Evaluation of pull production control strategies under uncertainty: An integrated fuzzy AHP-TOPSIS approach

Purpose: Just-In-Time (JIT) production has continuously been considered by industrial practitioners and researchers as a leading strategy for the yet popular Lean production. Pull Production Control Policies (PPCPs) are the major enablers of JIT that locally control the level of inventory by authorizing the production in each station. Aiming to improve the PPCPs, three authorization mechanisms: Kanban, constant-work-in-process (ConWIP), and a hybrid system, are evaluated by considering uncertainty.Design/methodology/approach: Multi-Criteria Decision Making (MCDM) methods are successful in evaluating alternatives with respect to several objectives. The proposed approach of this study applies the fuzzy set theory together with an integrated Analytical Hierarchy Process (AHP) and a Technique for Order Performance by Similarity to Ideal Solution (TOPSIS) method.Findings: The study finds that hybrid Kanban-ConWIP pull production control policies have a better performance in controlling the studied multi-layer multi-stage manufacturing and assembly system.Practical implications: To examine the approach a real case from automobile electro mechanical part production industry is studied. The production system consists of multiple levels of manufacturing, feeding a multi-stage assembly line with stochastic processing times to satisfy the changing demand.Originality/value: This study proposes the integrated Kanban-ConWIP hybrid pull control policies and implements several alternatives on a multi-stage and multi-layer manufacturing and assembly production system. An integrated Fuzzy AHP TOPSIS method is developed to evaluate the alternatives with respect to several JIT criteria.

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A Hybrid Push/Pull Production Control System for Multi-stage Manufacturing Processes

Achieving Competitive Edge Getting Ahead Through Technology and People ◽

10.1007/978-1-4471-1904-3_57 ◽

1991 ◽

pp. 341-346 ◽

Cited By ~ 2

Author(s):

Yasuhiro Hirakawa ◽

Kyoji Hoshino ◽

Hiroshi Katayama

Keyword(s):

Control System ◽

Production Control ◽

Manufacturing Processes ◽

Production Control System ◽

Multi Stage ◽

Pull Production

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Evaluation of Manufacturing Process Performance by CONWIP Hybridization of Pull Controlled Production Systems

MATEC Web of Conferences ◽

10.1051/matecconf/201814405006 ◽

2018 ◽

Vol 144 ◽

pp. 05006

Author(s):

O. Srikanth ◽

A. V. Sita Rama Raju ◽

B. V. Ramana Murty

Keyword(s):

Control System ◽

Production Control ◽

Production Systems ◽

Control Policy ◽

Line Production ◽

Event Simulation ◽

Work In Process ◽

Multi Stage ◽

Modeling Analysis ◽

Kanban Control

The main objective of this paper is pioneering an innovative tactic for the synchronization of multi-stage, multi-line, production system. This tactic is mainly depends on the optimization policy, by means of distinct event simulation process for modeling, analysis and distinction of the execution of two alternatives of Kanban control mechanism namely SEKCS (Simultaneous Extended Kanban Control System) and IEKCS (Independent Extended Kanban Control System). At this juncture the authors putting forward the two variants of Extended Kanban control system with the hybridization of CONWIP control policy to incite HSEKCS (Hybrid Simultaneous Extended Kanban Control System) and HIEKCS (Hybrid Independent Extended Kanban Control System) to make use of pooled benefits of a representative production situation in addition to improve the outcome. Therefore in this study the comparison in between different systems of proposed HEKCS specifically are HSEKCS and HIEKCS compared with the Extended Kanban Control Systems variants SEKCS and IEKCS. Simulation studies were conducted for all the five control policies considered and modeled on a multi-line, multi-stage assembly production control system. The relative performance parameters like Throughput or Production rate, Average Waiting Time and Average Work-in-Process, were assessed by means of exponentially varying demands.

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Optimal Attainment of Production Rates for a Multi-Stage Kanban Managed Production System With Time Varying Demand

Volume 4: Design and Manufacturing ◽

10.1115/imece2008-68486 ◽

2008 ◽

Author(s):

Yunmei Fang ◽

Y. J. Lin

Keyword(s):

Production System ◽

Raw Materials ◽

Raw Material ◽

Time Varying ◽

Operation Planning ◽

Production Rates ◽

Supply Chain System ◽

Work In Process ◽

Multi Stage ◽

Varying Demand

This paper delves into the evaluation of an operation planning for a realistic multi-stage, single-product Kanban managed production system with time varying production rates and finished goods demands. The study pursued is to dynamically and systematically manipulate the production rate of each stage and the raw material orders at the first stage which are corresponding to the minimum integrated inventory costs incurred due to raw materials, finished products and work-in-process (WIP) inventories under a varying demand of finished product. Simulation results verify the effectiveness of the proposed operation planning methodology for a multistage Kanban managed production and supply chain system.

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On control strategies in a multi-stage production system

International Journal of Production Research ◽

10.1080/00207540110098454 ◽

2002 ◽

Vol 40 (5) ◽

pp. 1155-1171 ◽

Cited By ~ 7

Author(s):

Zhao Xiaobo ◽

Qiguo Gong ◽

Jiancai Wang

Keyword(s):

Production System ◽

Control Strategies ◽

Multi Stage

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Selection of a pull production control system in multi-stage production processes

International Journal of Production Research ◽

10.1080/00207543.2014.1001530 ◽

2015 ◽

Vol 53 (14) ◽

pp. 4363-4379 ◽

Cited By ~ 10

Author(s):

Yacob Khojasteh ◽

Ryo Sato

Keyword(s):

Control System ◽

Production Control ◽

Production Control System ◽

Production Processes ◽

Multi Stage ◽

Pull Production ◽

Selection Of

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Mehrstufiges multikriterielles Job-Shop-Scheduling*/Multi-Stage and Multi-Criterial Job-Shop-Scheduling

wt Werkstattstechnik online ◽

10.37544/1436-4980-2018-04-16 ◽

2018 ◽

Vol 108 (04) ◽

pp. 210-216

Author(s):

C. Raue ◽

H.-M. Strehle ◽

J. Stoldt ◽

A. Schlegel ◽

M. Richter ◽

...

Keyword(s):

Production Control ◽

Job Shop ◽

Job Shop Scheduling ◽

Control Strategies ◽

Real Life ◽

Ongoing Research ◽

Shifting Bottleneck ◽

Shop Scheduling ◽

Planning And Control ◽

Multi Stage

Energiepolitische Veränderungen erhöhen den Druck auf Produktionsunternehmen, erneuerbare Energiequellen zu nutzen. Deren Einbindung erfordert die Entwicklung neuer Ansätze zur Produktionsplanung und -steuerung (PPS). Dazu wird ein mehrstufiges simulationsbasiertes Verfahren für ein reales Job-Shop-Problem vorgeschlagen, welches die Shifting-Bottleneck-Heuristik zur Findung einer kundenorientierten Ausgangslösung auf Basis des prognostizierten Energieangebots nutzt. Vom resultierenden Lastprofil ausgehend wird eine Feinterminierung zur Optimierung von Lastspitzen unter Beachtung der Ergebnisse der Vorplanung durchgeführt. Auswirkungen kurzfristiger stochastischer Einflüsse werden überdies durch intelligente Produktionssteuerung, aber auch durch aktives Energie- und Lastmanagement kompensiert. Im vorliegenden Beitrag werden für das Anwendungsszenario Flexibilitätspotentiale abgeleitet und das Konzept des „ZIEL“-Systems erläutert. Darüber hinaus wird der aktuelle Bearbeitungsstand abgegrenzt und weiterführende Arbeiten vorgestellt.   Taking responsibility for a sustained energy policy the industry is more and more forced to enhance their engagement in the use of renewable energy. To go beyond energy efficient equipment new approaches in production planning and control tailored to meet both economic and ecological goals are needed. Hence, a multistage simulation based procedure for a real-life oriented job shop production scenario is proposed. It combines a modified version of the Shifting Bottleneck Heuristic for gaining a production plan with energy supply constraints and a sophisticated energy simulation with Matlab Simulink. Short-term and stochastic effects are tackled with suited production control strategies as well as active energy- and load-management. In this paper flexibility options for the use case are derived and the concept of the „ZIEL“ system explained. The current work and the ongoing research are shown.

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Evaluation of Pull Production Control Mechanisms by Simulation

Processes ◽

10.3390/pr10010005 ◽

2021 ◽

Vol 10 (1) ◽

pp. 5

Author(s):

Nataša Tošanović ◽

Nedeljko Štefanić

Keyword(s):

Lean Manufacturing ◽

Lead Time ◽

Production Control ◽

Control Mechanism ◽

Control Mechanisms ◽

Lean Principles ◽

Work In Process ◽

Pull Production ◽

Pull Control ◽

Production Conditions

Today, companies need to continuously improve their production processes, which is a complex task. Lean manufacturing is one of the methodologies for production improvement, and one of the basic goals of any lean implementation is to reduce work-in-process (WIP) and shorten the production lead time. One of the basic lean principles for achieving these goals is pull principle. The adoption of this principle is quite challenging, as it requires a long-term commitment in the application and adoption of various lean techniques and tools that are prerequisites for the successful introduction of the pull principle. Kanban is the most well-known pull production control mechanism, and the first one developed within Toyota production system, but later, other pull control mechanisms were developed. Some of them include Conwip, Hybrid Kanban/Conwip, and Drum Buffer Rope (DBR), and those three, together with Kanban, were the research topic of this study. These four mechanisms were not explored and compared all together not for these specific production configurations considered in this research but also with regard to optimal parameters of control mechanisms. The goal was to analyze and compare how these pull control mechanisms affect lead time in different production conditions. For this purpose, simulation experiments were performed. The results showed that for different production conditions, different pull control mechanisms are optimal in terms of shortening lead time. This finding could help companies as a guideline for making a decision in terms of which pull control mechanism to choose.

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A Comparative Study of Unbalanced Production Lines Using Simulation Modeling: A Case Study for Solar Silicon Manufacturing

Sustainability ◽

10.3390/su14020697 ◽

2022 ◽

Vol 14 (2) ◽

pp. 697

Author(s):

Chen-Yang Cheng ◽

Shu-Fen Li ◽

Chia-Leng Lee ◽

Ranon Jientrakul ◽

Chumpol Yuangyai

Keyword(s):

Cycle Time ◽

Performance Optimization ◽

Production System ◽

Manufacturing Industry ◽

Production Systems ◽

Optimization Technique ◽

Production Lines ◽

Work In Process ◽

Pull Production ◽

Solar Silicon

In the solar silicon manufacturing industry, the production time for crystal growth is ten times longer than at other workstations. The pre-processing time at the ingot-cutting station causes work-in-process (WIP) accumulation and an excessively long cycle time. This study aimed to find the most effective production system for reducing WIP accumulation and shortening the cycle time. The proposed approach considered pull production systems, and the response surface methodology was adopted for performance optimization. A simulation-based optimization technique was used for determining the optimal pull production system. The comparison between the results of various simulated pull production systems and those of the existing solar silicon manufacturing system showed that a hybrid production system in which a kanban station was installed before the bottleneck station with a CONWIP system incorporated for the rest of the production line could reduce the WIP volume by 26% and shorten the cycle time by 16% under the same throughput conditions.

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