Using bottlenecks to control production inventory

In this paper, we investigate how to best optimise the level of Production Inventory or Work In Progress (WIP) in a factory. Using a simulation model of the factory, we show that a level of inventory can be optimised by controlling the buffer levels of the key bottleneck workcenters. By firstly identifying the key bottlenecks, and then systematically reducing the maximum buffer level for each bottleneck, results show that the throughput does not drop rapidly from it's high levels until the WIP is halved. Conversely, the production lead time decreases rapidly and levels out around the point of the optimum WIP level.

Simulating the change from a push to pull production system

This paper will document the initial discrete-event simulation performed to study a proposed change from a push to a pull system in an existing manufacturing company. The system is characterised by five machine lines with intermediate buffers, and five major part groupings. A simulation model has been developed to mimic the flow of kanban cards in the physical system, by using a series of requests that propagate back through the facility, which the machines must respond to. The customer
demand therefore controls the level of activity in the plant. The results of the initial modelling steps will be presented in this paper, especially the impact of kanban lot size and demand variability on the output and stability of the production system, from which a set of future work is proposed.

Analysis of stamping production data with view towards quality management

A quality analysis trial was undertaken at Ford Geelong Stamping Plant on a press line that was fitted with standard press sensors to measure press and binder force over the stamping cycle for each panel. The quality of randomly sampled panels was measured by obtaining the panel thicknesses at five points, for 135 panels in total. These points were chosen such that they exhibited different forming modes. This paper analyses the input force data and the output quality data from the trial to determine any potential relationships. The analysis of the production data was performed using statistical correlation techniques to determine initial potential relationships between input and output variables. An Active Shape Model was used to extract features when identifying the major sources of variation within the input data. However, the initial analysis of the data elicited no direct relationship between the input variables measured and the panel thicknesses. This result is significant as the data collected is from a standard sensor configuration found in many press lines through-out the world. The reason for the lack of a direct relationship is believed to come from the lack of sensitivity in the force measurements which are not able to identify small changes in the process, whereas gross geometric variations have in previous studies shown an obvious relationship with changes in the force press profile. This means that existing force sensors require augmentation by additional sensors if a detailed automatic quality control system for the press lines based on input sensors alone.

Application of co-operative agents in handling fluctuations in a pull production system

This paper presents the general details of the structure and strategy of a multi-agent system that is being developed to improve the performance of pull (kanban) production control to handle large fluctuations in product demand. Employing a set of generic, heterarchial agents each controlling a single product and co-operating together to ensure that all components, regardless of demand fluctuation, are manufactured on time as per basic kanban principles. Preliminary results indicate that the basic kanban model does not cater for large demand fluctuations and the application of this multi-agent strategy may be beneficial to improving the overall system performance and increase the likelihood that all products will be manufactured on time.

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.

Farm-level efficiency and productivity measurement using panel data: wool production in south-west Victoria

In this article we explore some issues surrounding the use of farm-level efficiency and productivity estimates for benchmarking studies. Using an eight-year balanced panel of Victorian wool producers we analyse annual variation between estimates of farm-level technical efficiency derived using Data Envelopment Analysis and Malmquist estimates of Total Factor Productivity. We find that farms change their relative rank in terms of efficiency across years. Also, unlike aggregate studies of Total Factor Productivity, we find at best erratic and modest growth, a worrying result for this industry. However, caution is needed when interpreting these results, and for that matter, benchmarking analysis as currently practised when using frontier estimation techniques like Data Envelopment Analysis.

The culture-based fisheries in small, farmer-managed reservoirs in two provinces of northern Vietnam: an evaluation based on three production cycles

In this paper the results of a study conducted on the culture-based fisheries in small (ranging from 2 to 160 ha), farmer-managed reservoirs in YenBai and ThaiNguyen Provinces in the northern highland region of Vietnam, for the production cycles of 1997/98, 98/99 and 99/00 are presented. The small reservoirs are leased to small farmers by the provincial authorities for fishery activities, and all lessees adopt culture-based fisheries when fingerlings of grass carp (Ctenopharyngodon idella), silver carp (Hypophthalmichthys molitrix), bighead carp (Aristichthys nobilis), common carp (Cyprinus carpio) and mrigal (Cirrihinus mrigala) are stocked between March and mid-April each year and harvested, using large seine nets, after approximately 11-12 months. The mean yields from reservoirs in YenBai and ThaiNguyen Provinces in 97/98, 98/99 and 99/00 production cycles were 251, 332 and 253, and 331, 372 and 210 kg ha⁻¹ respectively. There were major differences in the fish productivity in the reservoirs in the two Provinces, and in a reservoir between culture cycles. The stocking strategies appeared to be rather ad hoc, being determined by the availability of seed stock and the financial status of the lessees. Accordingly, there was no apparent consistent trend in the improvement of yields from the culture-based fishery practice throughout the growth cycles. The fish yields in reservoirs in each Province were significantly related to reservoir area (exponentially) and to mean weight of stocked fish and conductivity (logarithmically). Of the stocked fish, the highest returns were obtained with mrigal and bighead carp, which collectively contributed > 50% to the harvest. The return from common carp was the lowest. The mean growth rate of grass carp (2.7 g day⁻¹), followed by bighead carp (2.0 g day⁻¹) was the highest in reservoirs in YenBai Province, bighead carp (4.0 g day⁻¹) followed by grass carp (3.2 g day⁻¹) was the highest in ThaiNguyen Province. The seed stocked on average accounted for 65% and 48% of the total operating costs in YenBai and ThaiNguyen Provinces, and the mean cost:benefit ratio of the culture-based fishery in the two Provinces was 0.35 and 0.37 respectively. The culture-based fishery on average contributed about 28% to the gross income of a farmer lessee.