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Article
Publication date: 26 September 2008

Hamid Ullah and Erik L.J. Bohez

The purpose of this paper is to present a Petri net (PN) model based on assembly plan is presented for modeling a flexible assembly system (FAS) configuration, determining an…

Abstract

Purpose

The purpose of this paper is to present a Petri net (PN) model based on assembly plan is presented for modeling a flexible assembly system (FAS) configuration, determining an optimal work‐in‐process (WIP), lead time, throughput, and utilization of each station.

Design/methodology/approach

PN model is developed for design, analysis, and performance evaluation of a FAS, keeping in view the assembly line balancing. PN is optimized using weighted WIP. The throughput is bounded by the utilization of the bottleneck machines.

Findings

The PN optimization gives minimum WIP corresponding to the maximum production rate. Minimum WIP leads to minimum lead time. The weighted arcs make the model simple and reduce the optimized number of kanbans. Moreover, the PN model pushes more inventory to the initial assembly phase. This reduces the total cost of the WIP.

Research limitations/implications

In the proposed PN model, the transportation times are included in the transitions times. In the future research, the proposed model can be extended for inclusion of transportation times for AGVs.

Practical implications

Using the PN model, the assembly manager may design, analyze, evaluate, and even optimize the layout of the assembly system for minimum WIP, maximum throughput, and reduced lead time. The determination of the total WIP, total number of stations in the assembly system, and the number of servers at each station may be helpful in factory floor management. The same cycle time is managed at each assembly station for the purpose of line balancing. It may result in the highest efficiency and the shortest idling time along with ease of management and supervision.

Originality/value

This paper presents a new PN model for the design and performance evaluation of a dual kanban FAS.

Details

Assembly Automation, vol. 28 no. 4
Type: Research Article
ISSN: 0144-5154

Keywords

Article
Publication date: 8 March 2013

Liang Zhang

The purpose of this paper is to study kanban‐controlled pull‐systems with machines having the exponential reliability model and with buffers finite capacities.

1570

Abstract

Purpose

The purpose of this paper is to study kanban‐controlled pull‐systems with machines having the exponential reliability model and with buffers finite capacities.

Design/methodology/approach

Using Markovian analysis closed formulas are derived for the performance metrics such as customer service level, average inventory level, and throttling of raw part release, for one‐machine systems. Then, a recursive procedure is developed to extend the performance evaluation technique to multi‐machine systems.

Findings

Once system‐theoretic properties of the systems under consideration are investigated, the paper reveals methods for evaluating the smallest, i.e. lean, number of kanbans that ensure the desired level of customer service which are developed.

Originality/value

Production systems can operate in either push or pull regime. The push‐systems have been analyzed extensively for over 50 years, while the pull‐systems have been studied to a much lesser extent.

Details

Journal of Manufacturing Technology Management, vol. 24 no. 3
Type: Research Article
ISSN: 1741-038X

Keywords

Article
Publication date: 1 March 1985

Sumer C. Aggarwal and Sudhir Aggarwal

A detailed analysis of Material Requirements Planning (MRP), Kanban, optimised Production Technology (OPT) and Flexible Manufacturing Systems (FMS), including the applied…

Abstract

A detailed analysis of Material Requirements Planning (MRP), Kanban, optimised Production Technology (OPT) and Flexible Manufacturing Systems (FMS), including the applied assumptions behind these and their limitations and weaknesses, shows that each system is sound in its own way and can accomplish low cost, high quality, on‐time production. People problems, however, can destroy the effectiveness of any system and in this respect Kanban and OPT systems solve the majority of people problems, while FMS installations, by design, eliminate most problems of this type. The experience gained during the coming decade may lead factory managers to use two or more of these systems side by side.

Details

International Journal of Operations & Production Management, vol. 5 no. 3
Type: Research Article
ISSN: 0144-3577

Keywords

Article
Publication date: 1 September 1995

Houmin Yan

Considers manufacturing systems with a failure‐prone machine and astochastic demand. The production is controlled by a kanbanscheme. Although the kanban‐control enjoys many…

720

Abstract

Considers manufacturing systems with a failure‐prone machine and a stochastic demand. The production is controlled by a kanban scheme. Although the kanban‐control enjoys many applications, in a stochastic setting, the problem of defining the optimal number of circulating kanbans remains unsolved except for some special cases. Seeks an optimal kanban‐controlled policy which minimizes long run average inventory and backlog costs. Uses perturbation analysis to estimate the gradients of the cost functional with respect to the number of circulating kanbans, and then employs an iterative algorithm, which is a constant step‐size stochastic approximation procedure, to find the optimal number of circulating kanbans. Proves that the perturbed path is a shifted version of the nominal path, and the gradient estimate is consistent. Also conducts numerical experiments to investigate the performance of the proposed algorithms.

Details

International Journal of Operations & Production Management, vol. 15 no. 9
Type: Research Article
ISSN: 0144-3577

Keywords

Article
Publication date: 1 June 1988

D. Fallon and J. Browne

This paper describes the development and early use of a test bed for Just‐In‐Time GIT) control of Flexible Assembly Systems (FAS). JIT has, up to now, been used in repetitive…

450

Abstract

This paper describes the development and early use of a test bed for Just‐In‐Time GIT) control of Flexible Assembly Systems (FAS). JIT has, up to now, been used in repetitive manufacturing systems. However, increasingly, companies involved in batch production who frequently use Materials Requirements Planning (MRP) approaches, are seeking to achieve the benefits of JIT, and to use Kanban type control at the operational level. The test bed simulation can be configured by the user to model a range of assembly systems each of which can, within limits, be configured by the experimenter. It is built using the SLAM II simulation package. Kanban cards are modelled as resources, as are the individual assembly stations and the transportation devices which carry work between the assembly stations. The test bed can be used to experiment with batch sizes, set‐up times, assembly station breakdowns, various Kanban sequences, varying purchasing lead times, etc. It allows experimentation with the application of the Kanban system to manufacturing systems which are not purely repetitive in nature and more closely resemble batch manufacturing systems.

Details

International Journal of Operations & Production Management, vol. 8 no. 6
Type: Research Article
ISSN: 0144-3577

Keywords

Article
Publication date: 31 July 2018

José Chiu-C. Chen and Chen-Yang Cheng

The commercialization of non-profit organization (NPOs) has become a trend. Nonetheless, during the process of providing services and manufacturing products, NPOs frequently…

3064

Abstract

Purpose

The commercialization of non-profit organization (NPOs) has become a trend. Nonetheless, during the process of providing services and manufacturing products, NPOs frequently encounter obstacles, such as distinctive organizational characteristics and social loafing, which hinder development. These obstacles impede effective production management process, especially in responding to market competitive logic and associated demands. The purpose of this paper is to assist NPOs in resolving the unique challenges posed by commercialization.

Design/methodology/approach

This study first examined related literature on the social loafing and Lean-Kanban model. Subsequently, existing service procedures of the Assistive Technology Resource Center were introduced, and the loafing situation and operational management issues within the organization were analyzed. Based on observed experiences in the case study, this study investigated the social loafing situation that NPOs are likely to encounter during the commercialization process. Adaptive strategies were then proposed to mitigate this situation. Finally, this study presents a summary and analysis of the study results, and offers recommendations regarding future research directions.

Findings

The findings of this study provide valuable information regarding NPOs commercialization, indicating that an understanding of the non-profit concept in relation to internal and external customers must be incorporated into the commercialization process. Social loafing is a sensitive topic in organizational research, particularly for NPOs without HR professionals. This study recommends that NPOs use Lean-management tools to reduce operational management issues caused by various social loafing situations. Further interdisciplinary, integrated research on the commercialization of NPOs of various types should be conducted to clarify concerns regarding the overall NPO commercialization environment.

Originality/value

This study examined a social welfare foundation and applied the Lean thinking model to investigate whether Lean-management tools alleviate and eliminate social loafing. The solution depends on interdisciplinary integrated research for improving NPO management practice. These management tools can be used to adjust the division of labor and reduce operational management problems caused by social loafing. These tools can provide NPOs with a reference for establishing a fair and equitable internal work environment and developing strategies that respond to market pressure and efficiency during commercialization.

Details

Journal of Organizational Change Management, vol. 31 no. 5
Type: Research Article
ISSN: 0953-4814

Keywords

Article
Publication date: 1 July 1993

A.Z. Keller and A. Kazazi

Examines Just‐in‐Time (JIT) from its evolution as a Japaneseconcept through to a review of its philosophy and implementation. Citesseveral techniques of implementation. Includes a…

2605

Abstract

Examines Just‐in‐Time (JIT) from its evolution as a Japanese concept through to a review of its philosophy and implementation. Cites several techniques of implementation. Includes a review of the early work of various researchers and practitioners. Concludes that JIT is a very effective manufacturing philosophy which is universal in nature encompassing all aspects of manufacturing. Suggests a few deficiencies in current literature.

Details

Industrial Management & Data Systems, vol. 93 no. 7
Type: Research Article
ISSN: 0263-5577

Keywords

Article
Publication date: 1 July 1995

D.J. Stockton and R.J. Lindley

Functional plant layouts are normally adopted in organizations thatmanufacture large varieties of components in low annual volumes.Attempts to improve the efficiency of these…

3242

Abstract

Functional plant layouts are normally adopted in organizations that manufacture large varieties of components in low annual volumes. Attempts to improve the efficiency of these layouts have normally focused on the identification and implication of group technology cells which process a limited range of parts using flow process principles. Cell layouts provide the condition for kanban control procedures to operate, hence the benefits of just‐in‐time can be achieved in batch processing environments. However, in high variety/low volume (HV/LV) environments there is often insufficient commonality between part types to justify the formation of cells. Describes an alternative plant layout procedure (process sequence cell layout) currently being developed that allocates equipment to cells according to their position in the process routes of components. Uses a case study to illustrate how such a layout may be identified for an organization that has a typical high variety/low volume environment. Discusses the problems that need to be overcome if such systems are to be implemented and offers a description of how integrated MRP II/kanban control mechanisms can be used to control production.

Details

International Journal of Operations & Production Management, vol. 15 no. 7
Type: Research Article
ISSN: 0144-3577

Keywords

Article
Publication date: 1 June 1993

Scott R. Swenseth, Krishnamurty Muralidhar and Rick L. Wilson

Addresses the dynamic, continual‐improvement nature of the JITimplementation process. Learning curves are incorporated to analyse theimpact of continual reduction of processing…

Abstract

Addresses the dynamic, continual‐improvement nature of the JIT implementation process. Learning curves are incorporated to analyse the impact of continual reduction of processing time variation over time. The results provide valuable information on the relationship between the level of processing time variation, the output rate of the production system, and inventory between work processes. The methodology used in this study incorporates an additional dimension in analysing JIT. It also provides a general and effective tool for decision makers facing the complex task of implementing pull production processes.

Details

International Journal of Operations & Production Management, vol. 13 no. 6
Type: Research Article
ISSN: 0144-3577

Keywords

Article
Publication date: 1 March 1988

FRANCIS PEYRONNET

Manufacturing companies are facing up to the challenge of reducing lead‐time and in‐process stocks, and increasing flexibility. Kanban methods are being seen as an essential tool…

Abstract

Manufacturing companies are facing up to the challenge of reducing lead‐time and in‐process stocks, and increasing flexibility. Kanban methods are being seen as an essential tool in meeting the challenge. Francis Peyronnet, manager of Kanban and Production Control for Bendix Electronics, France, outlines the steps required for implementing Kanban links between several production workshops.

Details

Logistics World, vol. 1 no. 3
Type: Research Article
ISSN: 0953-2137

21 – 30 of over 1000