scholarly journals Implementation of POLCA Integrated QRM Framework for Optimized Production Performance—A Case Study

2021 ◽  
Vol 13 (6) ◽  
pp. 3452
Author(s):  
Wanzhu Wang ◽  
Qazi Salman Khalid ◽  
Muhammad Abas ◽  
Hao Li ◽  
Shakir Azim ◽  
...  
Keyword(s):  
Production Scheduling ◽  
Flexible Manufacturing ◽  
Lead Time ◽  
Manufacturing Industry ◽  
Agile Manufacturing ◽  
Production Performance ◽  
Manufacturing Strategy ◽  
Work In Process ◽  
Custom Made ◽  
Engineer To Order

Quick response manufacturing (QRM) is a relatively new concept that enfolds all the preceding approaches, namely, just in time (JIT), flexible manufacturing, agile manufacturing, and lean production. QRM is compatible with existing materials requirement planning (MRP) systems and can be implemented efficiently. The ideas from QRM have been highly influential in custom-made engineer-to-order and make-to-order (ETO/MTO) high-mix and low-volume production environments. This study investigates the effectiveness of the POLCA (paired cell overlapping loops of cards) integrated QRM framework for reducing lead time. The POLCA integrated QRM approach was implemented in a precise product manufacturing industry. The industry was facing high penalties due to improper planning and uncontrolled lead times. The implementation of QRM with the POLCA framework indicated optimized production scheduling and significant improvement in lead time and work in process (WIP). After implementing the new manufacturing strategy, the performance parameters showed significant improvement in terms of reducing the percentage loss of profit.

Quantitative Measurement of Fluorescent Layers with Respect to Spatial Thickness Variations and Substrate Properties

2020 ◽  
Vol 74 (4) ◽  
pp. 439-451
Author(s):  
Philipp Holz ◽  
Christoph Pönisch ◽  
Albrecht Brandenburg
Keyword(s):  
Manufacturing Industry ◽  
Quantitative Measurement ◽  
Fluorescence Emission ◽  
Fluorescence Analysis ◽  
Thin Layers ◽  
Fluorescence Signal ◽  
Functional Coatings ◽  
Custom Made ◽  
Substrate Properties ◽  
Thickness Variations

Imaging fluorescence spectroscopy proves to be a fast and sensitive method for measuring the thickness of thin coatings in the manufacturing industry. This encouraged us to systematically study, theoretically and experimentally, parameters that influence the fluorescence of thin layers. We analyzed the fluorescence signal as a function of the scattering and reflectance properties of the sample substrate. In addition, we investigated effects of the layer properties on fluorescence emission. A ray-tracing software is used to describe the influence of these parameters on the fluorescence emission of thin layers. Experiments using a custom-made system for imaging fluorescence analysis verify the simulations. This work shows a factor five variation of fluorescence intensity as a function of the reflectance of the sample substrate. Simulations show variations by a factor of up to eight for samples with different surface roughness. Results on tilted samples indicate a significant increase of the detected fluorescence signal, for fluorescent droplets on reflective substrates, if illuminated and coaxially observed at angles greater than 25°. These findings are of utmost relevance for all applications which utilize the fluorescence emission to quantify thin layers. These applications range from in-line lubricant monitoring in press plants to monitoring of functional coatings in medical technology and the detection of filmic contaminations.

Introduction of Flexible Manufacturing Systems as a Necessary Measure for the Russian Industrial Development

2019 ◽  
Vol 957 ◽  
pp. 195-202 ◽  
Author(s):  
Elizaveta Gromova
Keyword(s):  
Flexible Manufacturing ◽  
Flexible Manufacturing Systems ◽  
Industrial Development ◽  
Manufacturing Systems ◽  
Manufacturing System ◽  
Agile Manufacturing ◽  
Industrial Sector ◽  
Business Environment ◽  
Maximum Speed ◽  
Industrial Enterprises

With the onset of the Fourth Industrial Revolution, the business environment becomes inherent in changes that occur with maximum speed, as well as characterized by the systemic nature of the consequences. One of them is the transformation of operational management models in industrial enterprises. The modern manufacturing system should focus not only on speed of response and flexibility, but also on the cost and quality of products. Integration of effective models: agile manufacturing, quick response manufacturing and lean production, in order to extract the best from them is proposed. The purpose of this study is to analyze this flexible manufacturing system and to relate it to the current state of the Russian industrial development. Theoretical and practical aspects of this model are presented. The examples of the flexible models introduction in the Russian industrial sector is allocated. The conclusion about the necessity of the flexible manufacturing systems implementation for the Russian industrial development is drawn.

Production Scheduling of Flexible Manufacturing Systems

CIRP Annals ◽  
1982 ◽  
Vol 31 (1) ◽  
pp. 319-322 ◽  
Author(s):  
K. Iwata ◽  
A. Murotsu ◽  
F. Oba ◽  
K. Yasuda ◽  
K. Okamura
Keyword(s):  
Production Scheduling ◽  
Flexible Manufacturing ◽  
Flexible Manufacturing Systems ◽  
Manufacturing Systems

Research on DBR Production Scheduling System Application Based on Simulation

2014 ◽  
Vol 889-890 ◽  
pp. 1207-1212
Author(s):  
Guo En Sun ◽  
Zai Lin Guan ◽  
Lei Yue ◽  
Zhi Ming Zheng ◽  
Han Lin
Keyword(s):  
Production Scheduling ◽  
Simulation Optimization ◽  
Production Capacity ◽  
Production Plan ◽  
Process Scheduling ◽  
Scheduling System ◽  
Work In Process ◽  
Planning Methods ◽  
On Time Delivery ◽  
High Output

Traditional planning methods ignore the enterprise production capacity,the paper depend on the specific case in enterprise production to build a Production Scheduling System which applies Drum-Buffer-Rope theory. This system proposes the high output, low work in process and on time delivery as the goals, considering the bottleneck resource as well as providing the master production plan with the bottleneck resource, in addition employing the simulation optimization software-Simio to optimize the bottleneck process scheduling and raise the utilization ratio of bottleneck resource.

scholarly journals Alternativas para aumento de produtividade em uma célula de manufatura com uso das técnicas do sistema Toyota de produção: análise através da modelagem e simulação computacional

2014 ◽  
Vol 15 (1) ◽  
Author(s):  
Peter Bent Hansen ◽  
Rodrigo Gomes Da Rocha ◽  
Fernando De Oliviera Lemos
Keyword(s):  
Lead Time ◽  
Work In Process ◽  
De Se ◽  
Time Work

As mudanças que afetaram o segmento industrial nas últimas décadas conduziram ao desenvolvimento de técnicas destinadas ao aumento de produtividade e eliminação de perdas, entre as quais o Sistema Toyota de Produção (STP). Porém, o STP pode apresentar resultados diferenciados dependendo do ambiente onde é aplicado. O objetivo desta pesquisa é analisar os potenciais resultados e melhorias de produtividade passíveis de se alcançar pela aplicação de conceitos e técnicas do Sistema Toyota de Produção em uma célula de manufatura de uma empresa metal-mecânica, através da simulação computacional. O estudo constitui uma pesquisa aplicada, qualitativa e se caracteriza como um estudo de caso. Foram realizados 3 tipos de experimentos de aplicações de técnicas do STP via simulação computacional, tendo-se constatado que os mesmos produzem efeitos diferenciados em termos de produtividade, lead time, work-in-process e ociosidade dos operadores, apesar de todos convergirem para o aumento de produtividade da célula conforme esperado, porém em diferentes graus.

The effectiveness of flexible manufacturing strategies

2009 ◽  
Vol 58 (2) ◽  
pp. 119-135 ◽  
Author(s):  
Therese A. Joiner ◽  
X. Sarah Yang Spencer ◽  
Suzanne Salmon
Keyword(s):  
Financial Performance ◽  
Performance Measures ◽  
Flexible Manufacturing ◽  
Positive Association ◽  
Manufacturing Firms ◽  
Manufacturing Strategy ◽  
Organisational Performance ◽  
Content Type ◽  
Financial Performance Measures

PurposeAgainst a background of a customization imperative embraced by manufacturing firms in industrialised nations and the concomitant call for more balanced performance measurement systems (PMS), this study seeks to examine the mediating role of both non‐financial and financial performance measures in the relationship between a firm's strategic orientation of flexible manufacturing and organisational performance.Design/methodology/approachA path‐analytical model is adopted using questionnaire data from 84 Australian manufacturing firms.FindingsThe results indicate that, first, firms emphasising a flexible manufacturing strategy utilise non‐financial as well as financial performance measures; second, these performance measures are associated with higher organisational performance; and third, there is a positive association between a firm's strategic emphasis on flexible manufacturing and organisation performance via non‐financial and financial performance measures.Practical implicationsWhile there is agreement on the beneficial role of non‐financial performance measures in supporting strategic priorities associated with customization strategies, equivocal research results have emerged on the role of financial performance measures in this context. The study underscores the importance of both non‐financial and financial performance measures in this context.Originality/valueThe paper reinstates the value of financial performance measures for firms pursuing customization type strategies and adds to one's knowledge of PMSs by exploring the intervening role of such systems in linking flexible manufacturing strategy to organisation performance.

A Blackboard Architecture for Integrated Process Planning/Production Scheduling

1996 ◽  
Author(s):  
Thomas J. Laliberty ◽  
David W. Hildum ◽  
Norman M. Sadeh ◽  
John McA’Nulty ◽  
Dag Kjenstad ◽  
...  
Keyword(s):  
Process Planning ◽  
Production Scheduling ◽  
New Products ◽  
Agile Manufacturing ◽  
Electronic Data Interchange ◽  
Integrated Process ◽  
Blackboard Architecture ◽  
Process Plans ◽  
Mixed Initiative ◽  
Planning Production

Abstract As companies increase the level of customization in their products, move towards smaller lot production and experiment with more flexible customer/supplier arrangements such as those made possible by Electronic Data Interchange (EDI), they increasingly require the ability to quickly, accurately and competitively respond to customer requests for bids on new products and efficiently work out supplier/subcontractor arrangements for these new products. This in turn requires the ability to rapidly convert standard-based product specifications into process plans and quickly integrate process plans for new orders into the existing production schedule to best accommodate the current state of the manufacturing enterprise. This paper describes IP3S, an Integrated Process Planning/Production Scheduling (IP3S) Shell for Agile Manufacturing. The IP3S Shell is designed around a blackboard architecture that emphasizes (1) concurrent development and dynamic revision of integrated process planning/production scheduling solutions, (2) the use of a common representation for exchanging process planning and production scheduling information, (3) coordination with outside information sources such as customer and supplier sites, (4) mixed initiative decision support, enabling the user to interactively explore a number of tradeoffs, and (5) portability and ease of integration with legacy systems. The system is scheduled for initial evaluation in a large and highly dynamic machine shop at Raytheon’s Andover manufacturing facility.

scholarly journals Integrated Multi-Project Scheduling and Hierarchical Workforce Allocation in the ETO Assembly Process

2019 ◽  
Vol 9 (5) ◽  
pp. 885 ◽  
Author(s):  
Chun Jiang ◽  
Xiaofeng Hu ◽  
Juntong Xi
Keyword(s):  
Tabu Search ◽  
Project Scheduling ◽  
Hybrid Algorithm ◽  
Manufacturing Industry ◽  
Assembly Process ◽  
Solution Quality ◽  
Workforce Allocation ◽  
Benchmark Instances ◽  
Engineer To Order ◽  
Searching Ability

The engineer-to-order (ETO) production strategy plays an important role in today’s manufacturing industry. This paper studies integrated multi-project scheduling and hierarchical workforce allocation in the assembly process of ETO products. The multi-project scheduling problem involves the scheduling of tasks of different projects under many constraints, and the workforce allocation problem involves assigning hierarchical workers to each task. These two problems are interrelated. The task duration depends on the number of hierarchical workers assigned to the task. We developed a mathematical model to represent the problem. In order to solve this issue with the minimization of the makespan as the objective, we propose a hybrid algorithm combining particle swarm optimization (PSO) and Tabu search (TS). The improved PSO is designed as the global search process and the Tabu search is introduced to improve the local searching ability. The proposed algorithm is tested on different scales of benchmark instances and a case that uses industrial data from a collaborating steam turbine company. The results show that the solution quality of the hybrid algorithm outperforms the other three algorithms proposed in the literature and the experienced project manager.

scholarly journals CONWIP versus POLCA: A comparative analysis in a high-mix, low-volume (HMLV) manufacturing environment

2016 ◽  
Vol 9 (2) ◽  
pp. 432 ◽  
Author(s):  
Todd Frazee ◽  
Charles Standridge
Keyword(s):  
Discrete Event Simulation ◽  
Lead Time ◽  
Manufacturing Systems ◽  
Discrete Event ◽  
Model Verification ◽  
Manufacturing Environment ◽  
Event Simulation ◽  
Work In Process ◽  
Low Volume ◽  
Average Lead

Purpose: Few studies comparing manufacturing control systems as they relate to high-mix, low-volume applications have been reported. This paper compares two strategies, constant work in process (CONWIP) and Paired-cell Overlapping Loops of Cards with Authorization (POLCA), for controlling work in process (WIP) in such a manufacturing environment. Characteristics of each control method are explained in regards to lead time impact and thus, why one may be advantageous over the other.Design/methodology/approach: An industrial system in the Photonics industry is studied. Discrete event simulation is used as the primary tool to compare performance of CONWIP and POLCA controls for the same WIP level with respect to lead time. Model verification and validation are accomplished by comparing historic data to simulation generated data including utilizations. Both deterministic and Poisson distributed order arrivals are considered. Findings: For the system considered in this case study, including order arrival patterns, a POLCA control can outperform a CONWIP parameter in terms of average lead time for a given level of WIP. At higher levels of WIP, the performance of POLCA and CONWIP is equivalent. Practical Implications: The POLCA control helps limit WIP in specific áreas of the system where the CONWIP control only limits the overall WIP in the system. Thus, POLCA can generate acceptably low lead times at lower levels of WIP for conditions equivalent to the HMLV manufacturing systems studied.Originality/value: The study compliments and extends previous studies of  CONWIP and POLCA performance to a HMLV manufacturing environment. It demonstrates the utility of discrete event simulation in that regard. It shows that proper inventory controls in bottleneck áreas of a system can reduce average lead time.

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