Production Control in Practice - Ooijen, Henny van

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Résumé :

Practice-oriented coverage of production planning and control processes for goods and services, written for any industry

Production Control in Practice explores the operational control of production and inventory processes in organizations across industries, covering both tangible and intangible products and offering viable, efficient solutions to characteristic production control problems, such as what goods to produce when and how. A number of examples/stylized applications are included to help readers understand and apply the discussed concepts and theories to their own organizations.

This book distinguishes between the control of production units and the control of goods flow between these units and the market and discusses various coordination and material supply control mechanisms relevant to supply chains. It also presents a typology of production situations found in practice, using a structured approach to discussing the relevant control decisions for each situation.

This book is unique because (basic) control decisions are discussed for the different characteristic Decoupling Point Control and Production Unit Control situations from a holistic point of view, taking into account both mathematical considerations as well as various situational factors.

Sample topics covered in Production Control in Practice include:

• Terminology and concepts used in production control, including complexity, uncertainty, and flexibility
• Types of release triggers, covering just-in-time versus just-in-case and push versus pull in logistics
• Horizontal and vertical decomposition, and time series-related forecasting for stationary demand versus demand with trend
• Order size, covering optimal batch size in case of fixed order size, relaxation of assumptions, and single period considerations
• MRP systems, covering Material Requirements Planning (MRP-I) and Manufacturing Resource Planning Systems (MRP-II)

With excellent coverage of the subject across different products and industries and several examples to help readers follow along, Production Control in Practice is an ideal reference for bachelor students from universities of applied sciences and academic bachelor students, as well as practitioners in related disciplines....

Biographie:

Preface xi

Part I Production Control in General 1

1 Production Control - A Logistic Control Function 3

1.1 Logistics 3

1.2 Logistics Planning and Control 6

1.3 Logistic Concepts in Production 7

1.4 Terminology for Production Control 10

1.4.1 Concepts Used in Production Control 10

1.4.2 Complexity, Uncertainty, and Flexibility 12

References 13

2 Horizontal and Vertical Decomposition 15

2.1 Horizontal Decomposition 16

2.2 Vertical Decomposition 22

2.3 Types of Release Triggers 25

2.3.1 Just-in-Time Versus Just-in-Case 25

2.3.2 Push Versus Pull in Logistics 28

2.4 An Example of Decomposition 30

References 32

3 Planning and Control in Production Units 33

3.1 Production Control in General 33

3.2 Basic Forms of Production 35

3.2.1 Process-Wise Production 35

3.2.2 Mass Assembly/Flow Production 36

3.2.3 (Repetitive) Small Series Production (Also Called Job-Shop) 36

3.2.4 (Repetitive) Project-Wise Production 37

3.2.5 Throughput Time Production Units 37

References 39

4 Framework for Logistic Planning and Control in Production Systems 41

4.1 General Framework 41

4.2 Position of this Book 45

References 46

Part II Planning and Control of Decoupling Points 47

5 Decoupling Point Control 49

5.1 Decoupling Point Control - An Introduction 49

5.2 Performance Measures for Decoupling Point Control 53

5.3 Demand and Forecasting 58

5.3.1 Demand Pattern 59

5.3.2 Forecasting Methods 60

5.3.2.1 Time Series-Related Forecasting for Stationary Demand 63

5.3.2.2 Time Series-Related Forecasting for Demand with a Trend 67

5.4 Order Size 71

5.4.1 Optimal Batch Size in Case of Fixed Order Size 72

5.4.2 Relaxation of Assumptions 75

5.4.2.1 Known or Predicted Demand Variation 75

5.4.2.2 Quantity Discount 78

5.4.2.3 Minimum Order Quantity 79

5.4.2.4 No Variable Order-Related Costs 79

5.4.2.5 Interdependencies of Order Sizes - Not BOM Related 80

5.4.2.6 Interdependencies of Order Sizes - BOM Related 81

5.4.3 Single Period Problem 83

Appendix 5.A The Wagner-Whitin Algorithm 84

Appendix 5.B Example Impact Advanced and Optimal Approach for Determining Batch Sizes 87

Appendix 5.C Newsvendor Problem 87

References 90

6 Reorder Point Decoupling Point Control Systems 93

6.1 General Discussion of Reorder Point Systems 93

6.2 When to Order? 96

6.2.1 Continuous Review 97

6.2.2 Periodic Review 99

6.2.3 The Reorder Level - Continuous Review 100

6.2.4 The Reorder Level - Periodic Review 107

6.3 How Much to Order? 109

6.3.1 Fixed Amount 109

6.3.2 Maximum Level 109

6.3.2.1 (s, S) 109

6.3.2.2 (R, s, S) 110

Appendix 6.A Table of the One-Sided Standard Normal Distribution 110

Appendix 6.B Table Standard Normal Loss Function 112

Appendix 6.C Reorder Level Determination in Case of a General Distribution 113

6.C.1 Discrete Demand 113

6.C.2 Continuous Demand 115

6.C.3 Determining the Reorder Level 116

References 116

7 MRP Decoupling Point Control Systems 117

7.1 General Discussion of MRP Systems 117

7.1.1 Material Requirements Planning (MRP-I) 117

7.1.2 Manufacturing Resources Planning (MRP-II) 119

7.1.2.1 Engine 119

7.1.2.2 Front End 120

7.1.2.3 Back End 121

7.2 When to Order 122

7.3 How Much to Order? 125

7.4 Discussion on MRP-Related Issues 128

7.4.1 De...

Sommaire:

Henny Van Ooijen, PhD, is Professor in Production and Operations Management at the School of Industrial Engineering of Eindhoven University of Technology, The Netherlands. He teaches Introduction to Industrial Engineering, Analyses of Production, Warehousing and Transportation Systems, and other courses.

Corn? Dirne, PhD, is Professor in Operational Excellence at the Fontys University of Applied Sciences, The Netherlands. Earlier, he was senior lecturer and curriculum coordinator for Industrial Engineering at Avans University of Applied Sciences.