Model of Production Planning and Control with the Integration of WLC and TOC Mechanism

Abstract:

In the mixed-production context of make-to-stock (MTS) and make-to-order (MTO), the manufacturing system becomes more complex for comprehensive balance of multiple objectives, including resource utilization, work in process (WIP), on-time delivery and throughput. To deal with this complexity, a dynamic production plannning and control (PPC) model with the hybrid of workload control (WLC) and theory of constraint (TOC) is presented. While the proposed three-tiered hierarchy construction model is relatively similar to WLC model, but the way in which the workloads are controled has changed dramatically. The order acceptance deals with issues of order review and delivery setting in order to balance the overall resource capacity and requirements that is necessary for on-time delivery. The order release deals with issues of release mechanisms and rules in order to control the flow of work to the production floor that is necessary for WIP and resource utilization.And the scheduling deals with issues of bottleneck identicification and task sequencing in order to protect the bottleneck capacity that is necessary for throughput.

• Periodical: Advanced Materials Research (Volumes 433-440)
• Pages: 2230-2236
• DOI: https://doi.org/10.4028/www.scientific.net/AMR.433-440.2230
• Online since: January 2012
• Authors: Ya Rong Chen, Hong Ming Zhou, Zai Lin Guan, Xin Yu Shao
• Keywords: Make-to-Order, Make-to-Stock, Production Plannning and Control, Theory of Constraint, Workload Control

References

[1] M.G. Mehrabi, A.G. Ulsoy, Y. Koren, P. Heytler, Trends and perspectives in flexible and reconfigurable manufacturing systems. Journal of Intelligent Manufacturing, Vol 13, pp.135-146, (2002).

DOI: 10.1023/a:1014536330551

[2] J. Riezebos G.J. Korte, M.J. LAND, Improving a practical DBR buffering approach using Workload Control. International journal of production research, Vol 41, pp.699-712, April (2003).

DOI: 10.1080/0020754031000065485

[3] M. Stevenson, L.C. Hendry, Aggregate load-oriented workload control: A review and a re-classification of a key approach International Journal of Production Economics, Vol 104, pp.676-693, December (2006).

DOI: 10.1016/j.ijpe.2005.05.022

[4] L.D. Fredendall, D. Ojha, and J. Wayne Patterson, Concerning the theory of workload control. European Journal of Operational Research, Vol 201, pp.99-111, (2010).

DOI: 10.1016/j.ejor.2009.02.003

[5] B.G. Kingsman, Modeling input-output workload control for dynamic capacity planning in production planning systems. International Journal of Producti on Economics, Vol 68, pp.73-93, (2000).

DOI: 10.1016/s0925-5273(00)00037-2

[6] H. Eivazy,M. Rabbani, M. Ebadian, A developed production control and scheduling model in the semiconductor manufacturing systems with hybrid make-to-stock/make-to-order products. International Journal of Advanced Manufacturing Technology, Vol 45, pp.968-986, (2009).

DOI: 10.1007/s00170-009-2028-5

[7] M. Wu,J. Jiang,W. Chang, Scheduling a hybrid MTO/MTS semiconductor fab with machine-dedication features. International Journal of Production Economics, Vol 112, pp.416-426, (2007).

DOI: 10.1016/j.ijpe.2007.04.008

[8] Chang SH, Pai PF, Yuan K J, Wang B C, Li RK, Heuristic PAC Model for hybrid MTO and MTS production environment. International Journal of Production Economics, Vol 85, pp.347-358, (2003).

DOI: 10.1016/s0925-5273(03)00121-x

[9] L.D. Fredendall and B.R. Lea, Improving the product mix heuristic in the Theory of Constraints. International Journal of Production Research, Vol 35, p.1535–1544, (1997).

DOI: 10.1080/002075497195100