Finite Capacity Material Requirement Planning System for a Multi-stage Automotive-Part Assembly Factory (original) (raw)
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Finite capacity material requirement planning with supplier constraints
International Journal of Industrial and Systems Engineering, 2014
This paper aimed to develop a practical finite capacity material requirement planning (FCMRP) system based on the needs of an automotive-part manufacturing company in Thailand. The approach includes a linear programming model to determine the optimal start time of each operation to minimize the weighted average of total earliness, total tardiness, and average flow-time considering the finite capacity of all work centers and precedence of operations. Important factors of the proposed FCMRP system were objective function weights and dispatching rules. Effects of these factors on the performance measures were statistically analyzed based on a real situation of an auto-part factory. Statistical results showed that the dispatching rules and objective function weights had significant effects on the performance measures of the proposed FCMRP system. The proposed FCMRP system offered a good trade-off between conflicting performance measures and resulted in the best weighted average performance measure when compared with conventional forward and forward-backward finite capacity scheduling systems.
This paper aims to develop a practical finite capacity MRP (FCMRP) system based on the needs of an automotive parts manufacturing company in Thailand. The approach includes a linear goal programming model to determine the optimal start time of each operation to minimize the sum of penalty points incurred by exceeding the goals of total earliness, total tardiness, and average flow-time considering the finite capacity of all work centers and precedence of operations. Important factors of the proposed FCMRP system are penalty weights and dispatching rules. Effects of these factors on the performance measures are statistically analyzed based on a real situation of an auto-part factory. Statistical results show that the dispatching rules and penalty weights have significant effects on the performance measures. The proposed FCMRP system offers a good trade- off between conflicting performance measures and results in the best weighted average performance measures when compared to conventio...
E3S Web of Conferences
Production is one of the most important activities which guarantee the continued existence of man; however, it comes with its challenges which make it very difficult to meet up the consumer’s demand. In this regard, the system is required by production and manufacturing companies, human resources, and materials to be enhanced by scheduling and planning of production. In addressing this problem of scheduling over a mid-term possibility, material flow and production objectives should be forecast by solving the problems of planning. Only when the production planning problems have been solved then scheduling problems could be addressed. In this work, we relate scheduling with capacity planning in relation to the production of goods and services. Also reviewed the common problems associated with the industry and how they are overcome.
Finite capacity planning algorithm for semiconductor industry considering lots priority
IFAC-PapersOnLine, 2015
A finite capacity planning heuristic is developed for semiconductor manufacturing with highmix low-volume production, complex processes, variable cycle times and reentrant flows characteristics. The proposed algorithm projects production lots trajectories (start and end dates) for the remaining process steps, estimates the expected load for all machines and balances the workload against bottleneck tools capacities. It takes into account lots' priorities, cycle time variability and equipment saturation. This algorithm helps plant management to define feasible target production plans. It is programmed in java, and tested on real data instances from STMicroelectronics Crolles300 production plant which allowed its assessment on the effectiveness and efficiency. The evaluation demonstrates that the proposed heuristic outperforms current practices for capacity planning and opens new perspectives for the production line management.
Production and Machine Scheduling System Integrated with Materials Requirement Planning
Isico 2013, 2013
Production and machine scheduling is important for any corporation in order to meet the customers demand. Literatures show that integration between customer orders and materials availability is important combination. This paper presents the prototype for a production and machine scheduling system to improve and maximize the integration with materials requirement planning. In this paper, a software development life cycle was applied as the research methodology. The authors used unified modeling language for the analysis and design of the application. After requirements identification phase, the application prototype was built and presented to the application users. The results of this research are an application prototype that helps to record production data and could be accessed to know the production process integrated with materials requirement planning.
Research Square (Research Square), 2023
Material requirements planning (MRP) is an intelligent information system and a decision maker that determines the type of raw materials, the amount of them, and their supplying time in order to realize production schedule of products and work-in-process items in a manufacturing system. The inputs of MRP model include bill of materials, master production schedule, lead times, and inventory of the items. The main output of the model is material supplying schedule, and MRP sub-outputs include purchase advice, control report for the consumed items, nancial planning, budgeting, and so on. If in each manufacturing system we split production costs into three kinds of raw material costs, salary costs, and overhead costs, in the real environment, 60-90 percent of total costs are related to raw material costs. Therefore, in each manufacturing system, it is necessary to consider an appropriate inventory control system to control the costs of inventory system and provide right inventory, with right amount, at the right time, at the right price, and with appropriate quality. In this research, two constraints on the size of the packaging of goods and the minimum order amount that a supplier provides for a product are added to the model. By closing the existing gap, the mentioned model can be operationally implemented and provide appropriate decision-making outputs. Therefore, at rst, we will review the introduction and previous researches that have been done in this eld. Then, we will describe the components of the material requirements planning model. In the following, the abovementioned two constraints are added to the model and the material requirements planning system is presented.
Development of a rule-based finite capacity scheduling system
International Journal of Production Economics, 1994
This paper discusses the use of the finite capacity planning model as a basis for a job-shop scheduling system. The suitability of this approach for constructing short term schedules with very short lead times is examined. This paper introduces a rule-based scheduling system whose operation, unlike previous monolithic schedulers, is based around distinct though interlinked processes. Scheduling herein is defined as the selection of a set of orders for manufacture, and the allocation of processing time to each on an acyclic network of processing resources. The objectives are, firstly, compliance with all customer deadlines and, secondly, the efficient utilisation of available machine time and prevailing machine setups.
i ii Advanced planning and scheduling systems in manufacturing planning and control processes Abstract An advanced planning and scheduling (APS) systems is defined as any computer program that uses advanced mathematical algorithms or logic to perform optimization, and/or simulation on finite capacity scheduling, sourcing, capital planning, resource planning, forecasting, demand planning and others. The expectations of APS systems have been high, both from academia and industry in the subject area of manufacturing planning and control. Relative the massive interest there has not been much written about how APS systems are used in practice and what effects an APS approach really results in. This thesis focuses on the use of APS systems in manufacturing planning and control (MPC) processes, and the research questions is to explore how APS can support these processes, which benefits that can be achieved and which prerequisites to consider when using APS systems. Three case studies have been conducted including seven case companies that use APS in different MPC processes. The results are presented in four appended papers. Empirical data from the case studies have mainly been conducted thorough interviews with actors involved in MPC processes.
Applied Sciences
The overwhelming majority of methodologies for the flexible flow shop scheduling problem proposed so far have a common feature, which is the assumption of constant time and cost for the execution of individual technological operations (ignoring an optimal selecting combination of individual employees and tools). Even if the existence of the influence of the selection of production resources on the course of operations is signaled in the available works, the research so far has not focused on the measurable effect of such a solution that takes into account this phenomenon in scheduling. The proposed production scheduling methodology, including the influence of employees and tools, turned out to be more effective in terms of minimizing the maximum completion time and the cost of the production process compared to existing solutions. The efficiency of the new proposed scheduling methodology was assessed using examples of four technological processes. The research was carried out on the...
For a company's long-term profitability, most important processes are the way it starts parts of the manufacturing process before the customer order arrives and the way it determines and promises delivery quantities and times for the customer orders. In practical computer applications Material Requirement Planning and/or Reorder point systems are the base techniques mostly used. This article presents Cover-Time Planning, a variant of a reorder point system. Cover-Time Planning (CTP) is developed with a forward-looking forecasted demand rate and the decision variable is "time", instead of "quantity" for an ordinary reorder-point system. MRP and CTP are introduced and compared through a numerical example. MRP and CTP must treat practical "make-to-order"; therefore, this paper discuss available-to-promise, planning bills, and other help systems for practical applications of Master Production Scheduling. The paper presents how and why, in practice, a Master Production Scheduling system with an available-topromise function should be used and how this system should be designed. It is also argued that a fully Enterprise Resource Planning (ERP) system cannot only be created by MRP, but also by CTP.