• Journal of Korean Society of Industrial and Systems Engineering
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• v.17 no.32
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• pp.121-126
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• 1994

Setup Time Reduction is an important aspect of the Just-in-Time(JIT) and Zero Inventory(Zl) Concepts since it supports reductions in manufacturing lead times and inventories. It also enables small lot sizes and kanban systems implementation for material flow - achieving major improvements in production floor management. One concept fundamental to the pursuit of JIT production in Japan and other countries is adoption of a setup time reduction. This paper looks at the necessities of setup time reduction and the relations to machine utilization. By using an EOQ model for evaluate the effect of setup time reduction, we get the results that over 75 % reduction in setup time is obtain the desired results in the lot size reduction.

• IE interfaces
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• v.13 no.2
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• pp.217-224
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• 2000

This paper analyzes the effects of setup cost reduction in a dynamic lot-sizing model for a single-facility multi-product problem. In the model, demands for each product are known, no backlogging is allowed, and a single resource is employed. Also, setup cost is defined as a function of capital expenditure to invest in setup cost reduction. Furthermore, in each production period the facility (or plant) produces many products, each representing a fixed part of the involved production activity (or input resource quantity). In this paper, the structure of the optimal solution is characterized and an efficient algorithm is proposed for simultaneously determining the optimal lot size with reduced setup cost and the optimal investment in setup cost reduction. Also, the proposed algorithm is illustrated by a numerical example with a linear and an exponential setup reduction functions.

• Management Science and Financial Engineering
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• v.13 no.2
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• pp.117-139
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• 2007

This paper contributes by incorporating works addressing supply chain coordination and investing in setup reduction program. Consider a two-echelon, EOQ-like inventory system consisting of a supplier and a buyer. We assume that both the supplier and the buyer can invest in setup cost reduction programs in order to benefit from small order sizes. However, the costs of investing in setup cost reduction programs are different for the two parties, leading to mismatches in individually optimal setup costs and order cycle times. We propose a supply chain coordination contract that makes use of quantity discount as an incentive transfer scheme for supply chain coordination.

• Management Science and Financial Engineering
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• v.4 no.2
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• pp.15-42
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• 1998

A joint problem of order delivery, setup reduction, and cost-sharing in a two-echelon inventory system in which a vendor supplies multiple products to a group of buyers is studied here. The basic premise is that buyers have independently implemented setup reduction programs to acquire benefits from small order sizes. Doing so, however, causes the buyers' individually optimal order cycles to be differ from that of the vendor. In conjunction with this, two models are considered. In the first model, a multi-buyers single product situation is considered in which the vendor implements a joint supply cycle policy. However, buyers, as the dominant party, insist after implementing the individually optimal setup reduction that the vendor accept their individually optimal order schedules. In the second model. a multi-products, single buyer situation is considered in which the buyer implements a joint order policy. Here, the vendor, as the dominant party, refuses to cooperate fully with the buyer's individually reduced joint order schedule, and designs his own individually optimal setup reduction mix for each product under a given budget constraint. This led to a study of an integrated Setup Reduction/Break-even Pricing Policy for each situation to eliminate mismatches in individually optimal cycle times.

• Journal of the Korean Operations Research and Management Science Society
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• v.25 no.3
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• pp.49-64
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• 2000

A vendor supplies a product to a sole/major buyer on a lot-for-lot basis under deterministic inventory control conditions. The basic premise is that the setup cost reduction technologies are available to both the buyer and the vendor, and that the vendor's inventory and setup reduction investment costs differ from the buyer's. Therefore, an individually designed ordering and setup cost reduction policy will likely cause mismatches between the vendor's and the buyer's optimal cycle times. For this situation, we show that a joint optimal setup cost reduction and ordering policy, together with an appropriate side payment(quantity discount or premium price) schedule, can be designed in a spirit in a spirit of coordination to eliminate mismatches in individual optimal cycle times.

• Journal of the Korean Operations Research and Management Science Society
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• v.34 no.1
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• pp.11-28
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• 2009

Intelligent investment in setup cost reduction and process reliability improvement is crucial to an emerging integrated lean six sigma practice today. This study examines a cost-minimizing problem of jointly determining production lot size, setup cost reduction, and process reliability improvement decisions for a manufacturer with an imperfect production process. We develop models for previously untapped discrete shipping in a supply chain context as well as continuous shipping and solve them optimally using differential calculus and nonlinear programming. We also conduct analytic and numerical sensitivity analyses to provide various important managerial insights into practices.

• Management Science and Financial Engineering
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• v.3 no.1
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• pp.57-74
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• 1997

An EOQ-like inventory model for a manufacturing process is studied. The system is assumed to deteriorate during the production process. The results are either the production of a number of defective items, or the breakdown of the production machine. The optimal production lot size is derived. The model is extended to the case in which the probabilities of making defective items and machine breakdowns are a function of both the quantity (amount) and quality (performance) of the consumed setup cost (including the preventive maintenance cost). We further assume that the setup performance can be improved by investing in the performance improvement program. Hence, the same or a better setup outcome can be achieved with a lower setup cost. We then investigate the optimal setup cost and investment policy simultaneously, thereby achieving a better process quality and setup cost reduction concurrently.

• Journal of Korean Society of Industrial and Systems Engineering
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• v.34 no.2
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• pp.103-111
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• 2011

The reduction of setup time is very important in a lot production system. A punch press is a typical system of lot production. This paper describes a case study to reduce setup time of a punch press manufacturing system. Especially, this case study reduced the time of die exchange in the case that the standardization of die height is impossible realistically because of diversity on die height and heavy expenses. This study adopts a supplementary die and supplementary blocks to make the use of auto-clamping device possible. The paper also gives a sequencing algorithm to reduce the number of exchange of the supplementary die.

• Journal of Korean Society of Industrial and Systems Engineering
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• v.36 no.3
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• pp.95-108
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• 2013

The problem of constrained sequencing of a set of jobs on a conveyor system with the objective of minimizing setup cost is investigated in this paper. A setup cost is associated with extra material, labor, or energy required due to the change of attributes in consecutive jobs at processing stations. A finite set of attributes is considered in this research. Sequencing is constrained by the availability of conveyor junctions. The problem is motivated by the paint purge reduction problem at a major U.S. automotive manufacturer. We first model a diverging junction with a sequence-independent setup cost and predefined attributes as an assignment problem and this model is then extended for a more general situation by relaxing the initial assumptions in various ways.

• Proceedings of the Korea Society for Simulation Conference
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• 2003.06a
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• pp.129-134
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• 2003

In this paper, we determine optimal reduction in the lead time and setup cost for some stochastic inventory models. And we propose more general model that allow the backorder rate as a control variable. We first assume that the lead time demand follows a normal distribution. And we assume that the backorder rate is dependent on the length of lead time through the amount of shortages. The stochastic models analyzed in this paper are the classical continuous and periodic review policy models with a mixture of backorders and lost sales. For each of these models, we provide a sufficient conditions for the uniqueness of the optimal operating policy. We also develop algorithms for solving these models and provide illustrative numerical examples.