Abstract
Due to the increase in the variety of demands from downstream customers, companies are required to expand their production capacity by way of adding more plants. Many enterprises encounter difficulties in production planning because manufacturing environments have changed from traditional single-plant to current multi-plants. Therefore, the production planners must develop an integrated multi-site planning approach to coordinate all production resources of multiple plants within the enterprise. As the company may possess many manufacturing plants that are located in different places geographically, the planners will face production allocation problems in the multi-site environment. The decisions may involve the manufacturing routings of demand products and production quantities among multi-plants. As a result, a monolithic model of the multi-stage and multi-site production planning problem is proposed in this paper. The contribution of this planning model is to combine two different time scales, i.e., monthly and daily time buckets. In addition, we also consider other practical planning characteristics and constraints. For example, production transformation functions, capacity consumption constraints, materials supplying constraints, inventory balancing equations and so on. Through optimization procedures, the information on production and procurement in the multi-plant network is derived. Besides, an example from a thin film transistor- liquid crystal display (TFT-LCD) manufacturer case in Taiwan is illustrated for explaining the monolithic planning model.
Similar content being viewed by others
References
DisplaySearch, http://www.displaysearch.com
Lin JT, Chen TL, Huang CC (2004) A hierarchy planning model for TFT-LCD production chain. Int J Electron Bus Manage 2(1):59–68
Bhatnagar R, Chandra P, Goyal SK (1993) Models for multi-plant coordination. Eur J Oper Res 67:141–160
Billington PJ, Blackburn J, Maes J, Millen R, Van Wassenhove LN (1989) Multi-Product Scheduling in Capacited Multi-Stage System. Technical Report 8908/A. Erasmus Universiteit Rotterdam, The Netherlands
Roux W, Dauzere-Peres S, Lasserre JB (1999) Planning and scheduling in a multi-site environment. Prod Plan Control 10:19–28
Brahimi N, Dauzere-Peres S, Najid NM, Nordli A (2006) Single item lot sizing problems. Eur J Oper Res 168:1–16
Ozdamar L, Bozyel MA (2000) The capacitated lot sizing problem with overtime decisions and setup times. IIE Trans 32:1043–1057
Berretta R, Rodrigues LF (2004) A memetic algorithm for a multistage capacitated lot-sizing problem. Int J Prod Econ 87:67–81
Song Y, Chan GH (2005) Single item lot-sizing problems with backlogging on a single machine at a finite production rate. Eur J Oper Res 161:191–202
Al-Fawzan MA (2005) An algorithm for production planning in a flexible production system. Comput Ind Eng 48:681–691
Ozdamar L, Birbil SI (1998) Hybrid heuristics for the capacitated lot sizing and loading problem with setup times and overtime decisions. Eur J Oper Res 110:525–547
Sambasivan M, Yahya S (2005) A Lagrangean-based heuristic for multi-plant, multi-item, multi-period capacitated lot-sizing problems with inter-plant transfers. Comput Oper Res 32:537–555
Sridharan R (1995) The capacitated plant location problem. Eur J Oper Res 87:203−213
Pirkul H, Jayaraman V (1998) A multi-commodity, multi-plant, capacitated facility location problem: formulation and efficient heuristic solution. Comput Oper Res 25(10):869–878
Moon C, Kim J, Hur S (2002) Integrated process planning and scheduling with minimizing total tardiness in multi-plants supply chain. Comput Ind Eng 43:331−349
Vercellis C (1999) Multi-plant production planning in capacitated self-configuring two-stage serial systems. Eur J Oper Res 119:451–460
Timpe CH, Kallrath J (2000) Optimal planning in large multi-site production networks. Eur J Oper Res 126:422–435
Harland C (1997) Supply chain operational performance roles. Integr Manuf Syst 8(2):70–78
Acknowledgement
The authors thank the National Science Council, Taiwan, R.O.C., for support under contract No. NSC 92-2213-E-007-075 and NSC 93-2213-E-007-030.
Author information
Authors and Affiliations
Corresponding author
Rights and permissions
About this article
Cite this article
Lin, J.T., Chen, YY. A multi-site supply network planning problem considering variable time buckets– A TFT-LCD industry case. Int J Adv Manuf Technol 33, 1031–1044 (2007). https://doi.org/10.1007/s00170-006-0537-z
Received:
Accepted:
Published:
Issue Date:
DOI: https://doi.org/10.1007/s00170-006-0537-z