Control Chart Methods for Setting WIP Levels and Due Date Quotes in Production Lines to Meet Target Throughput Rates and Customer Service Rates

Control Chart Methods for Setting WIP Levels and Due Date Quotes in Production Lines to Meet Target Throughput Rates and Customer Service Rates

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Two control chart methods are developed that require almost about the underlying production process and that adapt quick manufacturing system. The first method, termed Statistical Throughput Control (STC), is a simple adaptive production control method for setting WIP (work in process) levels to meet target production rates in a pull production rates in a pull production systems operating under the CONWIP (CONstant Work In Process) protocol. The STC methods uses real-time data and a control chart approach to automatically adjust WIP levels (vian kanban cards) in the face of noisy estimates of throughput. The second method, termed Statistical Service Control (SSC), is a method for quoting manufacturing due dates to achieve a target service level (percent of customer orders filled on time). This method posits a very general function for determining leadtimes and also makes use of a control chart approach for adjusting the parameters of this function over time. Both methods do no require any particular distribution of process times nor do they require that the system be in steady-state. Consequently, these methods are well-suited to systems subject to environmental changes such as those induced by continuous improvement efforts. The effectiveness of these methods is demonstrated using simulation for a variety of conditions including single and multiproduct lines and routings with shared resources. Finally, leadtime quoting policies are derived to minimize average leadtime subject to customer service constraints on average fill rate, average leadtime and average relative leadtimes. It is shown that safety leadtimes implied by each policy change in terms of customer service indicating why some policies perform more robustly with respect to different measures of customer service than do others. Furthermore, a simple constant safety leadtime policy is shown to perform robustly well across the three different customer service performance measures making it an attractive basis for real-world leadtime quoting systems.The first method, termed Statistical Throughput Control (STC), is a simple adaptive production control method for setting WIP (work in process) levels to meet target production rates in a pull production rates in a pull production systems ...


Title:Control Chart Methods for Setting WIP Levels and Due Date Quotes in Production Lines to Meet Target Throughput Rates and Customer Service Rates
Author:Melanie Leigh Roof
Publisher: - 1999
ISBN-13:

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