Evaluation of Pull Production Control Mechanisms by Simulation

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.

A comparative study of different pull control strategies in multi-product manufacturing systems using discrete event simulation

Pull production control strategies coordinate manufacturing operations based on actual demand. Up to now, relevant publications mostly examine manufacturing systems that produce a single type of a product. In this research, we examine the CONWIP, Base Stock, and CONWIP/Kanban Hybrid pull strategies in multi-product manufacturing systems. In a multi-product manufacturing system, several types of products are manufactured by utilizing the same resources. We develop queueing network models of multi-stage, multi-product manufacturing systems operating under the three aforementioned pull control strategies. Simulation models of the alternative production systems are implemented using an open-source software. A comparative evaluation of CONWIP, Base Stock and CONWIP/Kanban Hybrid in multi-product manufacturing is carried out in a series of simulation experiments with varying demand arrival rates, setup times and control parameters. The control strategies are compared based on average wait time of backordered demand, average finished products inventories, and average length of backorders queues. The Base Stock strategy excels when the manufacturing system is subjected to high demand arrival rates. The CONWIP strategy produced consistently the highest level of finished goods inventories. The CONWIP/Kanban Hybrid strategy is significantly affected by the workload that is imposed on the system.

Semiochemicals Affecting Attraction of Ambrosia Beetle Euwallacea fornicatus (Coleoptera: Curculionidae: Scolytinae) to Quercivorol: Developing Push-Pull Control

Euwallacea fornicatus (Eichhoff), the polyphagous shot hole borer (PSHB), is an ambrosia beetle infesting avocado Persea americana Mill. limbs in North America and Israel. We conducted field experiments with sticky traps in avocado orchards to develop push–pull semiochemical methods of managing PSHB. Traps baited with 10-fold increasing doses (0.01 to 100× or 1.26 µg to 12.6 mg/d) of attractant quercivorol were previously shown to increasingly capture female PSHB (males flightless). We converted trap catch of this relationship to a standardized effective attraction radius (EAR) that predicts capture power of baited-traps regardless of insect flight density. Earlier, piperitone and verbenone were shown to strongly inhibit attraction of PSHB to quercivorol-traps. We tested increasing numbers of 1× piperitone dispensers at 0.75-m distance surrounding a quercivorol-trap and found PSHB catch to decline exponentially. Increasing decadic doses (0.01 to 10×) of either verbenone or piperitone released at 1× quercivorol-traps caused a sigmoidal first-order kinetic-decay in catch. Verbenone (1×) placed at increasing distances (0, 0.25, 0.5, 1, and 2 m) from a 1× quercivorol-trap became increasingly ineffective in reducing catch of PSHB. We found no evidence that ethanol released from 7.5 to 480 mg/d affected attraction of PSHB, but Scobicia chevrieri (Villa and Villa) (Coleoptera: Bostrichidae) was increasingly attracted. Due to their relatively short-range (<0.5 m) inhibition of attractive sources, piperitone, and verbenone dispensers should be placed on avocado trunks where PSHB aggregations occur before the flight season.