An full and extensive summary (100+ pages) based on the lecture slides complimented by chapters 1, 2, 3, 4, 5, 6, 7, 8, 9, 10, 12, 14, 15, 16 of the book: Lean Production for Competitive Advantage : A Comprehensive Guide to Lean Methodologies and Management Practices by John Nicholas 2th edition an...
Team-based Learning Sessions (TBL) questions & answers including literature
Summary of production planning and control
All for this textbook (8)
Written for
Rijksuniversiteit Groningen (RuG)
Pre-master Technology And Operations Management
Design and Planning of Production (EBB058B05)
All documents for this subject (2)
1
review
By: jennywiedebach • 1 year ago
Seller
Follow
tobiasschiphorst
Reviews received
Content preview
Summary Design and Planning of Production by Tobias Schiphorst
1. Manufacturing strategy, product/process matrix & resource based view ......................................... 6
1.1 Manufacturing strategy ................................................................................................................. 6
1.2 Product/Process matrix ................................................................................................................. 7
1.3 Resource based view ................................................................................................................... 12
1.4 Manufacturing Strategy: Defining the missing link Steven C. Wheelwright ............................... 14
1.4.1 Overview............................................................................................................................... 14
1.4.2 Management philosophy, driving forces and competitive advantage ................................. 14
1.4.3 Driving forces ........................................................................................................................ 15
1.4.4 Competitive priorities........................................................................................................... 15
1.4.5 Concept of manufacturing strategy ..................................................................................... 15
1.4.6 Three primary levels of strategy within manufacturing ....................................................... 16
1.4.7 Manufacturing functional strategy....................................................................................... 16
1.4.8 Manufacturing corporate strategy ....................................................................................... 16
1.4.9 Role of manufacturing in defining desired competitive advantage ..................................... 17
1.5 An Empirical Analysis of the Product-Process Matrix M. Hossein Safizadeh, Larry P. Ritzman,
Deven Sharma, Craig Wood .............................................................................................................. 17
1.5.1 Process choice ...................................................................................................................... 17
1.5.2 Process choice linked to product plans ................................................................................ 18
1.5.3 Process choice linked to competitive priorities ................................................................... 19
1.5.4 Process choice and performance ......................................................................................... 19
1.5.5 Propositions & findings ........................................................................................................ 19
1.5.6 Conclusion ............................................................................................................................ 20
1.6 A resource-based view of manufacturing strategy and the relationship to manufacturing
performance Roger G. Schroeder, Kimberly A. Bates and Mikko A. Junttila .................................... 21
1.6.1 Resource based view (RBV) .................................................................................................. 21
1.6.2 Manufacturing and RBV ....................................................................................................... 21
1.6.3 Internal learning ................................................................................................................... 21
1.6.4 External learning................................................................................................................... 22
1.6.4 Proprietary manufacturing processes and equipment ........................................................ 22
1.6.5 Manufacturing performance ................................................................................................ 22
1.6.6 Conclusions ........................................................................................................................... 22
2. Lean production ................................................................................................................................ 22
2.1 Introduction of Lean production ................................................................................................. 22
2.2 Lean toolbox ................................................................................................................................ 26
2.3 The human side of Lean .............................................................................................................. 36
1
,3. Layout and flow & small batches ...................................................................................................... 40
3.1 Layout and flow ........................................................................................................................... 40
3.2 Batch-size basics .......................................................................................................................... 43
3.3 Small batches............................................................................................................................... 43
3.3.1 Focus in batching .................................................................................................................. 43
3.3.2 Buffers .................................................................................................................................. 44
3.3.3 Cause of large batches.......................................................................................................... 44
3.4 Batch sizing .................................................................................................................................. 45
3.4.1 Batch-for-Batch and POQ ..................................................................................................... 45
3.4.2 Economic Order Quantity (EOQ) .......................................................................................... 45
3.4.3 Economic Manufacturing Quantity (EMQ) ........................................................................... 46
3.4.4 Batch size effects .................................................................................................................. 47
3.4.5 EOQ-based methods: Discussion .......................................................................................... 48
3.5 Appropriate coordination techniques ......................................................................................... 48
4. Scheduling ......................................................................................................................................... 49
4.1 What is scheduling ...................................................................................................................... 49
4.1.1 Why schedule ....................................................................................................................... 49
4.2 Mixed-Model Production: Heijunka ............................................................................................ 50
4.2.1 Heijunka ................................................................................................................................ 50
4.3 Priority rules ................................................................................................................................ 50
4.3.1 First-Come-First-Serve (FCFS) ............................................................................................... 51
4.3.2 Shortest-Processing-Time-First (SPTF) ................................................................................. 51
4.3.3 Earliest-Due-Date (EDD) ....................................................................................................... 52
4.4 Why should we schedule? ........................................................................................................... 52
4.5 Performance criteria & interconnections of planning................................................................. 53
4.6 An empirical investigation of scheduling performance criteria .................................................. 54
4.7 Outflanking Undecided Ever-changing puzzles ........................................................................... 56
4.7.1 Scheduling paradigms (models/theories) ............................................................................ 56
4.7.2 Why scheduling problems are difficult................................................................................. 56
4.7.3 Behavioural aspects of planning and scheduling ................................................................. 57
4.7.4 The organizational interconnectivity of planning and scheduling ....................................... 59
4.7.5 Computer support for planning and scheduling .................................................................. 60
4.7.6 Behavioural effects of using scheduling algorithms ............................................................. 60
4.7.7 Design methodology for scheduling support ....................................................................... 61
4.7.8 Discussion ............................................................................................................................. 62
5. Smart industry / Industry 4.0 ............................................................................................................ 63
2
, 5.1 Industrial revolutions .................................................................................................................. 63
5.2 Industry 4.0.................................................................................................................................. 63
5.3 Physical Internet (PI) ................................................................................................................... 64
5.4 Condition based maintenance (CBM) ......................................................................................... 64
5.5 Smart industry enablers .............................................................................................................. 64
5.6 Smart industry / industry 4.0 link to OM..................................................................................... 66
5.6 Paper : Industry 4.0 ..................................................................................................................... 68
5.6.1 Application-pull and technology-push ................................................................................. 68
5.6.2 Fundamental Concepts......................................................................................................... 68
5.6.3 Relevance for Business and Information Systems Engineering and Exemplary Fields of
Application..................................................................................................................................... 68
5.6.4 Summary and expected trends ............................................................................................ 69
5.7 Paper : Industry 4.0 Opportunities and challenges for operations management ...................... 69
5.7.1 Introduction .......................................................................................................................... 69
5.7.2 Additive manufacturing (3D printing) .................................................................................. 70
5.7.3 The Internet of Things .......................................................................................................... 70
5.7.4 Blockchain............................................................................................................................. 70
5.7.5 Advanced Robotics ............................................................................................................... 71
5.7.6 Artificial Intelligence ............................................................................................................. 71
5.7.7 Other technologies ............................................................................................................... 72
5.7.8 Conclusion ............................................................................................................................ 72
6. Pull production .................................................................................................................................. 73
6.1 Traditional coordination .............................................................................................................. 74
6.2 Pull production ............................................................................................................................ 74
6.3 2-bin system ................................................................................................................................ 75
6.4 Pull production with buffers (ROP) ............................................................................................. 75
6.5 Kanban ......................................................................................................................................... 76
6.5.1 Conveyance Kanbans ............................................................................................................ 77
6.5.2 Production Kanbans ............................................................................................................. 77
6.5.3 Lecture example Kanban ...................................................................................................... 78
6.5.4 More Kanban cards .............................................................................................................. 78
6.6 Rules for pull production with Kanban ........................................................................................ 79
6.7 Some additional notes................................................................................................................. 79
7. Cellular Manufacturing ...................................................................................................................... 80
7.1 What is Cellular Manufacturing? ................................................................................................. 80
7.2 From Process layout to Cellular Manufacturing .......................................................................... 80
3
, 7.2.1 Planning and control ............................................................................................................ 81
7.2.2 Organizational issues ............................................................................................................ 81
7.2.3 Attitudinal issues .................................................................................................................. 81
7.3 (Dis)advantages of Cellular Manufacturing ................................................................................. 81
7.4 How are the cells determined (group technology) ..................................................................... 82
7.4.1 Focused factories.................................................................................................................. 82
7.5 Group formation.......................................................................................................................... 83
7.5.1 Group technology (GT coding) ............................................................................................. 83
7.5.1 Visual cluster analysis ........................................................................................................... 83
7.5.2 Production Flow Analysis (PFA) ............................................................................................ 83
7.6 Binary Ordering algorithm example ............................................................................................ 84
7.6.1 Dense blocks, Then what? .................................................................................................... 87
7.6.2 Binary Ordering algorithm .................................................................................................... 87
7.7 Now organize the group itself ..................................................................................................... 88
7.7.1 Work cell design ................................................................................................................... 88
7.7.2 Assembly workcell formulas ................................................................................................. 88
7.7.3 Machining workcell formulas ............................................................................................... 90
8. Line balancing .................................................................................................................................... 90
8.1 Line production ........................................................................................................................... 91
8.1.1 Flow line ............................................................................................................................... 91
8.2 Balancing ..................................................................................................................................... 91
8.3 Line balancing .............................................................................................................................. 91
8.3.1 Line Balancing steps ............................................................................................................. 92
8.3.2 Precedence diagram; production of bicycles ....................................................................... 92
8.3.3 Calculate the efficiency of a sequence of workstations ....................................................... 93
8.3.4 Longest processing time ....................................................................................................... 93
8.3.5 Weighted average time ........................................................................................................ 97
8.3.6 Rank Positional Weight example .......................................................................................... 98
8.3.7 Uncertainty in task times.................................................................................................... 102
4
The benefits of buying summaries with Stuvia:
Guaranteed quality through customer reviews
Stuvia customers have reviewed more than 700,000 summaries. This how you know that you are buying the best documents.
Quick and easy check-out
You can quickly pay through credit card or Stuvia-credit for the summaries. There is no membership needed.
Focus on what matters
Your fellow students write the study notes themselves, which is why the documents are always reliable and up-to-date. This ensures you quickly get to the core!
Frequently asked questions
What do I get when I buy this document?
You get a PDF, available immediately after your purchase. The purchased document is accessible anytime, anywhere and indefinitely through your profile.
Satisfaction guarantee: how does it work?
Our satisfaction guarantee ensures that you always find a study document that suits you well. You fill out a form, and our customer service team takes care of the rest.
Who am I buying these notes from?
Stuvia is a marketplace, so you are not buying this document from us, but from seller tobiasschiphorst. Stuvia facilitates payment to the seller.
Will I be stuck with a subscription?
No, you only buy these notes for $4.81. You're not tied to anything after your purchase.