Production to Order

In this book, production rules are studied for situations which share some important elements. The most important one is that the products are manufactured according to customer specifications and they will not be manufactured unless they have been ordered. Other elements are the set-ups on the machines, which make a clustering of orders necessary, the backlogging of late orders, a production process with one bottle-neck and a stochastic demand. The purpose is to find a simple production rule, which offers possibilities for a simple adaptation to the varying wishes or to additional complications. The production rules under consideration are well-known heuristics such as the Silver-Meal heuristic and the Wagner-Whitin heuristic, which can be adapted for backlogging and for the stochastic demand. Also a new, simple rule is introduced: the (x,T)-rule. To determine and compare the performance of the production rules different techniques have been used, such as simulation, dynamic programming and markovian models. Among the situations that have been considered are situations with capacity restrictions, overtime possibilities and situations where the clients react to the performance of their orders.

Contenu

1. Introduction.- 1.1. Production to order.- 1.2. Description of the problem.- 1.3. The control rules.- 1.3.1. The control rules for the lead times.- 1.3.2. The control rules for the production planning.- 1.4. The performance of the control rules.- 1.5. Influences on the control rules.- 1.5.1. Influence of the market.- 1.5.2. Influence of the production facilities.- 1.6. The methods.- 1.7. Overview of the text.- 2. Preliminaries.- 2.1. The situation and the model.- 2.2. Costs as instruments for decision making.- 2.3. Control rules for production planning.- 2.4. Control rules for lead times and order acceptance.- 3. A Fixed Production Cycle.- 3.1. Introduction.- 3.2. Analysis of fixed production cycles.- 3.2.1. Extended gating cyclic service model.- 3.2.2. Normal gating cyclic service with strict capacity.- 3.2.3. Normal gating service with flexible capacity.- 4. Non Cyclic Methods for One Product Type.- 4.1. Introduction.- 4.2. Fixed lead times.- 4.2.1. Introduction.- 4.2.2. Description of the model.- 4.2.3. The optimal production policy.- 4.2.4. Heuristic procedures.- 4.2.4.1. Notation.- 4.2.4.2. The Silver-Meal approach.- 4.2.4.3. The Wagner-Whitin approach.- 4.2.4.4. The (x,T)-rule.- 4.2.5. Numerical results.- 4.2.5.1. Conclusions.- 4.2.6. Orders with different priorities.- 4.2.6.1. Introduction.- 4.2.6.2. Model.- 4.3. A fluctuating demand rate.- 4.3.1. Introduction.- 4.3.2. Model.- 4.3.3. Example of lateness-dependent demand.- 4.3.4. Numerical results.- 4.4. A decision rule for lead times.- 4.4.1. Introduction.- 4.4.2. The model.- 4.4.3. A cyclic approach.- 4.4.4. The dynamic programming rule.- 4.4.5. Simplified dynamic programming rule.- 4.4.6. Numerical results.- 5. Several Types of Products on One Machine.- 5.1. Introduction.- 5.1.1. Description of the model.- 5.1.2. Notation.- 5.2. No possibilities for working overtime.- 5.2.1 Introduction.- 5.2.2. Extended (x,T)-rule.- 5.2.2.1. Introduction to the extended (x,T)-rule.- 5.2.2.2. Formulation of the extended (x,T)-rule.- 5.2.3. The two-step rule.- 5.2.3.1. Introduction to the two-step rule.- 5.2.3.2. Formulation of the first part.- 5.2.3.3. Formulation of the second part.- 5.2.4. A semi-fixed cycle rule.- 5.2.4.1. Introduction.- 5.2.4.2. Determining a semi-fixed cycle.- 5.2.5. Numerical results.- 5.3. Situation in which extra capacity is available.- 5.3.1. Introduction.- 5.3.2. Extended overtime (x,T)-rule.- 5.3.2.1. Introduction to the extended overtime (x,T)-rule.- 5.3.2.2. Formulation of the extended overtime (x,T)-rule.- 5.3.3. The two-step overtime rule.- 5.3.4. The semi-fixed cycle rule.- 5.3.5. Numerical results.- 6. Analysis of Multi-Type Models.- 6.1. Introduction.- 6.2. The multi (x,T)-rule.- 6.2.1. Analysis of the multi (x,T)-rule.- 6.2.2. Numerical results.- 6.2.3. Other possibilities and conclusions.- 6.3. Continuous review model.- 6.3.1. Introduction.- 6.3.2. Production model.- 6.3.3. Decomposition model.- 6.3.4. Results for the normal extended service.- 6.3.5. Numerical results and comparison with fixed cycle.- 7. The (x,T)-Rule in Complex Situations.- 7.1. Description of the problem.- 7.2. The elements of the extended (x,T)-rule.- 7.2.1. The penalty points.- 7.2.2. The allocation of capacity.- 7.2.3. Planning on different machines.- 7.3. Determination of lead times.- 7.3.1. Acceptance of the lead times.- 7.4. Numerical results.- 8. Summary and Conclusions.- 8.1. Summary and conclusions.- References.