Staff View: Comparison of Parallel Kanban-Base Stock System to Control Multi-Product Multi-Stage Production with Rework Through Simulation

Comparison of Parallel Kanban-Base Stock System to Control Multi-Product Multi-Stage Production with Rework Through Simulation

Cabaran globalisasi baru-baru ini mencetuskan industri perkilangan untuk menawarkan a pelbagai jenis produk dengan pelbagai permintaan untuk memenuhi keperluan pelanggan mereka. Walau bagaimanapun, senario kompleks ini telah menyebabkan proses kerja yang tinggi (WIP) dan kecacatan, dengan itu men...

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Main Author:	Mustafa, Shaliza Azreen
Format:	Thesis
Language:	English
Published:	2016
Subjects:	T Technology TJ1-1570 Mechanical engineering and machinery
Online Access:	http://eprints.usm.my/40992/1/Comparison_of_Parallel_Kanban-Base_Stock_System_to_Control_Multi-Product_Multi-Stage_Production_with_Rework_Through_Simulation.pdf http://eprints.usm.my/40992/
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id	my.usm.eprints.40992
record_format	eprints
institution	Universiti Sains Malaysia
building	Hamzah Sendut Library
collection	Institutional Repository
continent	Asia
country	Malaysia
content_provider	Universiti Sains Malaysia
content_source	USM Institutional Repository
url_provider	http://eprints.usm.my/
language	English
topic	T Technology TJ1-1570 Mechanical engineering and machinery
spellingShingle	T Technology TJ1-1570 Mechanical engineering and machinery Mustafa, Shaliza Azreen Comparison of Parallel Kanban-Base Stock System to Control Multi-Product Multi-Stage Production with Rework Through Simulation
description	Cabaran globalisasi baru-baru ini mencetuskan industri perkilangan untuk menawarkan a pelbagai jenis produk dengan pelbagai permintaan untuk memenuhi keperluan pelanggan mereka. Walau bagaimanapun, senario kompleks ini telah menyebabkan proses kerja yang tinggi (WIP) dan kecacatan, dengan itu mengilhami banyak penyelidikan untuk menyiasat cara optimum untuk dikendalikan sistem pembuatan kompleks ini dalam skop sistem kawalan pengeluaran (PCS). Kebanyakan penyelidikan di PCS sebelum ini memberi tumpuan kepada sistem pengeluaran yang ideal dan kerja-kerja ulang jarang ditakrifkan. Kajian ini bertujuan untuk membangun dan menilai prestasi PCS hibrid baru yang dikenali sebagai saham asas Kanban Kanban (PKB) sistem untuk mengawal pengeluaran berbilang peringkat berbilang produk dengan pintu masuk kerja semula. Berbeza dengan sistem stok berasaskan kanban asal, sistem PKB mengambil kira tiga varian. Varian pertama adalah dua kelas produk keluarga yang dikenali sebagai pelari tinggi (HR) dan pelari rendah (LR) berdasarkan permintaan campuran produk. Variasi kedua ialah variasi peraturan pengiriman untuk mengawal selia keluarga produk yang dikategorikan sebagai runner-low runner-low (HL) dan rendah runner-high pelari (LH). Varian ketiga dianggap adalah dua dasar kemasukan semula yang dikelaskan sebagai menggabung (MR) dan asal (OR). Systemshave yang dikaji telah dimodelkan menggunakan simulasi acara diskret. Hasil simulasi dianalisis berdasarkan statistik kaedah termasuk analisis varians, regresi dan permukaan tindak balas metodologi. Pemilihan parameter, pemboleh ubah dan prestasi yang berkaitan Langkah-langkah agak berdasarkan kajian kesusasteraan dan amalan semasa kajian kes syarikat. Kajian ini telah dibahagikan kepada tiga kes. Untuk Kes 1, antara kerja semula dasar masuk, terutamanya polisi masuk semula SP yang menghasilkan lebih diingini keputusan seperti yang diperhatikan dalam langkah-langkah pencapaian, berbanding dengan kerja semula OR dasar masuk. Bagi Case 2, keputusan menunjukkan bahawa sistem PKB berbeza tuntutan pelanggan menunjukkan peraturan pengiriman HL lebih tinggi daripada peraturan pengiriman LH. Untuk kes 3, PKB-HL-MR memberikan keputusan optimum berbanding dengan model lain. Keseluruhannya penemuan menunjukkan bahawa sistem PKB mempunyai kelebihan Sistem Stok Pangkalan (untuk LR) dengan menyebabkan keluaran keseluruhan kira-kira 1.3% lebih tinggi dan kelebihan a Sistem Kanban (untuk Sumber Manusia) dengan mempunyai tahap WIP yang boleh dikawal. Ketara, ini penyelidikan menyumbang kepada pengetahuan dalam bidang PCS dalam multi-stage pelbagai produk persekitaran memandangkan proses kerja ulang. Untuk penyelidikan masa depan, kerja ini boleh diperluaskan kepada analisis konfigurasi sistem yang lebih kompleks seperti a pemecahan mesin dan menjalankan model simulasi untuk pelbagai jenis industri. ________________________________________________________________________________________________________________________ A recent globalization challenge compels manufacturing industries to offer a large variety of products with varied demands to suit their customers’ needs. However, these complex scenarios have led to high work-in-process (WIP) and defects, thus inspires many researches to investigate the optimum ways to manage this complex manufacturing system within the scope of production control system (PCS). Most research in PCS has previously focused on the ideal production system and rework is seldom being considered.This study aims to develop and to evaluate the performance of a new hybrid PCS known as Parallel Kanban-Base stock (PKB) system to regulate a multi-product multi-stage production with the entrance of rework. In contrast to the original hybrid kanban-base stock system, PKB system takes into account of three variants. First variant are two classes of the product families known as high-runner (HR) and low-runner (LR) based on the demand of the product mix. The second variant is the variations of dispatch rules to regulate product families categorized as high runner-low runner (HL) and low runner-high runner (LH). Third variant considered was two rework entrance policies classified as merge (MR) and original (OR). The studied systemshave been modeled using discrete-event simulation. The simulation results are analyzed based on statistical methods including analysis of variance, regression and response surface methodology. The selection of related parameters, variables and performance measures is relatively based on literature study and current practice of a case study company. This study has been divided into three cases. For Case 1, among rework entrance policies, predominantly MR rework entrance policy yields more desirable results as observed within the performance measures, compared to OR rework entrance policy. For Case 2, the results revealed that PKB system with different customer demands shows HL dispatch rule is superior to LH dispatch rule. For Case 3, PKB-HL-MR gives the optimum results compared to other models. Overall findings show that PKB system possesses the advantage of a Base stock System (for LR) by causing an approximately 1.3% higher total output and the advantage of a Kanban System (for HR) by having controllable WIP levels. Significantly, this research contributes to the knowledge in the area of PCS in multi-product multi-stage environment considering reworking process.For future research, this work can be extended to the analysis of more complicated system configurations such as a machine breakdownand run the simulation model for various types of industries.
format	Thesis
author	Mustafa, Shaliza Azreen
author_facet	Mustafa, Shaliza Azreen
author_sort	Mustafa, Shaliza Azreen
title	Comparison of Parallel Kanban-Base Stock System to Control Multi-Product Multi-Stage Production with Rework Through Simulation
title_short	Comparison of Parallel Kanban-Base Stock System to Control Multi-Product Multi-Stage Production with Rework Through Simulation
title_full	Comparison of Parallel Kanban-Base Stock System to Control Multi-Product Multi-Stage Production with Rework Through Simulation
title_fullStr	Comparison of Parallel Kanban-Base Stock System to Control Multi-Product Multi-Stage Production with Rework Through Simulation
title_full_unstemmed	Comparison of Parallel Kanban-Base Stock System to Control Multi-Product Multi-Stage Production with Rework Through Simulation
title_sort	comparison of parallel kanban-base stock system to control multi-product multi-stage production with rework through simulation
publishDate	2016
url	http://eprints.usm.my/40992/1/Comparison_of_Parallel_Kanban-Base_Stock_System_to_Control_Multi-Product_Multi-Stage_Production_with_Rework_Through_Simulation.pdf http://eprints.usm.my/40992/
_version_	1643710097038245888
spelling	my.usm.eprints.40992 http://eprints.usm.my/40992/ Comparison of Parallel Kanban-Base Stock System to Control Multi-Product Multi-Stage Production with Rework Through Simulation Mustafa, Shaliza Azreen T Technology TJ1-1570 Mechanical engineering and machinery Cabaran globalisasi baru-baru ini mencetuskan industri perkilangan untuk menawarkan a pelbagai jenis produk dengan pelbagai permintaan untuk memenuhi keperluan pelanggan mereka. Walau bagaimanapun, senario kompleks ini telah menyebabkan proses kerja yang tinggi (WIP) dan kecacatan, dengan itu mengilhami banyak penyelidikan untuk menyiasat cara optimum untuk dikendalikan sistem pembuatan kompleks ini dalam skop sistem kawalan pengeluaran (PCS). Kebanyakan penyelidikan di PCS sebelum ini memberi tumpuan kepada sistem pengeluaran yang ideal dan kerja-kerja ulang jarang ditakrifkan. Kajian ini bertujuan untuk membangun dan menilai prestasi PCS hibrid baru yang dikenali sebagai saham asas Kanban Kanban (PKB) sistem untuk mengawal pengeluaran berbilang peringkat berbilang produk dengan pintu masuk kerja semula. Berbeza dengan sistem stok berasaskan kanban asal, sistem PKB mengambil kira tiga varian. Varian pertama adalah dua kelas produk keluarga yang dikenali sebagai pelari tinggi (HR) dan pelari rendah (LR) berdasarkan permintaan campuran produk. Variasi kedua ialah variasi peraturan pengiriman untuk mengawal selia keluarga produk yang dikategorikan sebagai runner-low runner-low (HL) dan rendah runner-high pelari (LH). Varian ketiga dianggap adalah dua dasar kemasukan semula yang dikelaskan sebagai menggabung (MR) dan asal (OR). Systemshave yang dikaji telah dimodelkan menggunakan simulasi acara diskret. Hasil simulasi dianalisis berdasarkan statistik kaedah termasuk analisis varians, regresi dan permukaan tindak balas metodologi. Pemilihan parameter, pemboleh ubah dan prestasi yang berkaitan Langkah-langkah agak berdasarkan kajian kesusasteraan dan amalan semasa kajian kes syarikat. Kajian ini telah dibahagikan kepada tiga kes. Untuk Kes 1, antara kerja semula dasar masuk, terutamanya polisi masuk semula SP yang menghasilkan lebih diingini keputusan seperti yang diperhatikan dalam langkah-langkah pencapaian, berbanding dengan kerja semula OR dasar masuk. Bagi Case 2, keputusan menunjukkan bahawa sistem PKB berbeza tuntutan pelanggan menunjukkan peraturan pengiriman HL lebih tinggi daripada peraturan pengiriman LH. Untuk kes 3, PKB-HL-MR memberikan keputusan optimum berbanding dengan model lain. Keseluruhannya penemuan menunjukkan bahawa sistem PKB mempunyai kelebihan Sistem Stok Pangkalan (untuk LR) dengan menyebabkan keluaran keseluruhan kira-kira 1.3% lebih tinggi dan kelebihan a Sistem Kanban (untuk Sumber Manusia) dengan mempunyai tahap WIP yang boleh dikawal. Ketara, ini penyelidikan menyumbang kepada pengetahuan dalam bidang PCS dalam multi-stage pelbagai produk persekitaran memandangkan proses kerja ulang. Untuk penyelidikan masa depan, kerja ini boleh diperluaskan kepada analisis konfigurasi sistem yang lebih kompleks seperti a pemecahan mesin dan menjalankan model simulasi untuk pelbagai jenis industri. ________________________________________________________________________________________________________________________ A recent globalization challenge compels manufacturing industries to offer a large variety of products with varied demands to suit their customers’ needs. However, these complex scenarios have led to high work-in-process (WIP) and defects, thus inspires many researches to investigate the optimum ways to manage this complex manufacturing system within the scope of production control system (PCS). Most research in PCS has previously focused on the ideal production system and rework is seldom being considered.This study aims to develop and to evaluate the performance of a new hybrid PCS known as Parallel Kanban-Base stock (PKB) system to regulate a multi-product multi-stage production with the entrance of rework. In contrast to the original hybrid kanban-base stock system, PKB system takes into account of three variants. First variant are two classes of the product families known as high-runner (HR) and low-runner (LR) based on the demand of the product mix. The second variant is the variations of dispatch rules to regulate product families categorized as high runner-low runner (HL) and low runner-high runner (LH). Third variant considered was two rework entrance policies classified as merge (MR) and original (OR). The studied systemshave been modeled using discrete-event simulation. The simulation results are analyzed based on statistical methods including analysis of variance, regression and response surface methodology. The selection of related parameters, variables and performance measures is relatively based on literature study and current practice of a case study company. This study has been divided into three cases. For Case 1, among rework entrance policies, predominantly MR rework entrance policy yields more desirable results as observed within the performance measures, compared to OR rework entrance policy. For Case 2, the results revealed that PKB system with different customer demands shows HL dispatch rule is superior to LH dispatch rule. For Case 3, PKB-HL-MR gives the optimum results compared to other models. Overall findings show that PKB system possesses the advantage of a Base stock System (for LR) by causing an approximately 1.3% higher total output and the advantage of a Kanban System (for HR) by having controllable WIP levels. Significantly, this research contributes to the knowledge in the area of PCS in multi-product multi-stage environment considering reworking process.For future research, this work can be extended to the analysis of more complicated system configurations such as a machine breakdownand run the simulation model for various types of industries. 2016-04 Thesis NonPeerReviewed application/pdf en http://eprints.usm.my/40992/1/Comparison_of_Parallel_Kanban-Base_Stock_System_to_Control_Multi-Product_Multi-Stage_Production_with_Rework_Through_Simulation.pdf Mustafa, Shaliza Azreen (2016) Comparison of Parallel Kanban-Base Stock System to Control Multi-Product Multi-Stage Production with Rework Through Simulation. PhD thesis, Universiti Sains Malaysia.
score	13.211869

Comparison of Parallel Kanban-Base Stock System to Control Multi-Product Multi-Stage Production with Rework Through Simulation

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