Development of a Raw Material Requirement Balancing Model for a Production Process

Abstract:

Attainment of accuracy in raw materials mix for production processes has been the major problem in many production organizations in developing countries. Effects of unequal proportions of material required for a production process are not fully considered in the past studies. This study modeled the raw material requirements in a production process using proportionality based mixed linear programming approach. The objective was to find optimal mix of raw materials for the production of a unit tonnage of a product. The performance of the model was tested by comparing it with alternatively formulated model based on conventional material mix. This model was tested using a cement production system from which blasted limestone, crushed limestone; raw meal, gypsum, red alluvium, clinker and coal were used as raw materials. The conventional method of mixing materials led to 50 % surplus and shortage of materials in the process as compared with the new scheme. The model would be a good tool for accurate prediction of quantity of the raw material required in the production process.Nomenclature, the proportion of material used per ton of the processed product, the quantity of material in processed product (ton), the material proportional per ton of the product, andthe total quantity of materials needed per ton of the product,..., the counter for material type,..., the counter for material proportionality variant

• Periodical: Advanced Materials Research (Volume 824)
• Pages: 490-498
• DOI: https://doi.org/10.4028/www.scientific.net/AMR.824.490
• Online since: September 2013
• Authors: B. Kareem
• Keywords: Modeling, Process Parameter, Production, Raw Material, Waste Management

References

[1] M.A. Louly, A. Dolgui, Optimal MRP parameters for a single item inventory with random replenishment lead time, POQ policy and service level constraint, International Journal of Production Economics 143 (2013) 35-40.

DOI: 10.1016/j.ijpe.2011.02.009

[2] J.P. Garcia-Sabater, J. Maheut, J.A. Marin-Garcia, A new formulation technique to model materials and operations planning: The generic materials and operations planning (GMOP) problem European Journal of Industrial Engineering 7 (2013) 119-147.

DOI: 10.1504/ejie.2013.052572

[3] M.M. Jansen, T.G. de Kok, J.C. Fransoo, Lead time anticipation in Supply Chain Operations Planning, OR Spectrum 35 (2013) 251-290.

DOI: 10.1007/s00291-011-0267-y

[4] C. Öztürk, A.M. Örnek, A MIP based heuristic for capacitated MRP systems, Computers and Industrial Engineering 63 (2012) , pp.926-942.

DOI: 10.1016/j.cie.2012.06.005

[5] R. Guillaume, P. Zieliński, Decision making under scenario uncertainty in a requirement planning Communications in Computer and Information Science 300 CCIS (PART 4), 2012 pp.104-113.

DOI: 10.1007/978-3-642-31724-8_12

[6] R.J. Milne, C.J. Wang, C.K.A. Yen, K. Fordyce, Optimized material requirements planning for semiconductor manufacturing, Journal of the Operational Research Society 63 (2012), pp.1566-1577.

DOI: 10.1057/jors.2012.1

[7] W.J. Lewis, A mathematical model for assessment of material requirements for cable supported bridges: Implications for conceptual design, Engineering Structures 42 (2012) 266-277.

DOI: 10.1016/j.engstruct.2012.04.018

[8] D. Kovačić, L Bogataj, Multistage reverse logistics of assembly systems in extended MRP Theory consisting of all material flows, Central European Journal of Operations Research, 19 (2011) 337-357.

DOI: 10.1007/s10100-010-0168-1

[9] K. Feng, U.S. Rao, A. Raturi, Setting planned orders in master production scheduling under demand uncertainty, International Journal of Production Research, 49 (2011) 4007-4025.

DOI: 10.1080/00207543.2010.495955

[10] T. Timm, A. Blecken, A method for the hierarchical planning of the structure, dimension and material requirements of manufacturing systems, International Journal of Production Research 49 (2011) 3431-3453.

DOI: 10.1080/00207543.2010.495735

[11] A.A. Najafi, N. Zoraghi, F. Azimi, Scheduling a project to minimize costs of material requirements World Academy of Science, Engineering and Technology 78 (2011).

[12] Y. Chang, M Fang, Study on the model for the requirement planning of well-drilling materials Journal of Xi'an Shiyou University, Natural Sciences Edition 25 (2010) 96-98.

[13] T. Wuttipornpun, U, Wangrakdiskul, W. Songserm, An algorithm of finite capacity material requirement planning system for multi-stage assembly flow shop World Academy of Science, Engineering and Technology 46 (2010) 499-509.

[14] C.T. Leu, T.C. Wen, K.H. Chang, Development and application of a decision model for the integrated production and material planning of color filter manufacturing industry: An empirical studyInternational Journal of Industrial Engineering : Theory Applications and Practice, 17 (2010).

[15] Z. Guo, M. Qi, Research on the demand forecast of emergency material based on fuzzy Markov chain, 2010 International Conference on E-Product E-Service and E-Entertainment, ICEEE2010 , art. no. 5661145, (2010).

DOI: 10.1109/iceee.2010.5661145

[16] H. Xu, J. Zheng, Z. Wang, L. Yu, Research on materials sequence supply model of mixed-model productionper, 2010 Proceedings - 2010 WASE International Conference on Information Engineering, ICIE 2010 2 , art. no. 5571247 (2010) 71-75.

DOI: 10.1109/icie.2010.113

[17] N. Tu, X. Luo, H. Huang, T. Chai, B. Zheng, Method for hot rolling planning considering material requirements of downstream production lines, 2010 Proceedings of the World Congress on Intelligent Control and Automation (WCICA) , art. no. 5554758 (2010).

DOI: 10.1109/wcica.2010.5554758

[18] D.C.L. Yien, I. Kree, 2010 Practical material forecasting methodology & requirements planning application for semiconductor, IEEE International Conference on Industrial Informatics (INDIN), art. no. 5549668 (2010) 640-642.

DOI: 10.1109/indin.2010.5549668

[19] D. Xue, D., X. Huang, X. 2010, Material substitution selection algorithm for complex equipment assembling production, 2010 International Conference on Mechanic Automation and Control Engineering, MACE2010 , art. no. 5535623 (2010) 3305-3308.

DOI: 10.1109/mace.2010.5535623

[20] WAPCO, Environmental Audit Report of the West African Portland Cement PLC Ewekoro and Shagamu Quarries, Submitted to the Federal Ministry of Environment, Abuja by the West African Portland Cement PLC, Elephant House, Alausa Ikeja, Lagos, Nigeria, 2008, p.1.

DOI: 10.1177/1420326x07083572

[21] S. Ogbeide, Development of an Expert System for Process Planning in Cement Production, PhD Thesis in the Federal University of Technology, Akure, (2011).

[22] K. Seren, An Expert System for choosing the type of Ready Mix Concrete, The Nordic Concrete Federation, Finland, 1988, pp.45-49.

[23] B.H. Amstead, Manufacturing Processes, John Wiley and Sons, Canada, 1999, pp.705-710.

[24] J. Bielawski, and C. Lewand, An Expert System for Computer Fault Diagnosis, First International Joint Conference on Artificial Intelligence, 1997, pp.843-845.

[25] K.T. Davis, and S.P. Lenat, A knowledge based system for Factory Scheduling Expert Systems, 2001, pp.25-39.

[26] J.M. Fox, and P.K. Smith, Software and its Development, third, ed., Prentice Hall Inc., New Jersey, (1984).

[27] M.P. Groover, and E.W. Zimmers, Automation, Production System and Computer Integrated Manufacturing, third ed., Prentice Hall Inc., New Jersey, (1987).