Pub Date : 2023-11-06DOI: 10.24425/mper.2019.129596
Peter Burggraf, Johannes Wagne, Oliver Bischoff
Received: 23 November 2018 Abstract Accepted: 13 August 2019 Rescheduling is a frequently used reactive strategy in order to limit the effects of disruptions on throughput times in multi-stage production processes. However, organizational deficits often cause delays in the information on disruptions, so rescheduling cannot limit disruption effects on throughput times optimally. Our approach strives for an investigation of possible performance improvements in multi-stage production processes enabled by realtime rescheduling in the event of disruptions. We developed a methodology whereby we could measure these possible performance improvements. For this purpose, we created and implemented a simulation model of a multi-stage production process. We defined system parameters and varied factors according to our experiment design, such as information delay, lot sizes and disruption durations. The simulation results were plotted and evaluated using DoE methodology. Dependent on the factor settings, we were able to prove large improvements by real-time rescheduling regarding the absorption of disruption effects in our experiments.
{"title":"Performance improvements in horizontally integrated production networks through real-time reschedulingin the event of disruptions","authors":"Peter Burggraf, Johannes Wagne, Oliver Bischoff","doi":"10.24425/mper.2019.129596","DOIUrl":"https://doi.org/10.24425/mper.2019.129596","url":null,"abstract":"Received: 23 November 2018 Abstract Accepted: 13 August 2019 Rescheduling is a frequently used reactive strategy in order to limit the effects of disruptions on throughput times in multi-stage production processes. However, organizational deficits often cause delays in the information on disruptions, so rescheduling cannot limit disruption effects on throughput times optimally. Our approach strives for an investigation of possible performance improvements in multi-stage production processes enabled by realtime rescheduling in the event of disruptions. We developed a methodology whereby we could measure these possible performance improvements. For this purpose, we created and implemented a simulation model of a multi-stage production process. We defined system parameters and varied factors according to our experiment design, such as information delay, lot sizes and disruption durations. The simulation results were plotted and evaluated using DoE methodology. Dependent on the factor settings, we were able to prove large improvements by real-time rescheduling regarding the absorption of disruption effects in our experiments.","PeriodicalId":45454,"journal":{"name":"Management and Production Engineering Review","volume":"1995 9","pages":"0"},"PeriodicalIF":0.0,"publicationDate":"2023-11-06","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"135636043","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Pub Date : 2023-11-06DOI: 10.24425/mper.2019.129568
M. Pekarcikova, P. Trebuna, M. Kliment, J. Trojan
Received: 11 January 2019 Abstract Accepted: 31 May 2019 Industry 4.0 will affect the complexity of supply chain networks. It will be necessary to adapt more and more to the customer and respond within a time interval that is willing to accept the product waiting. From these considerations, there is a need for a different way of managing the supply chain. The traditional concept of supply chain as a linear system, which allows optimizing individual subsystems, thus obtaining an optimized supply chain, is not enough. The article deals with the issue of supply chain management reflecting demand behaviour using the methodology Demand Driven MRP system. The aim of the publication is to extend the knowledge base in the area of demand-driven supply logistics in the context of Industry 4.0 and verify the processed theoretical knowledge in a case study.
{"title":"Demand driven material requirements planning. Some methodical and practical comments","authors":"M. Pekarcikova, P. Trebuna, M. Kliment, J. Trojan","doi":"10.24425/mper.2019.129568","DOIUrl":"https://doi.org/10.24425/mper.2019.129568","url":null,"abstract":"Received: 11 January 2019 Abstract Accepted: 31 May 2019 Industry 4.0 will affect the complexity of supply chain networks. It will be necessary to adapt more and more to the customer and respond within a time interval that is willing to accept the product waiting. From these considerations, there is a need for a different way of managing the supply chain. The traditional concept of supply chain as a linear system, which allows optimizing individual subsystems, thus obtaining an optimized supply chain, is not enough. The article deals with the issue of supply chain management reflecting demand behaviour using the methodology Demand Driven MRP system. The aim of the publication is to extend the knowledge base in the area of demand-driven supply logistics in the context of Industry 4.0 and verify the processed theoretical knowledge in a case study.","PeriodicalId":45454,"journal":{"name":"Management and Production Engineering Review","volume":"1 1","pages":""},"PeriodicalIF":1.4,"publicationDate":"2023-11-06","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"68950836","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Pub Date : 2023-11-06DOI: 10.24425/MPER.2019.12959
G. Bocewicz, W. Bożejko, R. Wójcik, Z. Banaszak
The objective of the milk-run design problem considered in this paper is to minimize trans- portation and inventory costs by manipulating fleet size and the capacity of vehicles and storage areas. Just as in the case of an inventory routing problem, the goal is to find a pe- riodic distribution policy with a plan on whom to serve, and how much to deliver by what fleet of tugger trains travelling regularly on which routes. This problem boils down to de- termining the trade-off between fleet size and storage capacity, i.e. the size of replenishment batches that can minimize fleet size and storage capacity. A solution obtained in the declar- ative model of the milk-run system under discussion allows to determine the routes for each tugger train and the associated delivery times. In this context, the main contribution of the present study is the identification of the relationship between takt time and the size of replenishment batches, which allows to determine the delivery time windows for milk- run delivery and, ultimately, the positioning of trade-off points. The results show that this relationship is non-linear.
{"title":"Milk-run routing and scheduling subject to a trade-off between vehicle fleet size and storage capacity","authors":"G. Bocewicz, W. Bożejko, R. Wójcik, Z. Banaszak","doi":"10.24425/MPER.2019.12959","DOIUrl":"https://doi.org/10.24425/MPER.2019.12959","url":null,"abstract":"The objective of the milk-run design problem considered in this paper is to minimize trans- portation and inventory costs by manipulating fleet size and the capacity of vehicles and storage areas. Just as in the case of an inventory routing problem, the goal is to find a pe- riodic distribution policy with a plan on whom to serve, and how much to deliver by what fleet of tugger trains travelling regularly on which routes. This problem boils down to de- termining the trade-off between fleet size and storage capacity, i.e. the size of replenishment batches that can minimize fleet size and storage capacity. A solution obtained in the declar- ative model of the milk-run system under discussion allows to determine the routes for each tugger train and the associated delivery times. In this context, the main contribution of the present study is the identification of the relationship between takt time and the size of replenishment batches, which allows to determine the delivery time windows for milk- run delivery and, ultimately, the positioning of trade-off points. The results show that this relationship is non-linear.","PeriodicalId":45454,"journal":{"name":"Management and Production Engineering Review","volume":"1 1","pages":""},"PeriodicalIF":1.4,"publicationDate":"2023-11-06","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"68950988","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Pub Date : 2023-11-06DOI: 10.24425/mper.2019.128239
Jose Pascual Ruano, Ignacio Hoyuelos, Manuel Mateo, Angel M. Gento
Received: 8 January 2019 Abstract Accepted: 13 March 2019 This paper introduces the Lean School, a Learning Factory, along with a “game” of physical simulation that is developed in it. All this is focused on teaching-learning, both of students and professionals, of the potential advantages offered by the implementation of the Lean Production in the organizations. The participants gain a practical experience, based on experimental learning, which gives them a better understanding of the principles and tools of Lean philosophy. This physical environment is not limited to theoretical teaching, but goes beyond and implements a production system near a real one. It starts from a configuration of a production plant with an unbalanced system and throughout the different iterations, called productions, introduces and implement the Lean principles, which makes its participants acquire not only knowledge but also the skills needed to implement an efficient production in their organizations. All the constituent elements of the system will be described briefly: the product, the variations thereof, the initial design with its layout, as well as the subsequent productions, and the results of learning of each one.
{"title":"Lean School: a learning factory for training lean manufacturing in a physical simulation environment","authors":"Jose Pascual Ruano, Ignacio Hoyuelos, Manuel Mateo, Angel M. Gento","doi":"10.24425/mper.2019.128239","DOIUrl":"https://doi.org/10.24425/mper.2019.128239","url":null,"abstract":"Received: 8 January 2019 Abstract Accepted: 13 March 2019 This paper introduces the Lean School, a Learning Factory, along with a “game” of physical simulation that is developed in it. All this is focused on teaching-learning, both of students and professionals, of the potential advantages offered by the implementation of the Lean Production in the organizations. The participants gain a practical experience, based on experimental learning, which gives them a better understanding of the principles and tools of Lean philosophy. This physical environment is not limited to theoretical teaching, but goes beyond and implements a production system near a real one. It starts from a configuration of a production plant with an unbalanced system and throughout the different iterations, called productions, introduces and implement the Lean principles, which makes its participants acquire not only knowledge but also the skills needed to implement an efficient production in their organizations. All the constituent elements of the system will be described briefly: the product, the variations thereof, the initial design with its layout, as well as the subsequent productions, and the results of learning of each one.","PeriodicalId":45454,"journal":{"name":"Management and Production Engineering Review","volume":"9 9","pages":"0"},"PeriodicalIF":0.0,"publicationDate":"2023-11-06","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"135544912","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Pub Date : 2023-11-06DOI: 10.24425/mper.2022.142402
{"title":"142402","authors":"","doi":"10.24425/mper.2022.142402","DOIUrl":"https://doi.org/10.24425/mper.2022.142402","url":null,"abstract":"","PeriodicalId":45454,"journal":{"name":"Management and Production Engineering Review","volume":"2014 23","pages":"0"},"PeriodicalIF":0.0,"publicationDate":"2023-11-06","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"135637256","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Pub Date : 2023-11-06DOI: 10.24425/MPER.2019.128241
M. Bevilacqua, F. Ciarapica, S. Antomarioni
Received: 8 January 2019 Abstract Accepted: 7 March 2019 The application of the 5S methodology to warehouse management represents an important step for all manufacturing companies, especially for managing products that consist of a large number of components. Moreover, from a lean production point of view, inventory management requires a reduction in inventory wastes in terms of costs, quantities and time of non-added value tasks. Moving towards an Industry 4.0 environment, a deeper understanding of data provided by production processes and supply chain operations is needed: the application of Data Mining techniques can provide valuable support in such an objective. In this context, a procedure aiming at reducing the number and the duration of picking processes in an Automated Storage and Retrieval System. Association Rule Mining is applied for reducing time wasted during the storage and retrieval activities of components and finished products, pursuing the space and material management philosophy expressed by the 5S methodology. The first step of the proposed procedure requires the evaluation of the picking frequency for each component. Historical data are analyzed to extract the association rules describing the sets of components frequently belonging to the same order. Then, the allocation of items in the Automated Storage and Retrieval System is performed considering (a) the association degree, i.e., the confidence of the rule, between the components under analysis and (b) the spatial availability. The main contribution of this work is the development of a versatile procedure for eliminating time waste in the picking processes from an AS/RS. A real-life example of a manufacturing company is also presented to explain the proposed procedure, as well as further research development worthy of investigation.
{"title":"Lean principles for organizing items in an automated storage and retrieval system:an association rule mining – based approach","authors":"M. Bevilacqua, F. Ciarapica, S. Antomarioni","doi":"10.24425/MPER.2019.128241","DOIUrl":"https://doi.org/10.24425/MPER.2019.128241","url":null,"abstract":"Received: 8 January 2019 Abstract Accepted: 7 March 2019 The application of the 5S methodology to warehouse management represents an important step for all manufacturing companies, especially for managing products that consist of a large number of components. Moreover, from a lean production point of view, inventory management requires a reduction in inventory wastes in terms of costs, quantities and time of non-added value tasks. Moving towards an Industry 4.0 environment, a deeper understanding of data provided by production processes and supply chain operations is needed: the application of Data Mining techniques can provide valuable support in such an objective. In this context, a procedure aiming at reducing the number and the duration of picking processes in an Automated Storage and Retrieval System. Association Rule Mining is applied for reducing time wasted during the storage and retrieval activities of components and finished products, pursuing the space and material management philosophy expressed by the 5S methodology. The first step of the proposed procedure requires the evaluation of the picking frequency for each component. Historical data are analyzed to extract the association rules describing the sets of components frequently belonging to the same order. Then, the allocation of items in the Automated Storage and Retrieval System is performed considering (a) the association degree, i.e., the confidence of the rule, between the components under analysis and (b) the spatial availability. The main contribution of this work is the development of a versatile procedure for eliminating time waste in the picking processes from an AS/RS. A real-life example of a manufacturing company is also presented to explain the proposed procedure, as well as further research development worthy of investigation.","PeriodicalId":45454,"journal":{"name":"Management and Production Engineering Review","volume":"1 1","pages":""},"PeriodicalIF":1.4,"publicationDate":"2023-11-06","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"68950420","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Pub Date : 2023-11-06DOI: 10.24425/MPER.2019.131440
Zineb Ibn Majdoub Hassani, A. E. Barkany, I. E. Abbassi, A. Jabri, A. Darcherif
Received: 3 April 2019 Abstract Accepted: 30 October 2019 In this article we present an industrial application of our mathematical model that integrates planning and scheduling. Our main objective is to concretize our model and compare the reel results with the theoretical ones. Our application is realized on a conditioning line of pharmaceutical products at the ECAM EPMI production laboratory. For this reason and to save time, we used Witness simulation tool. It gives an overall idea of how the line works, the Makespan of each simulation and it highlights areas for improvement. We looked for the best resulting sequence which corresponds to the minest Makespan and total production cost. Then this sequence is applied on the conditioning line of pharmaceutical products for simulation. On the other hand, we program our mathematical model with the parameters of the conditioning line under python in version 3.6 and we adopt a simulation/optimization coupling approach to verify our model.
{"title":"Planning and Scheduling of Production System in Conditioning Line: Industrial Application, Optimizationand Simulation Approach","authors":"Zineb Ibn Majdoub Hassani, A. E. Barkany, I. E. Abbassi, A. Jabri, A. Darcherif","doi":"10.24425/MPER.2019.131440","DOIUrl":"https://doi.org/10.24425/MPER.2019.131440","url":null,"abstract":"Received: 3 April 2019 Abstract Accepted: 30 October 2019 In this article we present an industrial application of our mathematical model that integrates planning and scheduling. Our main objective is to concretize our model and compare the reel results with the theoretical ones. Our application is realized on a conditioning line of pharmaceutical products at the ECAM EPMI production laboratory. For this reason and to save time, we used Witness simulation tool. It gives an overall idea of how the line works, the Makespan of each simulation and it highlights areas for improvement. We looked for the best resulting sequence which corresponds to the minest Makespan and total production cost. Then this sequence is applied on the conditioning line of pharmaceutical products for simulation. On the other hand, we program our mathematical model with the parameters of the conditioning line under python in version 3.6 and we adopt a simulation/optimization coupling approach to verify our model.","PeriodicalId":45454,"journal":{"name":"Management and Production Engineering Review","volume":"10 1","pages":""},"PeriodicalIF":1.4,"publicationDate":"2023-11-06","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"68951272","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Pub Date : 2023-11-06DOI: 10.24425/mper.2022.142404
{"title":"142404","authors":"","doi":"10.24425/mper.2022.142404","DOIUrl":"https://doi.org/10.24425/mper.2022.142404","url":null,"abstract":"","PeriodicalId":45454,"journal":{"name":"Management and Production Engineering Review","volume":"2010 2","pages":"0"},"PeriodicalIF":0.0,"publicationDate":"2023-11-06","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"135636513","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Pub Date : 2023-11-06DOI: 10.24425/MPER.2019.129571
Maha Aikhatib, S. Altarazi
This study presents a customized root cause analysis approach to investigate the reasons, provide improvements measures for the cost overruns, and schedule slippage in paper-machine-building projects. The proposed approach is an analytical-survey approach that uses both actual technical data and experts’ opinions. Various analysis tools are embedded in the approach including: data collection and clustering, interviews with experts, 5-Whys, Pareto charts, cause and effect diagram, and critical ratio control charts. The approach was implemented on seven projects obtained from a leading international paper machine sup- plier. As a result, it was found that the main causes behind cost and schedule deviations are products’ related; including technical accidents in the Press section, damaged parts, de- sign issues, optimization of the machine and missing parts. Based on the results, prevention measures were perceived.
{"title":"A customized root cause analysis approach for cost overruns and schedule slippage in paper-machine-building projects","authors":"Maha Aikhatib, S. Altarazi","doi":"10.24425/MPER.2019.129571","DOIUrl":"https://doi.org/10.24425/MPER.2019.129571","url":null,"abstract":"This study presents a customized root cause analysis approach to investigate the reasons, provide improvements measures for the cost overruns, and schedule slippage in paper-machine-building projects. The proposed approach is an analytical-survey approach that uses both actual technical data and experts’ opinions. Various analysis tools are embedded in the approach including: data collection and clustering, interviews with experts, 5-Whys, Pareto charts, cause and effect diagram, and critical ratio control charts. The approach was implemented on seven projects obtained from a leading international paper machine sup- plier. As a result, it was found that the main causes behind cost and schedule deviations are products’ related; including technical accidents in the Press section, damaged parts, de- sign issues, optimization of the machine and missing parts. Based on the results, prevention measures were perceived.","PeriodicalId":45454,"journal":{"name":"Management and Production Engineering Review","volume":"1 1","pages":""},"PeriodicalIF":1.4,"publicationDate":"2023-11-06","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"68950443","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Pub Date : 2023-11-06DOI: 10.24425/MPER.2019.128245
M. Matharu, Neena Sinha
Received: 4 January 2019 Abstract Accepted: 2 March 2019 A robust manufacturing sector is imperative for achieving sustainable and inclusive development. Also, in the Indian context, Micro, Small and Medium Enterprises (MSMEs) are of vital importance due to their contribution to GDP, exports and employment. Indian Government has launched many schemes to vitalize and improve the competitiveness of Manufacturing MSMEs. ‘Lean Manufacturing Competiveness Scheme’ (LMCS) is a huge step aimed to act as a catalyst for lean adoption by Indian MSMEs. This paper uses SAP LAP framework to address critical questions regarding lean adoption by Indian manufacturing MSMEs in the context of the government scheme ‘LMCS’. The study adds to the existing body of knowledge on lean manufacturing that emphasizes on the importance of soft issues while implementing lean. It also benefits the stakeholders by suggesting suitable actions that can be taken to further improve the competitive priorities of MSMEs.
{"title":"Lean implementation in Indian manufacturing MSMES: a SAP-LAP analysis","authors":"M. Matharu, Neena Sinha","doi":"10.24425/MPER.2019.128245","DOIUrl":"https://doi.org/10.24425/MPER.2019.128245","url":null,"abstract":"Received: 4 January 2019 Abstract Accepted: 2 March 2019 A robust manufacturing sector is imperative for achieving sustainable and inclusive development. Also, in the Indian context, Micro, Small and Medium Enterprises (MSMEs) are of vital importance due to their contribution to GDP, exports and employment. Indian Government has launched many schemes to vitalize and improve the competitiveness of Manufacturing MSMEs. ‘Lean Manufacturing Competiveness Scheme’ (LMCS) is a huge step aimed to act as a catalyst for lean adoption by Indian MSMEs. This paper uses SAP LAP framework to address critical questions regarding lean adoption by Indian manufacturing MSMEs in the context of the government scheme ‘LMCS’. The study adds to the existing body of knowledge on lean manufacturing that emphasizes on the importance of soft issues while implementing lean. It also benefits the stakeholders by suggesting suitable actions that can be taken to further improve the competitive priorities of MSMEs.","PeriodicalId":45454,"journal":{"name":"Management and Production Engineering Review","volume":"1 1","pages":""},"PeriodicalIF":1.4,"publicationDate":"2023-11-06","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"68950585","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
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