Analysis of production resources improvement strategies in make-to-stock environments managed by the simplified drum-buffer-rope system

Abstract

Theory of Constraints (TOC) states that every system has a single constraint that limits its performance, on which improvement efforts should be concentrated. This paper compared, through computer simulation, several methods of identifying the capacity-constrained resource in the perspective of a process of continuous improvement. Six make-to-stock (MTS) production line configurations managed by the Simplified Drum-Buffer-Rope (S-DBR) system were simulated, in which six improvement methods were applied, three of them based on the TOC literature, and their performance measured and compared in terms of cycle time and order fill rate. The results showed that, in balanced systems, improvements spread over all resources allowed better results, because, in this case, it is necessary to improve everything to benefit the overall performance. In unbalanced environments, on the other hand, the three methods recommended by TOC, which recommend efforts concentrated on the weakest point of the system, achieved superior performance, with emphasis on the strategy based on the level of utilization. In addition to advancing the frontiers of knowledge in continuous improvement and TOC, the research results show that managers should focus their attention on the resource with the highest degree of utilization to get better and faster performance gains.

Analysis of a support method for offering delivery promises in environments managed by S-DBR system

“…To ensure that analysis of the proposed model takes into account the variability and uncertainties typical of productive environments, simulation was chosen as a research method, allowing new theories to be developed and knowledge about existing theories expanded (Davis et al, 2007;Banks et al, 2004;Borges et al, 2020). A further point that justifies the choice of simulation is that it has already been used to analyze the DBR, S-DBR and BM methods (Ok & Park, 2014;Millstein & Martinich, 2014;Lee & Seo, 2016;Thürer & Stevenson, 2018;Castro et al, 2022;Narita et al, 2021;Govoni et al, 2021;Thürer et al, 2022;Costa et al, 2023;Ikeziri et al, 2023).…”

Aplicación de la teoría de restricciones en un proceso productivo con enfoque a la industria 4.0

“…En el artículo (Govoni et al, 2021) "Analysis of production resources improvement strategies in make-to-stock enviroment managed by the simplified drum-buffer-rope system" se simulan mediante la informática varios métodos de identificación del recurso con limitación de la capacidad dentro de un proceso de mejora continua. En este paper toman en cuenta seis configuraciones de líneas de producción gestionadas por el sistema simplificado tambor-reserva y soga, de los seis métodos de mejora aplicados, tres de ellos basados en Teoría de Restricciones basándose el rendimiento mediante el tiempo de ciclo y la tasa de cumplimiento de pedidos.…”