• Journal of the Korea Society for Simulation
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• v.3 no.1
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• pp.99-105
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• 1994

Most of the companies are forced to cut down the manufacturing cost to survive in the competitive environment. Among others, material distribution cost alone takes substantial portion of the total manufacturing cost. In this study, we investigate the waiting phenomenon in the toll gate and propose a new toll booth layout to reduce the waiting time, thereby reduce the total material distribution cost. SIMAN, a simulation language, is employed to evaluate the proposed layout. The experimental results show that the layout reduces the waiting time significantly. Furthermore, the result indicates that determination of the intermediate buffer space affects the performance of the proposed layout.

• Journal of the Korea Safety Management & Science
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• v.3 no.3
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• pp.221-230
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• 2001

The assembly tolerance design methods have applied linear or nonlinear programming methods and used simulation method and search algorithms to optimize the tolerance allocation of each part in an assembly. However, those methods are only considered to the relationship between tolerance and manufacturing cost, which do not consider a quality loss cost for each part tolerance. In this paper, the integrated simulation model used genetic algorithm and the Monte-Carlo simulation method was developed for the allocation of the optimal tolerance considering the manufacturing cost and quality loss cost.

• Journal of Korean Society of Industrial and Systems Engineering
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• v.34 no.3
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• pp.115-122
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• 2011

The critical role played by manufacturing performance measurement systems in achieving competitive success is increasingly recognized. Developing an integrated performance measurement model is significant for strategic management. This study consist of several principal steps. Performance criteria from the literature and an questionnaire were utilized prior to building the performance model. The AHP(Analytic Hierarchy Process) is utilized to evaluate the weight of each criterion when generating the performance measurement model for Korea automobile parts manufacturing company. AHP analysis showed clear difference in the priority between 5 criteria and 24 sub-criteria in terms of manufacturing performance of Korean automobile parts manufacturing company. The result of priority evaluation in the 5 criteria of 2nd level was ranked quality, cost, delivery, employee, flexibility. And the critical sub-criteria in the 24 sub-criteria of 3rd level was ranked claim rate, process defect rate, outsourcing parts defect rate, ability to quality management innovation, claim cost, etc.

• Journal of Korean Society of Industrial and Systems Engineering
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• v.21 no.48
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• pp.269-277
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• 1998

In this study, a traditional concept of sampling inspection plan for the quality assurance system is extended to a consideration of economic aspects in total production system by representing and analyzing the effects between proceding/succeeding production process including inspection. This approach recognizes that the decision to be made at one manufacturing process (or assembly process) determine not only the cost and the average outgoing quality level of that process but also the input parameters of the cost and the incoming quality to the succeeding process. By analyzing the effects of the average incoming and outgoing quality, manufacturing/assembly quality level and sampling inspection plan on the production system, mathematical models and solution technique to minimize the total production cost for a single product manufacturing system with specified average outgoing quality limit (AOQL) are suggested.

• Journal of Korean Society of Industrial and Systems Engineering
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• v.18 no.36
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• pp.121-131
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• 1995

The purpose of a business's existence is to make profit. The objective of business can be attained through the most profitable activities such as the improvement of productivity, quality and the reduction of the manufacturing cost. In order to produce the goods with above said goal, it can be achieved by inducing and improving the manufacturing process. In this viewpoint, We'd like to develope an algorithm for improving productivity, quality and cutting the manufacturing cost under the limitation of the resources. This paper showed a practical method which gradually improves three factors [productivity, quality and cost-down] by calculating the effective value of single and multi process mutually.

• Journal of Korean Institute of Industrial Engineers
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• v.20 no.3
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• pp.93-104
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• 1994

One of the typical assumptions of the studies to determine economic production quantity is that yield rate of a given manufacturing process is 100% or constant after setup. However, in the real world, there are many manufacturing processes of which yield rates are quite low just after setup and then increasing with time until they reach the target rates which are set strategically. This period is usually called "stabilization period". During the stabilization period, defectives are produced, which incur cost (defective cost). In this study, an optimal production quantity for this situation is presented. Also, it is shown that defective cost acts like setup cost and therefore, increases the economic production quantity.

• Journal of Korean Society of Industrial and Systems Engineering
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• v.20 no.42
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• pp.87-98
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• 1997

product to assign objectives for target manufacturing cost on the basis of consumer's function envaluation. The principal purposes of the study include: to improve product differentiation for those products with major usability functions and to prepare effective steps of product concept formulation. Since scant research has been conducted toward the approach suggested above, this study suggests a new method using conjoint analysis for classifying goals of manufacturing costs based on customer's function evaluation. The ultimate goal of this study is to compare and check. The cost estimate for each structure, and eventually to decide target cost values to be reasonably understood by the R&D team.

• Journal of Korean Institute of Industrial Engineers
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• v.22 no.2
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• pp.231-245
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• 1996

Semiconductor manufacturing line includes several batch processes which are to be controlled effectively to enhance the productivity of the line. The key problem in batch processes is a dynamic batch sizing problem which determines number of lots processed simultaneously in a single botch. The batch sizing problem in semiconductor manufacturing has to consider delay of lots, setup cost of the process, machine utilization and so on. However, an optimal solution cannot be attainable due to dynamic arrival pattern of lots, and difficulties in forecasting future arrival times of lots of the process. This paper proposes an efficient batch sizing heuristic, which considers delay cost, setup cost, and effect of the forecast errors in determining the botch size dynamically. Extensive numerical experiments through simulation are carried out to investigate the effectiveness of the proposed heuristic in four key performance criteria: average delay, variance of delay, overage lot size and total cost. The results show that the proposed heuristic works effectively and efficiently.

• Journal of Korean Society for Quality Management
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• v.23 no.2
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• pp.10-27
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• 1995

This paper illustrates a method of developing a function of quality costs in manufacturing systems. It begins with a discussion of the problem statement of this research. A review of existing literatures related to quality costs and economic design of quality inspection methods are discussed. Next mathematical models that quantify the production cycle time and quality costs are formulated. This paper ends with an example that demonstrates the usefulness of the model and highlights the importance of using a system approach. The main contribution of this work is the more realistic considerations of the four types of quality costs (prevention cost, appraisal cost, internal failure cost, external failure cost) in manufacturing systems.

• Journal of the Korea Safety Management & Science
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• v.18 no.2
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• pp.109-118
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• 2016

IPS(Ideal Production System) is a strategic cost management establishing ideal target cost, innovating cost structure and reduction. However, IPS was commonly used in assembly industry acquiring components and using them to assemble vehicles etc. Applying IPS to steel industry is a new try and not easy because cost elements in flow manufacturing are clustered and obfuscated in a complicated way. This paper proposes ICM (Ideal Cost Management) method adaptive to steel industry. One of the biggest advantages is that ICM could classify and categorize costs in detail according to accounts and manufacturing machines. Based on ICM information, steps of extracting and maximizing ideas are followed effectively. From 2013, ICM was applied successfully to POSCO Pohang Steel Works 38 factories.