefits and barriers among European food processing SMEs. Design/methodology/approach – A structured questionnaire was developed to collect data. A total of 35 SMEs' representatives, mostly CEOs and operations managers, participated in the survey. The study investigated the role of two control variables in lean implementation: size of the company and country of origin. Findings – The findings show that lean manufacturing practice deployment in food processing SMEs is generally low and still evolving. However, some lean manufacturing practices are more prevalent than others; e.g. flow, pull and statistical process control are not widely used by the food processing SMEs, whereas total productive maintenance, employee involvement, and customer association are more widespread. The key barriers encountered by food SMEs in the implementation of lean manufacturing practices result from the special characteristics of the food sector, such as highly perishable products, complicated processing, extremely variable raw materials, recipes and unpredictable demand. In addition, lack of knowledge and resources makes it difficult for food processing SMEs to embark on the lean journey. Originality/value – The gap in the literature regarding the application of lean manufacturing in the food sector is identified and addressed in this study. The originality of this paper lies in analyzing the current status of the use of lean manufacturing practices among food SMEs in Europe and identifying potential barriers.

scholarly journals Genome Sequencing Identifies Two Nearly Unchanged Strains of Persistent Listeria monocytogenes Isolated at Two Different Fish Processing Plants Sampled 6 Years Apart

2013 ◽  
Vol 79 (9) ◽  
pp. 2944-2951 ◽  
Author(s):  
Anne Holch ◽  
Kristen Webb ◽  
Oksana Lukjancenko ◽  
David Ussery ◽  
Benjamin M. Rosenthal ◽  
...  
Keyword(s):  
Listeria Monocytogenes ◽  
Food Processing ◽  
Random Amplified Polymorphic Dna ◽  
The United States ◽  
Genome Comparison ◽  
Physiological Factors ◽  
Content Type ◽  
Human Pathogenic Bacterium ◽  
A Genome ◽  
Genome Analyses

ABSTRACTListeria monocytogenesis a food-borne human-pathogenic bacterium that can cause infections with a high mortality rate. It has a remarkable ability to persist in food processing facilities. Here we report the genome sequences for twoL. monocytogenesstrains (N53-1 and La111) that were isolated 6 years apart from two different Danish fish processers. Both strains are of serotype 1/2a and belong to a highly persistent DNA subtype (random amplified polymorphic DNA [RAPD] type 9). We demonstrate usingin silicoanalyses that both strains belong to the multilocus sequence typing (MLST) type ST121 that has been isolated as a persistent subtype in several European countries. The purpose of this study was to use genome analyses to identify genes or proteins that could contribute to persistence. In a genome comparison, the two persistent strains were extremely similar and collectively differed from the reference lineage II strain, EGD-e. Also, they differed markedly from a lineage I strain (F2365). On the proteome level, the two strains were almost identical, with a predicted protein homology of 99.94%, differing at only 2 proteins. No single-nucleotide polymorphism (SNP) differences were seen between the two strains; in contrast, N53-1 and La111 differed from the EGD-e reference strain by 3,942 and 3,471 SNPs, respectively. We included a persistentL. monocytogenesstrain from the United States (F6854) in our comparisons. Compared to nonpersistent strains, all three persistent strains were distinguished by two genome deletions: one, of 2,472 bp, typically contains the gene forinlF, and the other, of 3,017 bp, includes three genes potentially related to bacteriocin production and transport (lmo2774,lmo2775, and the 3′-terminal part oflmo2776). Further studies of highly persistent strains are required to determine if the absence of these genes promotes persistence. While the genome comparison did not point to a clear physiological explanation of the persistent phenotype, the remarkable similarity between the two strains indicates that subtypes with specific traits are selected for in the food processing environment and that particular genetic and physiological factors are responsible for the persistent phenotype.

scholarly journals Implementing ManPy, a Semantic-free Open-source Discrete Event Simulation Package, in a Job Shop

Procedia CIRP ◽  
2014 ◽  
Vol 25 ◽  
pp. 253-260 ◽  
Author(s):  
Oladipupo Olaitan ◽  
John Geraghty ◽  
Paul Young ◽  
Georgios Dagkakis ◽  
Cathal Heavey ◽  
...  
Keyword(s):  
Open Source ◽  
Discrete Event Simulation ◽  
Job Shop ◽  
Discrete Event ◽  
Event Simulation ◽  
Free Open Source ◽  
Simulation Package

scholarly journals Análise de problemas de partição de instalações em sistemas job-shops por meio de modelos de redes de filas

2007 ◽  
Vol 27 (2) ◽  
pp. 333-356 ◽  
Author(s):  
Claudio Rogerio Negri da Silva ◽  
Reinaldo Morabito
Keyword(s):  
Job Shop ◽  
Job Shops

Este artigo estuda o problema de projeto de fábrica focalizada envolvendo a partição da instalação (planta) em subplantas e a alocação de capacidade em cada estação de trabalho das subplantas. O sistema de manufatura job-shop é representado por meio de uma rede de filas aberta genérica, e aproximações baseadas em métodos de decomposição são utilizadas para avaliar e otimizar o desempenho do sistema. O objetivo é reduzir a complexidade do sistema do ponto de vista da gestão do produto ou da gestão da estação, por exemplo, limitando-se a variância dos leadtimes dos produtos na rede. Apresenta-se um modelo de programação não-linear inteira para o problema e um algoritmo heurístico para resolvê-lo. Aplicando-se o algoritmo em alguns problemas testes, mostra-se que a partição da instalação em subplantas pode reduzir a variância dos leadtimes dos produtos na rede, sem necessidade de investimentos adicionais em capacidade. Além disso, algumas vezes é possível manter (ou até melhorar) o desempenho da rede, particionando-a em subplantas que necessitam de menos capacidade do que a configuração original da rede como uma planta única.

The cost competitiveness, competitiveness and sustainability of the hospitality industry in India

2016 ◽  
Vol 8 (4) ◽  
pp. 432-443 ◽  
Author(s):  
Madhu Vij
Keyword(s):  
Hospitality Industry ◽  
Cost Optimization ◽  
Cost Effective ◽  
Comprehensive Treatment ◽  
Global Level ◽  
Content Type ◽  
Present Context ◽  
Cost Competitiveness ◽  
Internal Operations ◽  
The Cost

Purpose This study aims to provide a comprehensive treatment of the various issues surrounding the concept of the cost competitiveness, competitiveness and sustainability of the hospitality industry. We also investigate how innovations in the Indian hospitality industry can optimize costs without compromising the quality of the product or the services offered. Design/methodology/approach The methodology used is mainly survey-based with the use of both structured and unstructured questionnaires. In addition, some interviews were conducted with policy-makers and academics to explore from their perspectives what might be the innovations and sustainability issues in the next decade. Findings The paper helps to identify the essential aspects of cost competitiveness, competitiveness and sustainability in the hospitality industry and to better understand if cost optimization can be accomplished simply by realigning process or cost. These issues have become very important in India in the present context of globalization. Practical implications With growing competition on a global level, the hospitality industry needs to proactively manage its internal operations and focus on reducing costs and raising service quality. In this context, the paper helps to reveal sustainable cost effective practices that are geared to today’s competitive environment. Originality/value The inspiration to write this paper arises from the recent global economic slowdown and the fact that the hospitality industry is confronted with growing competition on a global level. This study highlights how value can be created for customers by applying suitable strategies.

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