An Integrated Production System Model and Project Plan Restricted Pull-Way Production Control Method for Lean Shipbuilding

Abstract:

Shipyards are facing challenges when trying to manage their project plan under make to order mode and, at the same time, control their production process in a pull way according to the lean manufacturing principle. A Lean shipbuilding planning and pull-way control integrated system (LSPCIS) model is established, which provides the architecture of realizing the lean principle in planning and production control area for shipbuilding. Then, a Project Plan Restricted Pull-way production control method (PPRP) is introduced where the bottom level is based on pull principle, while under the restriction of receding horizon plan and project plan. The study reveals that even under the make to order production mode of shipbuilding, it is still possible to establish a leanness oriented planning and production Control system, where the receding horizon plan can work as a middle level between the project plan and pull-way production control. The result of a production process simulation is introduced at the end of the paper, to validate the advantage of the PPRP control method comparing with the normal KANBAN control and pure push way of material delivery.

• Periodical: Applied Mechanics and Materials (Volumes 385-386)
• Pages: 1852-1859
• DOI: https://doi.org/10.4028/www.scientific.net/AMM.385-386.1852
• Online since: August 2013
• Authors: Ming Di Zong, Hou Fang Sun
• Keywords: Lean Manufacturing, Production Control, Receding Horizon Plan, Shipbuilding

References

[1] Luo Zhenbi, Me Ruhu, Luo Jie, et. Lean Production and Management (Part three): The Progression of world manufacturing, World Manufacturing Engineering & Market, vol 5(2007), pp.90-97.

[2] Zhang Minghua, Huang Sheng, Lean Shipbuilding-Study of Japanese Shipbuilding System, Ship Engineering, Vol 27(2005), pp.62-66.

[3] Jeffrey K. Liker, The Toyota Way, Beijing, China Financial & Economic Publishing House(2004).

[4] Lan Boxiong, Jiang Nan, Dynamic Enterprise Resource Optimization Model Based on Rolling Planning, Operations Research and Management Science, vol 19(2010), pp.136-143.

[5] S. Pierucci, G. Buzzi Ferraris, Rolling-Horizon Algorithm for Scheduling under Time-Dependent Utility Pricing and Availability, Pedro M. Castro, Iiro Harjunkoski, Ignacio E. Grossmannc, 20th European Symposium on Computer Aided Process Engineering, vol 28(2008).

DOI: 10.1016/s1570-7946(10)28196-8

[6] Shao Hao, Chen Hunping, Sun Guangzhong, et., Efficient rolling horizon algorithms for resources-constrained scheduling problems with buffers, Systems Engineering～Theory＆Practice, vol 30(2010), pp.119-125.

[7] Pan Quanke, Zhu Jianying, Rolling time horizon Job Shop Scheduling Strategy in Dynamic Environment, Journal of Nanjing University of Aeronautics and Astronautics, vol 37(2005), pp.262-268.

[8] Liu Yi, Gao Qi, Job Selection Method of Job Rolling Scheduling Based on Rough-Neural Network, Modular Machine Tool and Automatic Manufacturing Technique, ( 2010) pp.104-107.

[9] Spearman, M.L., Woodruff, D.L., Hopp, W.J., CONWIP: A pull alternative to Kanban, International Journal of Production Research, vol 23(1996), p.879–894.

DOI: 10.1080/00207549008942761

[10] Richard P. Marek, Debra A. Elkins Donald R. Smith, Understanding the Fundamentals of Kanban and CONWIP Pull Systems Using Simulation, Proceedings of the 2001 Winter Simulation Conference(2001), pp.921-929.

DOI: 10.1109/wsc.2001.977394

[11] Spearman M. and Zazanis,M., Push and pull production systems: Issues and comparisons, Operations Research, vol 40(1992), p.521–532.

DOI: 10.1287/opre.40.3.521

[12] Lee L C. A, comparative study of the push and pull productions systems, International Journal of Operations and Production Management, vol 9(1989), pp.5-18.

[13] Jose M. Framinan, Pedro L. Gonza' Lez, Rafael Ruiz-Usano, The CONWIP production control system: review and research issues, Production Planning & Control, vol 4(2003), p.255–265.

DOI: 10.1080/0953728031000102595

[14] Spearman, M., Customer service in pull production systems, Operations Research, vol 40(1992), p.948–958.

DOI: 10.1287/opre.40.5.948

[15] Bonvik, A. M., Couch, C. E., and Gershwin, S. B., A comparison of production-line control mechanisms, International Journal of Production Research, vol 35(1997), pp.789-804.

DOI: 10.1080/002075497195713

[16] Kumar Satyam and Ananth Krishnamurthy, Performance evaluation of a multi- product system under CONWIP control, IIE Transactions, vol 40(2008), p.252–264.

DOI: 10.1080/07408170701488086

[17] Luo Ming, Gu Hanyu, CONWIP Release Method in Multi-reentrant Production Lines, Computer Simulation, vol 23(2006), pp.232-235.

[18] Brüggemann, Wolfgang Jahnke, Hermann, The discrete lot-sizing and scheduling problem: Complexity and modification for batch availability, European Journal of Operational Research, vol 124(2000), p.511–528.

DOI: 10.1016/s0377-2217(99)00190-3

[19] Bonvik, A. M., and Gerhwin, S. B., Beyond Kanban: Creating and analyzing lean shop floor control policies, Manufacturing and Service Operations Management Conference Proceedings, Dartmouth College, The Amos Tuck School, Hanover, New Hampshire 03755(1996).

[20] Framinan, J. M., Ruiz-Usano, R., Leisten, R., Input control and dispatching rules in a dynamic CONWIP flow-shop, International Journal of Production Research, vol 38(2000), p.4589–4598.

DOI: 10.1080/00207540050205523