Advertisement

Workload and Cycle Time in the Production Unit

  • Hubert Missbauer
  • Reha Uzsoy
Chapter
  • 43 Downloads

Abstract

Our description of the PPC problem in Chap.  1 identified the effective management of cycle times as a critical link between the planning level and the realized performance of the production units it seeks to coordinate. Most of the PPC systems prevalent in industry today approach this issue through planned lead times and maximum capacity loading, assuming that as long as the capacity loading does not exceed the agreed-upon maximum level, the production units will be able to complete work within the planned lead time with high probability. This chapter argues that reliance on exogenous planned lead times represents a significant drawback of this approach because cycle times through a production unit are, in fact, an outcome of the work release decisions made by the PPC system. Since this dependence between cycle times and work release decisions lies at the center of the problems addressed in this volume, we now discuss the relationship between a production unit’s workload and cycle time in more detail.

References

  1. Agnew C (1976) Dynamic modeling and control of some congestion prone systems. Oper Res 24(3):400–419CrossRefGoogle Scholar
  2. Asmundsson JM, Rardin RL, Turkseven CH, Uzsoy R (2009) Production planning models with resources subject to congestion. Nav Res Logist 56(2):142–157CrossRefGoogle Scholar
  3. Aurand S, Miller P (1997) The operating curve: a method to measure and benchmark manufacturing line productivity. In: 1997 IEEE/SEMI Advanced Semiconductor Manufacturing Conference and Workshop ASMC 97 Proceedings, IEEE, Cambridge, pp 391–397Google Scholar
  4. Bertrand JWM, Wortmann JC, Wijngaard J (1990) Production control: a structural and design oriented approach. Elsevier, AmsterdamGoogle Scholar
  5. Buzacott JA, Shanthikumar JG (1993) Stochastic models of manufacturing systems. Prentice-Hall, Englewood CliffsGoogle Scholar
  6. Curry GL, Feldman RM (2000) Manufacturing systems modelling and analysis. Springer, BerlinGoogle Scholar
  7. Ehteshami B, Petrakian R, Shabe P (1992) Trade-offs in cycle time management: hot lots. IEEE Trans Semicond Manuf 5(2):101–106CrossRefGoogle Scholar
  8. Fandel G (1991) Theory of production and cost. Springer, BerlinCrossRefGoogle Scholar
  9. Godinho Filho M, Uzsoy R (2014) Assessing the impact of alternative continuous improvement programmes in a flow shop using system dynamics. Int J Prod Res 52(10):3014–3031CrossRefGoogle Scholar
  10. Hackman S (2008) Production economics. Springer, BerlinGoogle Scholar
  11. Häussler S, Missbauer H (2014) Empirical validation of meta-models of work centres in order release planning. Int J Prod Econ 149:102–116CrossRefGoogle Scholar
  12. Hopp WJ, Spearman ML (2004) To pull or not to pull: what is the question? Manuf Serv Oper Manag 6(2):133–148CrossRefGoogle Scholar
  13. Hopp WJ, Spearman ML (2008) Factory physics: foundations of manufacturing management. Irwin/McGraw-Hill, BostonGoogle Scholar
  14. Kacar NB, Uzsoy R (2015) Estimating clearing functions for production resources using simulation optimization. IEEE Trans Autom Sci Eng 12(2):539–552CrossRefGoogle Scholar
  15. Kacar NB, Irdem DF, Uzsoy R (2012) An experimental comparison of production planning using clearing functions and iterative linear programming-simulation algorithms. IEEE Trans Semicond Manuf 25(1):104–117CrossRefGoogle Scholar
  16. Kekre S (1984) The effect of number of items processed at a facility on manufacturing lead time. Working Paper Series. University of Rochester, RochesterGoogle Scholar
  17. Kendall DG (1953) Stochastic processes occurring in the theory of queues and their analysis by the method of the imbedded Markov chain. Ann Math Stat 24(3):338–354CrossRefGoogle Scholar
  18. Kim S-C, Bobrowski PM (1995) Evaluating order release mechanisms in a job shop with sequence-dependent setup times. Prod Oper Manag 4(2):163–180CrossRefGoogle Scholar
  19. Kingman JFC (1961) The single server queue in heavy traffic. Math Proc Camb Philos Soc 57(4):902–904CrossRefGoogle Scholar
  20. Liker J (2004) The Toyota way: 14 management principles from the world’s greatest manufacturer. McGraw-Hill, New YorkGoogle Scholar
  21. Little JDC (1961) A proof of the queueing formula L =ƛw. Oper Res 9:383–387CrossRefGoogle Scholar
  22. Missbauer H (1997) Order release and sequence-dependent setup times. Int J Prod Econ 49:131–143CrossRefGoogle Scholar
  23. Missbauer H (2009) Models of the transient behaviour of production units to optimize the aggregate material flow. Int J Prod Econ 118(2):387–397CrossRefGoogle Scholar
  24. Pinedo M (2012) Scheduling. Theory, algorithms, and systems. Springer, New YorkGoogle Scholar
  25. Schoemig AK (1999) On the corrupting influence of variability in semiconductor manufacturing. In: Proceedings of the Winter Simulation Conference, P. A. Farrington, H. B. Nembhard, D. T. Sturrock, G. W. Evans (eds), 1999, pp. 837–842, IEEEGoogle Scholar
  26. Selçuk B, Fransoo JC, de Kok AG (2007) Work in process clearing in supply chain operations planning. IIE Trans 40(3):206–220CrossRefGoogle Scholar
  27. Shortle JF, Thompson JM, Gross D, Harris CM (2018) Fundamentals of queueing theory. Wiley, HobokenCrossRefGoogle Scholar
  28. Sugimori Y, Kusunoki K, Cho F, Uchikawa S (1977) Toyota production system and Kanban system: materialization of just-in-time and respect for human system. Int J Prod Res 15(6):553–564CrossRefGoogle Scholar
  29. Thürer M, Silva C, Stevenson M, Land M (2012) Improving the applicability of workload control (Wlc): the influence of sequence dependent setup times on workload controlled job shops. Int J Prod Res 50(22):6419–6430CrossRefGoogle Scholar
  30. Wiendahl HP (1995) Load oriented manufacturing control. Springer, HeidelbergCrossRefGoogle Scholar
  31. Yang F, Ankenman B, Nelson BL (2006) Efficient generation of cycle time-throughput curves through simulation and metamodeling. Nav Res Logist 54(1):78–93CrossRefGoogle Scholar

Copyright information

© Springer Science+Business Media, LLC, part of Springer Nature 2020

Authors and Affiliations

  • Hubert Missbauer
    • 1
  • Reha Uzsoy
    • 2
  1. 1.Department of Information Systems, Production and Logistics ManagementUniversity of InnsbruckInnsbruckAustria
  2. 2.Edward P. Fitts Department of Industrial and Systems EngineeringNorth Carolina State UniversityRaleighUSA

Personalised recommendations