MRP-production planning in agile manufacturing

Over the years many researchers have been investigating the area of MRP production planning and still is an area of high interest today. This paper look at production planning where there is unpredictable demands due to the type of product and market a company produces for. Production planning becomes difficult when demand fluctuates unpredictably, and hence a historical sales forecast is used as the initial data for production planning. The sales from previous years, especially in a seasonal market, don't necessarily correlate well to the current and future sales for the next year. A planner working in such environment would have himself frustrating to create a feasible production plan that not only needs to meet customer's demands but also to built up the 'correct' amount of stock for that peak sell season. To overcome some of these problems, This work describes a production planning methodology that can be implemented robustly and quickly. This paper has studied two multi-item lot-sizing problems. We detailed the development of the planning problem mathematically and highlight some solutions to initial problems investigated.

MRP-production planning in agile manufacturing

The research studied a production planning problem in a manufacturing firm. Some production planning software was developed that enabled the efficient and rapid reproduction of an optimum production forecast. Not only was the production cost reduced but a significant length of planning time cn be saved using the software.

Decision support tool for production planning of a machining line

A decision support tool for production planning was developed to perform the difficult and time consuming task of allocating resources within the industrial partner's machining line, consisting of identical Computerized Numerically Controlled machines. The production-planning tool identified significant labour savings in a number of the industrial partner's production plans.

Aggregate planning for seasonal demand : reconciling theory with practice

Purpose: The paper reports on the ramifications for production planning when monthly sales exhibit predictable seasonal highs and lows. The literature first acknowledged and dealt with the (aggregate planning) problem 50 years ago. Nevertheless, there is neither evidence that industry has adopted any of the mathematical techniques that were subsequently developed, nor a convincing explanation as to why not. Hence this research sets out to discover the methods manufacturers use to cope with seasonal demand, and how germane the published algorithms really are.

Design/methodology/approach: Forty-two case studies were compiled by interviewing senior managers and then conducting plant tours. No prior assumptions were made and the list of questions covered the gamut of production planning.

Findings: The main finding is that manufacturers select a straightforward production strategy, right from the outset, so the fundamental cost-balancing format is not relevant. The majority pick a “chase” strategy, since most organizations subscribe to a “just in time” ethos. Whenever a different strategy is preferred the rationale springs from skilled labour considerations or binding facilities constraints. The chosen strategy serves as a road map for resources acquisitions, and the master production schedule is constructed directly. So, the complex issue of how to disaggregate an optimal aggregate plan never even arises. Managers do not seek perfect solutions, but strive to eliminate, or contain, the most significant marginal costs. The nature of the business determines the most appropriate tactics to employ.

Originality/value: These findings break the mould as far as orthodox aggregate planning is concerned and show why theory is at odds with practice, whilst reaffirming the importance of concepts such as “flexibility”, “integration”, and “just-in-time production”.

Simulation-based support tool for operator performance in batch manufacturing

In industry, the workload and utilization of shop floor operators is often misunderstood. In this paper, we will present several real case studies, using Discrete Event Simulation (DES) models, which allow us to better understand operators in a batch manufacturing environment. The first study investigates labour in a machining plant consisting of multiple identical CNC machines that batch produce parts. The second study investigates labour in an eight station, gravity die casting rotary table. The results from these studies have shown that there can be potential improvements made by the production planners in the current labour configuration. In the first case study, a matrix is produced that estimates what the operator's utilization levels will be for various configurations. From this, the preferred operator to machine ratio over a range of cycle times is presented. In the second study, the results have shown that by reducing the casting cycle time, the operator would be overloaded. A discrete event simulation of these two cases highlighted areas that were misunderstood by plant management, and provided them with a useful decision support tool for production planning.

A decision support tool for resource allocation in batch manufacturing

A decision support tool for production planning is discussed in this paper to perform the job of machine grouping and labour allocation within a machining line. The production plans within the industrial partner have been historically inefficient because the relationship between the cycle times, the machine group size, and the operator's utilisation hasn't been properly understood. Starting with a simulation model, a rule-base has been generated to predict the operator's utilisation for a range of production settings. The resource allocation problem is then solved by breaking the problem into a series of smaller sized tasks. The objective is to minimise the number of operators and the difference between the maximum and minimum cycle times of machines within each group. The results from this decision support tool is presented for the particular case study.

Development of an optimum factory model for a manufacturing operation through computer simulation

Often manufacturing enterprises will maintain high levels of Work In Progress (WIP) to maximise production throughput. Using computer simulation, this thesis investigates a manufacturing facility and identifies an optimal level of WIP. At this optimum throughput is maximised, manufacturing lead times are minimised, and the WIP level is significantly reduced.

Strategy not tactics drives aggregate planning

The aggregate planning model supposedly shows how manufacturers cope with seasonally biased sales. Unfortunately, industry has failed to embrace any of the sophisticated algorithms that were developed to solve the corresponding resources allocation problem. This paper reveals why such methods have proven so unattractive. Aggregate planning is a chimera. In practice, planners construct the master production schedule directly, in line with a preferred production strategy. A “chase” plan is the most popular choice. When this option proves infeasible, management plumps for another predetermined strategy. The resultant stockpiling brings certain financial risks. However, companies take various measures to reduce their exposure.

IT based approaches for integrating construction safety regulations with construction planning

The concept of a construction accident is extending from the traditional construction operation accident to contain all non-construction operation accidents in personnel's safety and health, global and local environment, and the insufficient facility planning for security and emergency. Construction accidents may cause human, social and sustainable tragedies directly, and indirectly delay construction progresses and adversely affect the reputation of construction industry. In order to reduce all possible construction accidents, lots of non-construction operation regulations are constituted according to the authoritative regulations and previous construction experiences. However, these non-construction operation regulations are not integrated with the construction production or process planning. This may cause that some of these non-construction operation regulations ,are disregarded in the practical construction progress. The aim of this research is to explore the possibility, methodology and techniques in practice in order to identify and specify the non-construction operation regulations for every individual construction production and process. Therefore, the construction planning does not only represent the time and resources of each construction product or process, but also its non-construction operation regulations. The main outcomes of this research are a systematic identification of non-construction operation regulations, and the potential techniques for integrating them with the construction planning.

Visualisation development for building demolition planning

Demolition has recently been more concerned with the potential damage to the environment by its generated wastes. Waste exchange is apparently the main means by which the problem is currently dealt with. There is little or no consideration on wastes during the planning or designing stage. By utilising a knowledge system and visualisation technologies, a waste management plan can be integrated into the 4D model so as to effectively promote the interactions between demolition waste demanders and the demolition designer. As a result, the 4D visualisation provides not only the graphical schedule for the demolition process, but also the waste handling plan and waste production schedule. This research aims to analysis the integration technology of a waste management plan and the 4D visualisation model for a demolition project and to discuss the related technical and management issues. The integrated demolition visualisation enables to facilitate waste handling during the demolition processes thus to achieve environmentally friendly demolition.

Waste production simulation for building deconstruction projects

The recently erected concept of building deconstruction has significantly promoted building components and materials reuse and recycling where building is carefully dismantled into reusable parts. Current research and practices of building deconstruction mainly focus on issues of process before and during the deconstruction such as hazardous material detection, deconstruction design and deconstruction technology. The issues after the deconstruction project are rarely considered. Waste reuse and recycling are enabled through deconstruction yet not practically achieved, and especially the demands of waste building components and materials are hard to appear and match the actual waste production in a building deconstruction project. To deal with this awkward situation, the waste production needs to be conducted in a demand-oriented way. It needs to be thoughtfully planned and scheduled prior to the physical deconstruction as an essential portion of deconstruction project planning and scheduling. Furthermore, the relationship between waste production and structural characteristics of the building creates a serious consideration affecting a deconstruction plan. As a result, a waste production simulation will facilitate waste reuse and recycling in a deconstruction project. It serves as a crucial section of deconstruction planning and design. This research aims to describe the concept of waste production simulation and investigate various management and technical aspects of waste production simulation for building deconstruction projects.

Investigation into the interactive multimedia production processes of novice multimedia designer /producers in a constructivist environment

The main purpose of this study was to investigate the instructional interactive multimedia (IMI) production processes of adult novice multimedia production course. The study aimed at discovering whether a constructivistic teacher-learning environment facilitated these multimedia novice designer / producers to further develop metacognitivestates of higher-order thinking like schema formation, problem-solving and cognitive construction when producing their interactive multimedia project. To achieve this study examined the facilitative and limiting activities in planning, design and development that have assisted or hindered the NMDPs during their multimedia production work This research utilises a qualitative paradigm and makes extensive use of multiple data sources such as the participants’ proposals, planning aids, logs and final projects for single as well as cross-case analyses and discussion. Three cases were selected for in-depth analysis in the study because they provided interviews and more complete documentation and "thick descriptions" of their multimedia production activities. Findings about the NMDPs multimedia production endeavours showed that they learnt best about multimedia technology for teacing and learning by producing an interactive multimedia project themselves. Factors that enabled some of the NMDPs to flourish in a constructivistic environment included their ability to utilise their new and extended schemata to problem solve, their self regulation and a creative and positive attitude to demanding multimedia work NMDPs who utilised facilitative planning aids and design strategies produced impressive work. The study further indicates that the NMDPs’ holistic multimedia production experience made them aware of the levels of complexity involved and boosted their confidence about multimedia production for educational purposes. Suggestions for further research include examining the production styles of adult multimedia novices and young novices and investigating the implications of designing multimedia for large audience presentation rather than for single or small group learner usage.

Culture clash : artistic production and the school environment

Artists-in-schools programs involving contemporary art practices can be transformational for the participants when environmental considerations are integral to the planning and structure of the project and both the form and content of the program are reflected upon critically.

Exposing young children to music through the production and presentation of music-appreciation television programs

This paper reports on a research study of the effectiveness of a series of music-appreciation activities for young children in Hong Kong. These activities were designed using world music and were presented as part of a local early childhood television program for community interest. One-undred-and-sixty-eight local preschool children (mean age 4.25) and their classroom teachers, from 16 childcare centres or kindergartens, participated in this study. Qualitative data was collected using individual structured interviews with both children and teachers. The data showed that these music-appreciation activities enriched children's musical experiences and teachers' musical repertoires in early childhood settings. Teachers also showed positive preferences to learn the activities using multimedia tools. Implications for the curriculum planning and teacher training of early childhood music education are discussed.

Virtual Werribee : a planning support tool

Virtual Werribee is collaborative research in applying 3-D modelling and visualisation as a planning support tool in comparison to 2-D plans and drawings. It was a joint initiative involving Deakin University and the Wyndham City Council to demonstrate the use of 3-D visualisation for planning process in the actual context of a planning authority in Australia. The objective of this project was to assist the council in preparing for the revised Local Structure Plan. By reconstructing the council’s data into easily understood information, 3-D model and visualisation served as a verification and discussion tool for decision making. The integration of wider site context also provided a better understanding of the surrounding development areas. This could equip other stakeholders as well as the community to participate in council’s planning agenda activities, such as increasing the urban density and building heights limit.

Virtual Werribee included the development planning agenda, categorised as new, re-development and hypothetical. The modelling process progressed with sufficient data from the council. Some changes to the initial plan were made, including the use of CAD modelling software instead of GIS software, and production of a block model with selected detail buildings, instead of a full draped 3-D model. The council decided that the block model would be sufficient for their planning purposes. This was determined while taking into consideration the available facilities at the council.

The potentials of the model as a planning tool were demonstrated in this paper, and further compared to the council’s existing materials prepared by the project developers. The advantages of the 3-D interactive model and visualisation over the conventional materials have provided the council officer with a tool for better empowerment in the planning process. This was also evident in the increasing engagement level between the officer and the model as the process developed. As a result of this, the project scope has also expanded, finally covering the entire city.

While Virtual Werribee has the potential to better communicate council’s planning agendas to the stakeholders and the community, the key factor, coupled with its visualisation components, was its interactive capability. Property layers with aerial site image that provided a realistic background served as a virtual city platform for different users. Although limited in its analytic capability found in GIS software, this model offered high visualisation content to assist visual impact assessment through its interactive mode along with a series of still images and a simulation movie.