• IE interfaces
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• v.14 no.1
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• pp.9-19
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• 2001

Production planning and control system plays an important role in manufacturing companies because it determines all production capacity planning, material procurement planning, and production scheduling which are needed in the process of producing products. Many researches on production planning and control system have been conducted for many manufacturing companies for recent decade. But, a considerable research achievement has mainly been obtained on the forecast-driven production for a make-to-stock and an assemble-to-order. The reason is that there are some hardships such as difficulties of standardizing product information, the frequent changes of design and material, and the unexpected dynamic events that influence the production of customer's order in a make-to-order or an engineering-to-order environments. By these characteristics and their complexities, some studies for production planning and control system in a make-to-order environment are presented recently. In this paper, we present the framework of the hietachical production planning and control for a make-to-order environment with dynamic events. In order to illustrate the usefulness of the proposed framework for a hietachical production planning and control, the information system for a make-to-order production was implemented with the object of the company of producing electricity transformer.

• IE interfaces
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• v.11 no.2
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• pp.177-190
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• 1998

The work-order performs an important role in make-to-order production. The development of work-order system in this production is more complex than work-order system in planing production. To construct work-order system, load of directors for work-order must be decreased, and production management between scheduling of master plan and current workshop conditions must be considered. In this study, we grasped troubles in present work-order system and flows of information for work order. Using these results are made database schemas and data flow diagrams for effective development of work-order system. And then, for successful establishment of work-order system and actual use of directors, we considered systematic and easy user-interface. For a case study, development procedures of work-order system are presented for plant factory.

• IE interfaces
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• v.16 no.2
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• pp.185-194
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• 2003

This paper deals with a realistic production scheduling under a make-to-order production environment. The practical case is studied on the transformer winding process in the 'H' company. The transformer winding is a process that rolls a coil that is coated with an electric insulation material in order to generate the required voltage using the voltage fluctuation. This process occupies an important position among the production processes in the transformer manufacturing company. And this process is composed of parallel machines with different performances according to the voltage capacity and winding type. In this paper, we propose a practical heuristic algorithm for production scheduling to satisfy the customer’s due date under a make-to-order production environment. Also, we implement the production scheduling system based on the proposed heuristic algorithm. Consequently, the proposed heuristic algorithm and the implemented production scheduling system are currently working in the transformer production factory of the ‘H’ company.

• Journal of Korean Institute of Industrial Engineers
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• v.38 no.2
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• pp.89-97
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• 2012

This paper considers a manufacturer with a two-station make-to-stock and make-to-order serial production system. The MTS facility produces a single type of component and provides components for the MTO facility that produces customized products. In addition to the internal demand from the MTO facility, the MTS facility faces demands from the spot market with the option of to accept or reject each incoming demand. This paper addresses a joint component inventory rationing and batch production control which maximizes the manufacturer's profit. Using the Markov decision process model, we investigate the structural properties of the optimal inventory rationing and batch production policy, and present two types of heuristics. We implement a numerical experiment to compare the performance of the optimal and heuristic policies and a simulation study to examine the impact of the stochastic process variability on the inventory rationing and batch production control.

• IE interfaces
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• v.18 no.2
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• pp.148-157
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• 2005

The manufacturing industry with Make-to-Order production system is difficult to decide the standard information for the product and the demand is variable to estimate. In this paper, we concerned with the process planning method using data mining in the manufacturing industry with Make-to-Order environment. The subject of our study is the industry transformer plant which is received an diverse order of customer and then produced the product. Currently, process planning method is classified the standard information by hand based on the acquired knowledge through the experience. The standard information stored the various information, such as work sequence, time and so on. This process planning method needs an experts which possesses the field experience for several years. For the product specification which is varied in each order, current process planning method is not efficient due to need many times To solve this problem, we extract the information using data mining process for each processing time, and then construct the knowledge base. We propose a method which is the process planning of the industry transformer product in Make-to-Order environment using the knowledge base.

• Industrial Engineering and Management Systems
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• v.9 no.3
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• pp.196-203
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• 2010

Make-to-forecast production is a way to realize high customization and fast responsiveness. This study firstly investigates the effect of introducing a common component in a make-to-forecast production environment. The common component can eliminate a modification step, which is a major cost component in make-to-forecast production. It is illustrated, however, that introducing a versatile component that merely covers several variants is unattractive, and thus adding values to the common component is inevitable in this environment. Secondly, an order-matching rule under the condition that two partially overlapped delivery lead time intervals exist is proposed. The rule considers the effect of matching orders to units that can cover both intervals. An alternative re-matching rule is also developed and examined. Numerical experiments clarify that the proposed rule generally realizes higher contribution ratio and lower percentages of orphans and rejected orders. The proposed re-matching rule increases the average contribution ratio at the expense of increased orphans and order rejections.

• Journal of Korean Society of Industrial and Systems Engineering
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• v.42 no.1
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• pp.64-73
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• 2019

The manufacturing companies under Make-To-Order (MTO) production environment face highly variable requirements of the customers. It makes them difficult to establish preemptive production strategy through inventory management and demand forecasting. Therefore, the ability to establish an optimal production schedule that incorporates the various requirements of the customers is emphasized as the key success factor. In this study, we suggest a process of designing the simulation model for establishing production schedule and apply this model to the case of a flat glass processing company. The flat glass manufacturing industry is under MTO production environment. Academic research of flat glass industry is focused on minimizing the waste in the cutting process. In addition, in the practical view, the flat glass manufacturing companies tend to establish the production schedule based on the intuition of production manager and it results in failure of meeting the due date. Based on these findings, the case study aims to present the process of drawing up a production schedule through simulation modeling. The actual data of Korean flat glass processing company were used to make a monthly production schedule. To do this, five scenarios based on dispatching rules are considered and each scenario is evaluated by three key performance indicators for delivery compliance. We used B2MML (Business To Manufacturing Markup Language) schema for integrating manufacturing systems and simulations are carried out by using SIMIO simulation software. The results provide the basis for determining a suitable production schedule from the production manager's perspective.

• Journal of the Korean Operations Research and Management Science Society
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• v.30 no.2
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• pp.117-129
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• 2005

This paper considers a make-to-order inventory-production system in which customer orders are admitted only when the number of outstanding customer orders is below a value committed by the system. We deal with general distributions for the customer order Inter-arrival, production, and replenishment lead time processes. Monotonicities of the optimal average cost with respect to these distribution parameters are established using sample path coupling arguments. When distributions are given as an exponential one, we implement a sensitivity analysis on the optimal inventory policy and show that it has monotonicities with respect to system costs using dynamic programming.

• Journal of the Korean Operations Research and Management Science Society
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• v.26 no.4
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• pp.143-153
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• 2001

In this study we develop a computer simulation model to evaluate the effects of various production and order processing policies measured in terms of on-time delivery rate and average waiting time of job orders. Policies considered include : eliminating inflated due date, lot splitting, loss time reduction, attaining full flexibility in production lines, and selective order promising scheme. Actual order-production data from a chemical company were used in the simulation model. Based on the simulation results, we make several suggestions that can significantly reduce the production lead time and increase the on-time delivery rate.

• Journal of the Korean Operations Research and Management Science Society
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• v.16 no.2
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• pp.125-125
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• 1991

This paper presents a framework for the hierarchical PPC(Production Planning and Control) in make-to-order environment with job shop. The characteristics of the environment are described as : 1) project with non-repetitive and individual production, 2) short delivery date, 3) process layout with large scales manufacturing. 4) job shops. The PPC in a make-to-order typically are organized along hierarchical fashions. A model is proposed for the hierarchical job shop scheduling based on new concepts of production system, work and worker organization. Then, a new integrated hierarchical framework is also developed for the PPC based on concepts of the proposed job shops scheduling model. Finally, the proposed framework has been implemented in the Electric Motor Manufacturing and the results showed good performance.