A double decoupling postponement approach for integrated mixed flow production systems

Ni, Yanting; Wang, Yi

doi:10.1108/k-10-2014-0229

Cited by 4 publications

(3 citation statements)

References 18 publications

(19 reference statements)

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“…Manuj et al (2014) develop approaches to supply chain management involving postponement practices, assessing their impacts on system performance and considering the supply-side risk through a simulation model. Ni and Wang (2015) present a simulation approach that uses double decoupling postponement (DDP) to respond to external variations of requests in real time. An algorithm is incorporated to determine the work in process and available inventory days to allow comparison of inventory status and orders.…”

Section: Simulation and Its Applications Involving The Postponement Strategymentioning

confidence: 99%

Evaluation of postponement strategy in the production of table wine in Brazil: a discrete event simulation approach

Gualberto

Rodrigues

Ferreira

2021

IJWBR

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Purpose The purpose of this paper is to develop an approach to evaluate the partial postponement strategy and compare it with postponement and make-to-stock (MTS) strategies in the production of table wine in wineries in the state of Minas Gerais (south-eastern Brazil). Design/methodology/approach An approach based on discrete event simulation was developed to support decision-making in the wine sector. Simulation models were used to analyse partial postponement, postponement and MTS strategies in wine production. These models were inspired by a typical table wine producer selected from an exploratory study conducted in 12 wineries of Minas Gerais state in Brazil. Findings Hybrid strategies, such as partial postponement, favour the advantages of postponement and MTS depending on the portion of semi-finished and finished goods adopted. Wine production characteristics favour postponement and partial postponement with high semi-finished product levels (customer order-driven product) because this allows companies to reduce their inventory of bottles, despite possible increases in lost sales and costs. MTS and partial postponement with high finished product levels (forecast-driven product) present higher costs with bottled wine storage; however, these strategies reduce lost sales and improve agility and reliability in deliveries. Research limitations/implications Future research should analyse the production of table wines in other regions of the country and the production of fine wines. Practical implications The findings suggest promising perspectives for real-life applications in wineries in Brazil and other countries. Originality/value Simulation techniques allow the analysis of production strategies in little-known industries, such as table wine production in Brazil. The approach developed is flexible enough to support decisions and to be adapted to companies’ and markets’ characteristics and to test specific strategies.

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Section: Simulation and Its Applications Involving The Postponement Strategymentioning

confidence: 99%

Evaluation of postponement strategy in the production of table wine in Brazil: a discrete event simulation approach

Gualberto

Rodrigues

Ferreira

2021

IJWBR

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“…Ni and Wang (2015) assisted manufacturers in achieving real-time ordering and obtaining integrated optimization of shop floor production planning and scheduling for mixed flow production systems.…”

Section: Theoretical Backgroundmentioning

confidence: 99%

Implementation of hybrid Kanban-CONWIP system: a case study

Leonardo

Sereno

Silva

et al. 2017

JMTM

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Purpose Shop floor control systems are generally major points of discussion in production planning and control literature. The purpose of this paper is to investigate how lean production control principles can be used in a make-to-order (MTO) job shop, where the volume is typically low and there is high variety. This paper examines the procedures involved in implementing a constant work-in-process (CONWIP)/Kanban hybrid system in the shop floor environment and also provides insights and guidelines on the implementation of a hybrid system in a high-variety/low-volume environment. Design/methodology/approach The authors review literature on Kanban, CONWIP, and CONWIP/Kanban hybrid systems to analyze how lean production control principles can be used in a MTO job shop. The second part focuses on the process of implementation. Using a case study of a manufacturer of electromechanical components for valve monitoring and controls, the paper describes how the operation is transformed by for more efficient shop floor control systems. Real experiments are used to compare pre- and post-improvement performance. Findings The study shows that the proposed hybrid Kanban-CONWIP system reduced the cycle time and achieved an increase of 38 percent in inventory turnover. The empirical results from this pilot study provide useful managerial insights for a benchmarking analysis of the actions to be taken into consideration by companies that have similar manufacturing systems. Research limitations/implications The statistic generalization of the results is impossible due to the use of a single case method of study. Originality/value This paper provides insights and guidelines on the implementation of a hybrid system in a high-variety/low-volume environment. The literature on real applications of hybrid CONWIP/Kanban by case study is limited.

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“…The literature shows the adaptability PPCSs in industries with different environments. The case studies report the implementation of policies in environments with automated automobile assembly lines to job shops (Ni & Wang, 2015;Gilland, 2002;Parakash & Chin, 2014;Farnoush & Wiktorson, 2013;Slomp, Bokhorst & Germs, 2009;Yang, Fu & Yang, 2007). Reviewing the cases, the reported environmental conditions and barriers can highlight the areas of improvement in PPCS research.…”

Section: Introductionmentioning

confidence: 99%

Evaluation of pull production control strategies under uncertainty: An integrated fuzzy AHP-TOPSIS approach

Torkabadi

Mayorga

2018

JIEM

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Abstract:Purpose: Just-In-Time (JIT) production has continuously been considered by industrial practitioners and researchers as a leading strategy for the yet popular Lean production. Pull Production Control Policies (PPCPs) are the major enablers of JIT that locally control the level of inventory by authorizing the production in each station. Aiming to improve the PPCPs, three authorization mechanisms: Kanban, constant-work-in-process (ConWIP), and a hybrid system, are evaluated by considering uncertainty.Design/methodology/approach: Multi-Criteria Decision Making (MCDM) methods are successful in evaluating alternatives with respect to several objectives. The proposed approach of this study applies the fuzzy set theory together with an integrated Analytical Hierarchy Process (AHP) and a Technique for Order Performance by Similarity to Ideal Solution (TOPSIS) method. Findings:The study finds that hybrid Kanban-ConWIP pull production control policies have a better performance in controlling the studied multi-layer multi-stage manufacturing and assembly system. Practical implications:To examine the approach a real case from automobile electro-mechanical part production industry is studied. The production system consists of multiple levels of manufacturing, feeding a multi-stage assembly line with stochastic processing times to satisfy the changing demand.Originality/value: This study proposes the integrated Kanban-ConWIP hybrid pull control policies and implements several alternatives on a multi-stage and multi-layer manufacturing and assembly production system. An integrated Fuzzy AHP TOPSIS method is developed to evaluate the alternatives with respect to several JIT criteria.

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A double decoupling postponement approach for integrated mixed flow production systems

Cited by 4 publications

References 18 publications

Evaluation of postponement strategy in the production of table wine in Brazil: a discrete event simulation approach

Evaluation of postponement strategy in the production of table wine in Brazil: a discrete event simulation approach

Implementation of hybrid Kanban-CONWIP system: a case study

Evaluation of pull production control strategies under uncertainty: An integrated fuzzy AHP-TOPSIS approach

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