1. A GENERIC CONCEPT OF A MANUFACTURING SYSTEM FOR VARIOUS PLANNING AND EXECUTION SYSTEMS Nico J. Vandaele University of Antwerp Department of Technology Management nico.vandaele@ua.ac.be

2. Prof. Dr. Nico Vandaele, University of Antwerp Basic Dimensions of Planning Material Time Resources

3. Prof. Dr. Nico Vandaele, University of Antwerp Lead Time Distribution 0 0,01 0,02 0,03 0,04 0,05 1591317212529333741454953576165 f(t) Lead Time

4. Prof. Dr. Nico Vandaele, University of Antwerp Lead Time Distribution 0 0,01 0,02 0,03 0,04 0,05 1591317212529333741454953576165 f(t) Lead Time

5. Prof. Dr. Nico Vandaele, University of Antwerp Lead Time Reduction Safety time What about customer service and lead times quotes?

6. Prof. Dr. Nico Vandaele, University of Antwerp Lead Time Variability Reduction What about customer service and lead times quotes?

7. Prof. Dr. Nico Vandaele, University of Antwerp Combined Safety time What about customer service and lead times quotes?

8. Prof. Dr. Nico Vandaele, University of Antwerp Production Lead Times: Application for Planning? Material Requirements Planning Just In Time Theory Of Constraints Finite Scheduling ACLIPS POLCA...

9. Prof. Dr. Nico Vandaele, University of Antwerp MRP Logic Tube x Cap 1 Leg 4 Surface 1 Screw 16 Box 1 Table 1

10. Prof. Dr. Nico Vandaele, University of Antwerp MRP Logic

11. Prof. Dr. Nico Vandaele, University of Antwerp JIT Logic Box SurfaceScrew Cap Tube Cutting Welding Chroming Fixing Cap Assembly Quality Control Packing

12. Prof. Dr. Nico Vandaele, University of Antwerp TOC Logic Tube Cutting Welding Cap Chroming Fixing Cap Surface Assembly Box Quality Control Packing Screw

13. Prof. Dr. Nico Vandaele, University of Antwerp TOC Logic 202122232431302928272625 constraint rope constraint operation shipping rope releasedue-date

14. Prof. Dr. Nico Vandaele, University of Antwerp TOC Example 101 Time: Cash: 3000 Week Su Machines Pace: D-FG 9 8 7 6 4 3 5 2 1 RM Length in weeks: 2Weekly expenses: 11 000 H B-20 G C-10 R M-10 W-30 2 2 200 43 6 3 44 1 3 2 100 D C F 20 40 50 350 3 2 12 7 1 22 1 AB 60 10 40 9578 10 3 3 3 3 4 22 22 2 2 2 1 1 1 1 6 44 7 GE

15. Prof. Dr. Nico Vandaele, University of Antwerp FS Logic packing quality control assembly fixing cap chroming cutting welding

16. Prof. Dr. Nico Vandaele, University of Antwerp ACLIPS A Capacity and Lead Time Integrated Procedure for Scheduling Lot Sizing & Lead Time Estimation Phase Tuning Phase Scheduling Phase Execution Phase Orders Resources Calandars BOM Routing Overtime Offloads Late Orders Late Orders Lot Sizes Lead Times Dispatch Lists Dispatch Lists Picking Lists Picking Lists WIP Lots New Lots F.G. Inventory F.G. Inventory Scrap Rework Real Time Update Work Progress Work Progress

17. Prof. Dr. Nico Vandaele, University of Antwerp Mini Metal Cutter Grinder Lathe PP S S

18. Prof. Dr. Nico Vandaele, University of Antwerp Customer Orders Product POrder12345 Quantity15324 Due Date2228374144 Product SOrder12345 Quantity13231 Due Date1718192224 Order678910 Quantity13231 Due Date2627303334 Order1112131415 Quantity23311 Due Date3536394244

19. Prof. Dr. Nico Vandaele, University of Antwerp Production Parameters ProductMachineAverageVarianceAverageVariance SetupSetupProcessingProcessing TimeTimeTimeTime PCutter20 030 0 Grinder20 40010 100 Lathe24 012 0 SLathe16 08 0 Grinder20 40010 100

20. Prof. Dr. Nico Vandaele, University of Antwerp Lot Size and Lead Time Results Product Optimal Operation Utilization Waiting Setup Processing Lead Lot Size Time Time Time Time P 4 cutter 73 7 20 120 147 grinder 87 109 20 40 169 lathe 82 41 24 48 113 collection 72 total 501 S 6 lathe 82 41 16 48 105 grinder 87 109 20 60 189 collection 61 total 355

21. Prof. Dr. Nico Vandaele, University of Antwerp Grouping Customer Orders Lot Customer# Average Planned Due Release Orders Lead Lead Date Date Time Time P11-26534 719 528 -191 P23-45482 521 888 367 P354430 472 1056 584 S11-2-36295 351 408 57 S24-5-65277 336 528 192 S37-85277 336 648 312 S49-10-11-129349 397 792 395 S513-14-155277 336 936 600

22. Prof. Dr. Nico Vandaele, University of Antwerp Network a(50) 7(140) c(30) 1(200) 4(170) 3(96) 6(84) 9(72) b(84) 8(60) d(80) 2(80) 5(70) 11(80) 19(70) 13(70) 15(70) 17(110) 10(64) 18(56) 12(56) 14(56) 16(88) E B

23. Prof. Dr. Nico Vandaele, University of Antwerp Gantt-chart 11 12 11 12 21 22 21 32 31 42 13 523222 332351 ij operation j of order i of product P operation j of order i of product S 41 31 100203040

24. Prof. Dr. Nico Vandaele, University of Antwerp The POLCA Control System Paired-cell Overlapping Loops of Cards with Authorization Relates the releases on the shop floor to a push-signal and a pull-signal Suri, Quick Response Manufacturing, 1998 Krishnamurthy, 2004

25. Prof. Dr. Nico Vandaele, University of Antwerp For P1 to start working on the order, the order needs to be authorized and P1 should have a P1/F2 POLCA card 2 P1 F2 P1/F2 LOOP MATERIAL IN P1’S INPUT BUFFER P1/F2 F2’S INPUT BUFFER P1 AVAILABLE P1/F2 CARDS P1/F2 P1 Cell Team’s Decision Process (after Authorization)

26. Prof. Dr. Nico Vandaele, University of Antwerp 2 P1 F2 P1/F2 LOOP MATERIAL IN P1’S INPUT BUFFER P1/F2 F2’S INPUT BUFFER P1 AVAILABLE P1/F2 CARDS P1 Cell Team’s Decision Process (after Authorization) For P1 to start working on the order, the order needs to be authorized and P1 should have a P1/F2 POLCA card

27. Prof. Dr. Nico Vandaele, University of Antwerp 2 P1 F2 P1/F2 LOOP MATERIAL IN P1’S INPUT BUFFER P1/F2 F2’S INPUT BUFFER P1 AVAILABLE P1/F2 CARDS P1 Cell Team’s Decision Process (after Authorization) For P1 to start working on the order, the order needs to be authorized and P1 should have a P1/F2 POLCA card

28. Prof. Dr. Nico Vandaele, University of Antwerp For F2 to start working on the order, the order needs to be authorized and F2 should have an F2/A4 POLCA card F2/A4 LOOP P1/F2 LOOP P1 A4 F2 P1/F2 F2/A4 AVAILABLE P1/F2 CARDS P1/F2 F2 Cell Team’s Decision Process (after Authorization)

29. Prof. Dr. Nico Vandaele, University of Antwerp F2/A4 LOOP P1/F2 LOOP P1 A4 F2 P1/F2 F2/A4 P1/F2 F2/A4 AVAILABLE P1/F2 CARDS F2 Cell Team’s Decision Process (after Authorization) For F2 to start working on the order, the order needs to be authorized and F2 should have an F2/A4 POLCA card

30. Prof. Dr. Nico Vandaele, University of Antwerp F2/A4 F2/A4 LOOP P1/F2 LOOP P1 A4 F2 P1/F2 AVAILABLE P1/F2 CARDS P1/F2 F2 Cell Team’s Decision Process (after Authorization) For F2 to start working on the order, the order needs to be authorized and F2 should have an F2/A4 POLCA card

31. Prof. Dr. Nico Vandaele, University of Antwerp The POLCA Control System Trade-off: Push - Authorization: urgency Pull - Card: capacity feasibility POLCA does control the release as a function of available capacities downstream Determination of I. Release authorizations II. Number of POLCA cards

32. Prof. Dr. Nico Vandaele, University of Antwerp I. Release Authorizations A Capacity and Lead time Integrated Procedure for Scheduling (Vandaele et al., 1998): - Lot Sizing and Lead Time Estimation Phase - Tuning Phase - Scheduling phase  POLCA - Execution

33. Prof. Dr. Nico Vandaele, University of Antwerp I. Release Authorizations Product 1: A => B => C Product 2: C => B

34. Prof. Dr. Nico Vandaele, University of Antwerp II. Number of POLCA Cards

35. Prof. Dr. Nico Vandaele, University of Antwerp II. Number of POLCA Cards A. The number of manufacturing orders that go from workstation l to workstation m during the planning horizon D:

36. Prof. Dr. Nico Vandaele, University of Antwerp II. Number of POLCA Cards B. The weighted ‘average’ lead time: Weights: relative # of manufacturing orders Safety cards: on queue time Function of manufacturing batch size

37. Prof. Dr. Nico Vandaele, University of Antwerp Load Based Version of POLCA Multiply the number of cards by the average workload of the operations planned in the loop during the planning horizon:

38. Prof. Dr. Nico Vandaele, University of Antwerp E-POLCA at Spicer Off-Highway Products Division A few years ago, the company implemented the software i-CLIPS, which computerizes the aggregate planning. Provides authorizations At each workstation a display will show: list mentioning the authorized production orders production orders Green: capacity is available (POLCA card) Red: capacity not available now (no POLCA card) E stands for paperless environment

39. Prof. Dr. Nico Vandaele, University of Antwerp Machine XMachine Y PCNPCN MachineLoadMachineLoadMachineLoadMachineLoadMachineLoadMachineLoad A5X4Y5X2Y6A4 B7X2F2X3Y5E8 D6X3Y1A5Y4G5 A4X6Y1A8Y8D2 C2X5A2A9Y5A5 C5X4D4X4Y2B1 A5X8Y5C2Y5B1 E8X5B6X5Y1D4 G4X2B8X1Y3D8 D2X5B5D2Y5B5 A3X1Y2X2Y8D2 B5X1A3X4Y9D5 B8X2C4X8Y4E1 D9X5Y2C5Y2E6 D4X5Y1A2Y6E5 E2X6D5X5Y5A4 E5X4D2X1Y4C8 E1X2Y4A1Y8B5 A2X1Y1X2Y5D2 C2X3D1D5Y2A5 LOOP XY 125Wait Y89 Open X36

40. Prof. Dr. Nico Vandaele, University of Antwerp Conclusions ARP is a generic approach for many planning and execution systems ARP is based on stochastic modelling of manufacturing systems Industry is eager to use the models