Research on enhancement of TOC Simplified Drum-Buffer-Rope system using novel generic procedures

Lee, Jun-Huei; Chang, Jia-Ging; Tsai, Chih‐Hung; Li, Rong-Kwei

doi:10.1016/j.eswa.2009.11.049

Cited by 27 publications

(42 citation statements)

References 22 publications

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“…A reliable due-date assignment means DDP is kept at least 80%. Schragenheim and Dettmer (2001), Schragenheim (2006) and Lee et al (2010) stated that by adopting the conventional SDBR method, high DDP can be achieved in a non-RFS environment. However, the above-mentioned drawbacks made the conventional SDBR not efficient when applied to a random RFS and motivated this research.…”

Section: Introductionmentioning

confidence: 97%

“…However, high penetrations between multi-reentrant orders in front of CCR are not modelled, and uncertainties were not taken into account. Lee et al (2010) further defined BS as the dispatching rule of CCR. In other words, the order with the high value of BS results in a higher sequence of CCR.…”

Section: Introductionmentioning

confidence: 99%

“…They still did not take the re-entry and uncertainties into consideration. Moreover, Lee et al (2010) defined that if CCR is located in the front end of the routing, the order release date is equal to the PL minus PB multiplied by α, where α is a positive number below 0.5. They also defined that if CCR is located in the back end of the routing, the order release date is equal to the PL minus PB multiplied by β, where β is a positive number between 0.5 and 1.…”

Section: Introductionmentioning

confidence: 99%

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An enhanced model for SDBR in a random reentrant flow shop environment

Chang

Huang

2013

International Journal of Production Research

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This study proposed an enhanced simplified drum-buffer-rope (SDBR) model to be applied in a reentrant flow shop (RFS) in which job processing times are generated from a discrete uniform distribution and machine breakdowns are subject to an exponential distribution. In this enhanced SDBR model, the due-date assignment method, order release rule and dispatching rule were improved. The due dates and release dates of orders were determined by considering the total planned load of the capacity-constrained resource (CCR) in a random RFS. The deviation rate of buffer status is used as a dispatching rule to eliminate the influence of machine breakdowns. Simulations based on a real case company are used to evaluate the effective of the proposed model. The experimental results showed that our approach yields better performance than the other methods in terms of six due-date-related indexes when the product mix is with a large proportion of multi-reentrant orders and when the utilisation of CCR increases from 60 to 90%.Keywords: simplified drum-buffer-rope; due-date assignment; reentrant flow shop; random environments IntroductionThis research enhanced the simplified drum-buffer-rope (SDBR) method to be applied in a random reentrant flow shop (RFS). In a RFS, job processing times are deterministic, and machines are subject to randomly breakdown. In most cases, the constraint in a make-to-order (MTO) environment is market demand, and the order due date represents the market demand. Schragenheim and Dettmer (2001) introduced the SDBR method that can be easily applied in most MTO environments when other methods seem to be complicated in practice. SDBR is a management structure which includes not only the due-date assignment method but also order release rule and dispatching rule. In SDBR, the drum is treated as the due-date assignment method, and the rope is treated as the order release rule. Furthermore, the buffer is treated as the dispatching rule for a bottleneck machine on shop floor. The detail of SDBR method is described in Subsection 2.1. We found that when SDBR method was implemented in a random RFS (such as machine breakdowns) in practice, two potential drawbacks may be found. The first potential drawback is about the due-date assignment method (i.e. the drum) and the order release rule (i.e. the rope). The SDBR method utilises the planned load on one bottleneck machine to determine both the due dates and the release dates of all orders. The planned load of an order depends only on when it is arrived without considering if the process flow has re-entry property or the random breakdown situations on the bottleneck machine. The second potential drawback is about the dispatching rule (i.e. the buffer). The SDBR method (hereby referring as the 'conventional SDBR') utilises the priorities based on buffer status (BS) to dispatch jobs. Two jobs may receive the same priorities even when they are at different reentrant layers. The priorities may also be distorted when random breakdowns occur on the bottleneck machine.In order...

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Section: Introductionmentioning

confidence: 97%

Section: Introductionmentioning

confidence: 99%

Section: Introductionmentioning

confidence: 99%

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An enhanced model for SDBR in a random reentrant flow shop environment

Chang

Huang

2013

International Journal of Production Research

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“…The only different is that in S_DBR the market demand is the major system constraint. Lee et al (2010) examined two conditions that handled with SDBR solutions. They considered following characteristics and solved an example: (1) capacity constraint resource (CCR) is not always located in the middle of the routing.…”

Section: Literature Reviewmentioning

confidence: 99%

A Markov chain analysis of the effectiveness of drum-buffer-rope material flow management in job shop environment

Rabbani

Tanhaie²

2015

10.5267/j.ijiec

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The theory of constraints is an approach for production planning and control, which emphasizes on the constraints in the system to increase throughput. The theory of constraints is often referred to as Drum-Buffer-Rope developed originally by Goldratt. Drum-Buffer-Rope uses the drum or constraint to create a schedule based on the finite capacity of the first bottleneck. Because of complexity of the job shop environment, Drum-Buffer-Rope material flow management has very little attention to job shop environment. The objective of this paper is to apply the Drum-BufferRope technique in the job shop environment using a Markov chain analysis to compare traditional method with Drum-Buffer-Rope. Four measurement parameters were considered and the result showed the advantage of Drum-Buffer-Rope approach compared with traditional one.

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“…To Georgiadis and Politou (2013), DBR approaches provide production managers with effective tools to manage production disruptions and improve operational performance. To Lee et al (2010) DBR works effectively in typical job shop environments. Traditional DBR uses a three-buffer system to protect both the due-dates and detailed finite capacity schedule of the capacity constraint resources (CCR).…”

Section: It Is Verified In This Equationmentioning

confidence: 99%

Strategies for increasing productivity in production systems

Pacheco

Pergher

Jung

et al. 2014

Ind. Jour. Manag. & Prod.

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The main objective of this article is to point a set of practical strategies that can be adopted to increase the capacity of constraints resources on production systems, when the constraint is inside the factory and not is in the market. To serve this purpose will be presented strategies based on best practices of the Theory of Constraints, Lean Manufacturing and Total Productive Maintenance. This article also presents the mains tools for the deployment of these methodologies.The survey results have provided an objective set of practical strategy that can be used to increase the capacity and productivity of production systems according to the needs of each manufacturing system.

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Research on enhancement of TOC Simplified Drum-Buffer-Rope system using novel generic procedures

Cited by 27 publications

References 22 publications

An enhanced model for SDBR in a random reentrant flow shop environment

An enhanced model for SDBR in a random reentrant flow shop environment

A Markov chain analysis of the effectiveness of drum-buffer-rope material flow management in job shop environment

Strategies for increasing productivity in production systems

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