Design and Analysis of Lean Production Systems

, by Askin, Ronald G.; Goldberg, Jeffrey B.

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ISBN: 9780471115939 | 0471115932
Cover: Paperback
Copyright: 11/16/2001

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This book covers the design and improvement of single and multistage production systems. Following the standard production planning and scheduling decision hierarchy, it describes the inputs and outputs at each level of the decision hierarchy and one or more decision approaches. The assumptions leading to each approach are included along with the details of the model and the corresponding solution. Modern system concepts and the engineering methods for creating lean production systems are included.

Preface

vii

The Industrial Enterprise

(18)

Measures of Competitiveness

(1)

Functional Areas of the Firm

(1)

Product Design, Manufacture, and Delivery

(8)

Integrated Product, Process, Tooling, and Test Design

(5)

Manufacturing

(1)

Distribution

(1)

Maintenance and Support

(1)

Disposal

(1)

Business Processes

(2)

Accounting Systems: Acquisition and Management of Model Data

(4)

Summary

(1)

References

(1)

Problems

(1)

Introduction to the Production System and the Role of Inventory

(31)

The Production System

(9)

System Objectives

(1)

System Components and Hierarchy

(3)

Types of Production Systems

(1)

Physical Organization Schemes

(1)

Key Resources

(1)

Product Flow Control

(1)

Order Initiation

(1)

Production Authorization

(1)

Product Volume and Variety

(1)

Product Structure--Fabrication and Assembly

(1)

Time Horizon (Static vs. Dynamic Environments)

(1)

The Role of Inventory

(7)

Inventory Definitions and Decisions

(1)

Types of Inventory

(2)

Justification of Inventory

(1)

Inventory Costs and Tradeoffs

(1)

Ordering and Setup Costs

(1)

Inventory Carrying Costs

(1)

Shortage Costs

(1)

The Trade Offs: Inventory vs. Setup and Shortages

(1)

The Role of Information

(2)

Principles of Production Systems

(6)

Learning Curves: Decreasing Marginal Costs

(1)

The Product Demand Life Cycle

(1)

Production Setups Drive Operations for Low- and Medium-Volume Products

(1)

Inventory Is Needed to Support Production

(2)

Capacity Balancing

(1)

Customer-Defined Value

(1)

Large Inventories Imply Long Throughput Times

(1)

Throughput Time ≥ Cumulative Move and Processing Time for a Transfer Batch

(1)

Production System Models

(3)

Definition of a Model

(1)

Role of Models

(2)

A Systems Perspective

(1)

Summary

(1)

References

(1)

Problems

(2)

Market Characterization

(34)

Forecasting Systems

(4)

Purpose and Use of Forecasts

(1)

Hierarchical Forecasting Systems

(1)

Model Building

(1)

Checking Model Adequacy

(1)

Time Series Extrapolation for Short-Term Forecasting

(14)

Simple Exponential Smoothing

(2)

Seasonal Forecasting Methods (Winter's)

(1)

Updating Equations

(2)

Forecasting Equation

(1)

Initialization

(3)

Tracking Signals and Monitoring of Forecasts

(2)

Adaptive Control

(1)

Time Series Decomposition

(4)

Box-Jenkins Time Series Models

(1)

Medium-Term Extrapolative and Causal Models

(10)

Linear Regression Methods

(1)

Parameter Estimation

(3)

Model Adequacy

(3)

Model Building

(3)

Econometric Models

(1)

Judgmental Forecasting

(2)

The Delphi Method

(1)

Market Surveys

(1)

Combining Forecasts

(1)

Summary

(1)

References

(1)

Problems

(3)

Manufacturing Strategy and the Supply Chain

(46)

Manufacturing Strategy

(12)

Dimensions of Manufacturing Strategy

(1)

Core Competencies

(1)

Customer Markets and Distribution

(1)

Vertical Integration

(1)

The Level of Flexibility

(1)

Supporting Decisions

(1)

Make vs. Buy Decision

(1)

Make-to-Stock vs. Make-to-Order

(2)

Selection of Technologies and Equipment

(2)

Justification of New Systems and Technologies

(3)

Supply Chain Management Concepts

(25)

Global Logistics

(3)

Logistics Information Systems

(1)

Variance Acceleration: The Bullwhip Effect

100

(9)

Product Design and Customization

109

(1)

Vendor Selection, Certification, and Contracting

109

(1)

Operational Decisions in Distribution Systems

110

(1)

Locating Inventory

111

(1)

Basic Trade-Off: Centralization vs. Responsiveness

112

(1)

Distributing Inventory Through the Supply Chain

113

(4)

Echelon vs. Installation Accounting

117

(4)

Multifacility Location-Allocation Models: Designing the Logistics Network

121

(3)

Synthesizing the Concepts

124

(1)

Summary

124

(1)

References

125

(1)

Problems

125

(3)

Case Study: Elba Electronics

128

(2)

Aggregate Planning

130

(39)

Planning Trade-Offs: Inventory, Workforce Changes, Overtime, Shortages

132

(1)

Basic Network Models

133

(5)

Linear Programming Models

138

(17)

Dynamic, Single-Stage Models

139

(7)

Dynamic Multistage Models

146

(1)

Multistage Production Facilities

147

(2)

Multifacility Production-Distribution Networks

149

(6)

Schedule Generation with Lot-Sizing

155

(3)

Parametric Production Planning

158

(1)

Other Approaches

159

(1)

Disaggregation

160

(3)

Single-Cycle Run-Out Time Model

160

(2)

Multiple Cycle Disaggregation

162

(1)

Run-Out Time with Dynamic Demand

163

(1)

Summary

163

(1)

References

164

(1)

Problems

164

(4)

Case Study: 3F Manufacturing

168

(1)

Single-Stage Inventory Control

169

(52)

Reorder Point Inventory Models for Static, Deterministic Demand

169

(17)

Economic Order Quantity (EOQ) Model

169

(3)

Economic Manufactured Quantity Model

172

(4)

The Case of Fixed Setup Cost

176

(1)

Price Breaks

177

(2)

Multiproduct Coordination Models

179

(1)

Organizational Constraints

179

(2)

Rotation Cycle Policies

181

(3)

Lead-Time Minimization

184

(2)

Reorder Point Inventory Models for Stochastic Demand

186

(15)

Service Levels

186

(1)

Continuous Review Systems

187

(7)

Periodic Review Systems

194

(1)

Order-Up-to R Policies

194

(2)

Single-Period Model

196

(4)

Discrete and Slow Demand

200

(1)

Multiproduct Systems

201

(1)

Dynamic Models

201

(12)

Infinite Capacity, Dynamic Lot-Sizing Models

202

(1)

Continuous Review: A Simple Runout Time Model

202

(1)

Periodic Review: The Wagner-Whitin Algorithm

203

(5)

Rolling Schedules and the Silver-Meal Heuristic

208

(1)

Limited Capacity Models

209

(4)

Model Implementation

213

(2)

ABC Analysis

213

(1)

Exchange Curves

214

(1)

Extensions

215

(1)

Summary

215

(1)

References

216

(1)

Problems

216

(5)

Decentralized Pull Systems

221

(48)

Techniques for Production Authorization

221

(4)

Information Requirements for Production Operations

222

(3)

Kanban Systems

225

(25)

The Kanban Authorization Concept

226

(1)

Single-Kanban System

226

(1)

Dual-Kanban Systems

227

(2)

Hybrid Single-Kanban Systems

229

(1)

Rules for Scheduling Kanban Production

229

(3)

Integration Through the Supply Chain

232

(1)

Specifying Parameter Values

233

(1)

Selection of Container Size

233

(2)

Selecting the Number of Kanbans

235

(4)

Selection of Production Quantity

239

(1)

Environmental Requirements for Kanban Systems

240

(3)

Average Inventory Level

243

(4)

Dynamic Management of WIP Levels

247

(1)

Defining the System Control Points

248

(2)

CONWIP: A Constant Work-in-Process Pull Alternative

250

(11)

Prioritizing Order Releases

252

(2)

Performance Evaluation of CONWIP Systems

254

(6)

CONWIP Variations and Extensions

260

(1)

Summary

261

(1)

References

262

(1)

Problems

263

(3)

Case Study: Safe-T Lock Company

266

(3)

Multistage Production Systems: Materials Requirements Planning for Dependent Demand

269

(41)

Materials Requirements Planning Basics

270

(5)

Data and Support System Requirements

270

(2)

Bill of Materials and Requirements Matrix

272

(3)

Requirements Explosion and Order Release Planning

275

(7)

Scrap Losses

281

(1)

Safety Stock and Safety Lead Time

281

(1)

Capacity Planning

282

(6)

Rough-Cut Capacity Planning

283

(2)

Capacity Requirements Planning

285

(2)

Load Reports

287

(1)

Incorporating Stochastic Behavior

288

(1)

Lot-Sizing Decisions

288

(3)

Managing Change

291

(8)

Net Change vs. Regenerative Updates

291

(2)

Order Issuance

293

(2)

Order Pegging

295

(1)

Firm-Planned Orders

296

(3)

Limitations and Reality of MRP

299

(3)

Environmental Assumptions

299

(1)

Structural Limitations

300

(2)

Extensions and Integration Into the Firm

302

(4)

Manufacturing Resources Planning (MRP II)

302

(1)

Enterprise Resources Planning (ERP)

303

(1)

Hybrid Systems

303

(3)

MRP Performance Level

306

(1)

Summary

306

(1)

References

307

(1)

Problems

307

(3)

Multistage Models

310

(42)

Multistage Product Structures

310

(2)

Types Of Inventory

312

(2)

Inventory Costs

314

(1)

Linear Models For Low Setup Time (Non-Bottleneck) Facility

315

(3)

Continuous Time Models for Stationary Data

318

(9)

Assembly Structures-Lot Aggregation

318

(2)

Assembly Structures-Lot Splitting

320

(2)

Reorder Cycle Policies-Power-of-Two Heuristics for Assembly Structures

322

(2)

General Structures

324

(3)

Discrete Time Models for Non-Stationary Data

327

(20)

Serial Structures

328

(2)

Assembly Structures

330

(2)

Optimal Solution to ASE

332

(1)

Heuristic Solution to ASE--Level by Level Lot Sizing with Cost Adjustments

333

(3)

Heuristic Solution to AKG-e--Parallel Heuristic

336

(1)

Schedule Construction for the t + 1 Period Problem

337

(2)

Schedule Selection for the t + 1 Period Problem

339

(3)

General Product Structures

342

(1)

Afentakis and Gavish Model

342

(2)

Integer Programming Approaches

344

(3)

Application

347

(1)

Summary

348

(1)

References

348

(1)

Problems

349

(3)

Lean Manufacturing and the Just-in-Time Philosophy

352

(56)

Lean, Just-in-Time Production Systems

352

(1)

Improving the Production Environment

353

(20)

Eliminating Waste

353

(2)

Employee Cross-Training and Job Rotation

355

(2)

Employee Empowerment and Involvement

357

(1)

JIT Purchasing

358

(1)

Impact of Reducing Variability

358

(6)

Techniques for Mistake-Proofing Processes

364

(2)

Economics of Setup Time Reduction

366

(3)

Technology of Setup Time Reduction

369

(4)

Quality Engineering

373

(17)

Statistical Process Control

373

(1)

Determining Process Capability

374

(2)

Control Charts for Monitoring Statistical Control

376

(1)

X-bar and S Charts for Variables Data

377

(5)

Proportion Defective Charts for Attribute Data

382

(1)

Process Adjustments During Setup

383

(2)

Design of Experiments for Process Optimization

385

(1)

Process Improvement vs. Product Grading

386

(1)

Total Productive Maintenance

386

(4)

Improving Product Flow

390

(10)

Process Flow Charts

391

(1)

Forming Manufacturing Cells

392

(3)

Capacity Balancing

395

(5)

The Transition to Lean

400

(2)

Was Taylor Lean?

400

(1)

From Mass to Lean

400

(1)

Push vs. Pull Control

401

(1)

Summary

402

(1)

References

402

(1)

Problems

402

(4)

Case Study: Dream Desk Company

406

(2)

Shop Scheduling

408

(62)

Scheduling System Requirements, Goals and Measures of Performance

409

(5)

Order Release Strategies

414

(4)

Dispatching Approaches

415

(2)

Mathematical Programming Approaches

417

(1)

Bottleneck Scheduling

418

(4)

The Theory of Constraints (TOC)

419

(1)

Identification of Bottlenecks

420

(1)

Forward and Backward Scheduling

421

(1)

Single-Machine Scheduling

422

(15)

Flow-Time Related Criteria

423

(4)

Lateness and Tardiness Related Criteria

427

(10)

Flow-Shop Scheduling

437

(7)

Scheduling Two Machines-Johnson's Rule

438

(3)

M-Machine Flow Shops

441

(3)

Job Shop Scheduling

444

(20)

Real-Time Dispatching Rules for Multiple Machines

444

(2)

Mathematical Programming Approaches

446

(16)

Intelligent Scheduling Systems

462

(2)

Summary

464

(1)

References

464

(1)

Problems

465

(5)

Shop Floor Control: Systems and Extensions

470

(45)

Control System Architecture

471

(2)

Hierarchical Control Systems

471

(1)

Heterarchical Control Systems

472

(1)

Manufacturing Execution Systems

473

(2)

Design and Control of Flow Shop Systems

475

(25)

Assembly Line Balancing

476

(1)

Ranked Positional Weight

477

(5)

Random Processing Times and Buffers

482

(2)

Mixed-Model Releases

484

(1)

Determining Workstation Spacing

485

(4)

Lot-Streaming

489

(5)

Flexible Flow Lines

494

(6)

Re-Entrant Flow Lines

500

(2)

Tool Management Systems

502

(1)

Flexible Manufacturing Systems

503

(7)

Formation of Part Batches

505

(2)

Tool Loading

507

(2)

Resource Allocation

509

(1)

Summary

510

(1)

References

510

(1)

Problems

511

(4)

Appendices

515

(8)

IB Standard Normal Distribution Function

515

(1)

IB Unit Normal Linear Loss (L(u))

516

(1)

II Linear Programming

517

(6)

Index

523

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Design and Analysis of Lean Production Systems

Summary

Author Biography

Table of Contents

Supplemental Materials

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Design and Analysis of Lean Production Systems

Summary

Author Biography

Table of Contents

Supplemental Materials

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