A simulation and comparative study of the CONWIP, Kanban and MRP production control systems in a cold rolling plant

Huang, Min; Wang, Dingwei; Ip, W. H.

doi:10.1080/095372898233579

Cited by 22 publications

(11 citation statements)

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“…Utilisations of the tableting machine and packaging line do not change significantly. These results are in line with the findings presented by Gupta and Gupta (1989), Yavuz and Şatir (1995b) and Huang, Wang, and Ip (1998).…”

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confidence: 96%

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Integrating Kanban principles in a pharmaceutical campaign production system

Strohhecker

Sibbel

Dick

2013

Production Planning & Control

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Centralised planned campaign production is the predominant production system in process industries. In this study, we investigate whether a decentralised Kanban control system, which has proven to offer advantages in other industries, can be successfully integrated in a campaign production environment. The used research methodology combines model-based and case-study-based elements. Using the example of a pharmaceutical internal five-stage supply chain, we conceive a Kanban concept that integrates campaign formation, develop a discrete-event simulation model and conduct a range of explorative simulation experiments. We find that a Kanban campaign production system is not merely feasible but would also be favourable: throughput times can be reduced without increasing customer lead times. Sensitivity analysis shows that the system's performance is relatively robust to changes in Kanban key configuration parameters such as number of Kanban cards or campaign size. We conclude by discussing our findings and formulating three propositions that might stimulate future research.

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confidence: 96%

“…Simulation approaches are also used to compare various versions of pull and/or push policies based on real cases (e.g. Huang, Wang, and Ip 1998;Yang 2000;Khojasteh-Ghamari 2009). …”

Section: Introductionmentioning

confidence: 99%

Integrating Kanban principles in a pharmaceutical campaign production system

Strohhecker

Sibbel

Dick

2013

Production Planning & Control

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“…They showed that the optimal hybrid push/pull is effectively CONWIP/pull. Huang et al (1998) developed simulation models to compare the performance among MRP, kanban and CONWIP systems implemented in a semi-continuous manufacturing environment: a cold rolling plant. The results showed that CONWIP is the most efficient among the three control systems, which can greatly decrease the WIP, average inventory and average inventory costs and meanwhile provide a higher throughput rate and facility utilization.…”

Section: Comparison Between Different Types Of Production Schedulingmentioning

confidence: 99%

Comparing dynamic risk-based scheduling methods with MRP via simulation

Sun

Heragu

Chen

et al. 2012

International Journal of Production Research

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Material Requirements Planning (MRP) is one of the earliest production scheduling approaches that utilizes computers. MRP is still regarded as one of the most widely used systems for production scheduling. Even though MRP has made contributions, there are some fundamental problems (i.e. the assumption of infinite capacity and fixed lead times) which make the MRP system vulnerable to effects of uncertainty. To overcome this fundamental flaw, there was a trend towards the development of detailed finite-capacity scheduling systems (i.e. MRP II, ERP, and APO). All these MRP-based systems still ignore variability and randomness and are inherently push systems. Instead of creating a detailed schedule based on forecast, Factory Physics Inc. developed Dynamic Risk-Based Scheduling (DRS), which creates a set of policy parameters (e.g. WIP level, lot sizes, reorder point, and reorder quantity) that work for a range of situations to calculate the production schedule. IV This thesis compares the key performance measures of DRS and MRP-based scheduling systems. We begin with a single-machine problem and develop simulation models for varying levels of uncertainty in forecast demand (i.e. base demand scenario, underestimated scenario and overestimated scenario) and two levels of variability in the system (i.e. moderate variability and no variability). Then the experiment is extended to multiple-machine problems. We also introduce more constraints into the DRS and MRP models to improve their performance. We also test the performance of MRP models for different planning horizons. We find that the DRS strategy is more robust to forecast error than MRP-based strategies. DRS also usually obtains better performance than MRPbased models in terms of higher fill rate and lower inventory. v

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“…A literatura sobre o CONWIP (tanto CNE quanto o H) é relativamente vasta. Dentro desta literatura, merecem destaque a utilização do CONWIP para a gestão da cadeia de suprimentos (OVALLE;MARQUEZ, 2003) e estudos que trazem comparações entre a performance do CONWIP e a de outros SCO, como por exemplo: CONWIP e Kanban (TAKAHASHI; MYRESHKA, 2005;NAKAMURA, 2002); CONWIP e MRP (RODERICK et al, 1994); CONWIP, Kanban e MRP (HUANG et al, 1998); CONWIP, Kanban, estoquebase e combinação Kanban-CONWIP (BONVIK et al, 1997); CONWIP e DBR (KOH; BULFIN, 2004); dentre muitos outros.…”

Section: Sistema Conwip H (Híbrido)unclassified

Sistemas de coordenação de ordens: revisão, classificação, funcionamento e aplicabilidade

Fernandes

Filho

2007

Gest. Prod.

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O foco deste trabalho são os ordering systems, os quais são sistemas de informação que programam ou organizam as necessidades em termos de componentes e materiais e/ou controlam a emissão/liberação das ordens de produção e compra, podendo conter ou não regras de seqüenciamento das ordens. Dentro deste contexto, o presente artigo tem por objetivos: apresentar uma nova nomenclatura para os ordering systems, sistemas de coordenação de ordens de produção e compra (SCO); apresentar uma tipologia que permita classificar os diversos sistemas de forma racional; destacar alguns sistemas altamente promissores em termos de aplicação e que são relativamente desconhecidos no Brasil e, trazer à tona um tema importantíssimo dentro do planejamento e controle da produção (PCP) e que está um tanto esquecido na literatura científica nacional.

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A simulation and comparative study of the CONWIP, Kanban and MRP production control systems in a cold rolling plant

Cited by 22 publications

References 0 publications

Integrating Kanban principles in a pharmaceutical campaign production system

Integrating Kanban principles in a pharmaceutical campaign production system

Comparing dynamic risk-based scheduling methods with MRP via simulation

Sistemas de coordenação de ordens: revisão, classificação, funcionamento e aplicabilidade

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