• Proceedings of the Korean Institute of Intelligent Systems Conference
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• 2003.09a
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• pp.187-190
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• 2003

Many manufacturing companies consider the integrated and concurrent scheduling because they need the global optimization technology that could manufacture various products more responsive to customer needs. In this paper, we propose an advanced scheduling model to generate the schedules considering resource constraints and precedence constraints in make-to-order (MTO) manufacturing environments. Precedence of work- in-process(WIP) and resources constraints have recently emerged as one of the main constraints in advanced scheduling problems. The advanced scheduling problems is formulated as a multiobjective mathematical model for generating operation schedules which are obeyed resources constraints, alternative workstations of operations and the precedence constraints of WIP in MTO manufacturing. For effectively solving the advanced scheduling problem, the multi-objective hybrid genetic algorithm (m-hGA) is proposed in this paper. The m-hGA is to minimize the makespan, total flow time of order, and maximum tardiness for each order, simultaneously. The m-hGA approach with local search-based mutation through swap mutation is developed to solve the advanced scheduling problem. Numerical example is tested and presented for advanced scheduling problems with various orders to describe the performance of the proposed m-hGA.

• Journal of the Korea Society for Simulation
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• v.21 no.4
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• pp.11-24
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• 2012

We compared a DBR(drum-buffer-rope) system with a CONWIP(constant work-in-process) system in a production line with constant processing times. Based on the observation that a WIP-controlled line production system such as DBR and CONWIP is equivalent to a m-node tandem queue with finite buffer, we applied a max-plus algebra based solution method for the tandem queue to evaluate the performance of two systems. Numerical examples with 6 workstations were also used to demonstrate the proposed analysis. The mathematical analyses support that CONWIP outperforms DBR in terms of expected waiting time and WIP. Unlike the CONWIP case, sequencing workstations in a DBR affects the performance of the system. Delaying a bottleneck station in a DBR reduces expected waiting time.

• Journal of Korean Institute of Industrial Engineers
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• v.28 no.4
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• pp.344-350
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• 2002

An alternative to traditional production planning and control systems such as MRP and JIT is the drum-buffer-rope(DBR). Using the DBR system, companies can achieve a large reduction of work-in-process (WIP) and finished-goods inventories (FGI), significant improvement in scheduling performance, and substantial earnings increase. The purpose of this paper is to analyze the effect of the DBR system in a serial production line. Using Markov process, we modeled a DBR system with three stages. For the model developed, we analyze the system characteristics and then present an optimization model for system design. The system performance is also analyzed through sensitivity analysis.

• Journal of Biosystems Engineering
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• v.36 no.6
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• pp.461-466
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• 2011

The purpose of this study is basically for the use of simulations to enhance productivity. In this paper, the optimal number of allocation in a small and medium industry which produces eleutherococcus senticosus sap, is performed using simulations. The simulation model was developed under considerations of production layout, process & operation, process time, total work time, work in process (WIP), utilization, failure rate, and operation efficient as inputs, and was validated with careful comparisons between real behaviors and outputs of the production line. Therefore, we can evaluate effects and changes in productivity when some strategies and/or crucial factors are changed. Although too many workers and machines could decrease productivity, the eleutherococcus senticosus sap production line in this paper has been maintained many machines. To solve this problem, we determined the optimal number of workers and machines that could not cause any interrupt in productions using simulations. This simulation model considers diverse input variables which could influence productivity, and it is very useful not only for the production line of Eleutherococcus Senticosus Sap, but also for other production lines with various purposes, especially, in the small and medium industries.

• Proceedings of the Korean Operations and Management Science Society Conference
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• 2002.05a
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• pp.470-475
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• 2002

An alternative to traditional production planning and control systems such as MRP and JIT is the drum-buffer-rope (DBR). Using the DBR system, companies can achieve a large reduction of work-in-process (WIP) and finished-goods inventories (FGI). significant improvement in scheduling performance, and substantial earnings increase. The purpose of this paper is to analyze the effect of the DBR system in a serial production line. Using Markov process, we modeled a DBR system with three stages. For the model developed we analyze the system characteristics and then present an optimization model for system design. The system performance is also analyzed through sensitivity analysis.

• 제어로봇시스템학회:학술대회논문집
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• 2005.06a
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• pp.1118-1122
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• 2005

In order to keep production balance at a mixed-model assembly line and a painting line, large WIP(Work- In-Process) inventories are required between two lines. To increase the efficiency of line handling through reducing the inventories under this circumstance, this paper concerns with a sequencing problem for a mixed-model assembly line that includes a painting line where the uncertain elements regarding the defective products exist. Then, we formulate a new type of the sequencing problem minimizing the line stoppage time and the idle time with forecasting the supply time of the products from the painting line. Finally, we examine the effectiveness of the proposed sequencing through computer simulations.

• Proceedings of the Korea Society for Simulation Conference
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• 1999.04a
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• pp.217-221
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• 1999

본 연구는 직렬생산시스템의 제공품(Work in Process Inventory)을 최소화하기 위하여 완충 저장시설의 최적소요 및 배분을 위한 시뮬레이션 모델의 개발이다. 이를 위하여 먼저 목표 생산률을 만족하기 위한 완충저장시설의 총소요산출을 위하여 적정설비배치를 고려한 완충저장시설의 수요 및 적정배분을 함께 고려한 혼합모델을 개발하였다. 먼저 목표생산률의 만족과 적정설비배치를 동시에 고려할 경우, 완충저장시설의 총소요산출을 위한 CAN-WIP 모델을 개발하고 이를 최적 배분하기 위하여 이진탐색(Binary Search)방법과 휴리스틱 방법인 Beam Search 방법을 사용하였다. 이를 기존의 시뮬레이션 모델 (FACTOR/AIM, AutoMod 등)을 사용하여 그 결과를 비교하였다. 이를 위한 전산프로그림을 개발하고 예제를 통하여 그 결과를 보였다.

• Proceedings of the Korea Society for Simulation Conference
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• 1994.10a
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• pp.9-9
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• 1994

FMS를 비롯한 대부분의 제조시스템의 운용을 위해서는 크게 전략적 의사결저오가 전술적 읫사결저이 필요하며, 이 중 전술적 의사결증은 부품 선택, 생산율 결정, 부하할당, 부품 투입, 일정계획 문제등과 관련되어 있다. 본 연구에서는 부품투입시점과 부품투입순서에 의해 결정된 부품투입 정책이 시스템 성능에 미치는 영향을 알아보기 위해서, 서울대학교부설 자동화시스템공동연구소(ASRI)내의 FMS/CIM Center를 대상으로 시뮬레이션을 수행하였다. ASRI-FMS /CIM Center 는 기계가공과 조립이 동시에 이루어지는 FMAS(Flexible Mauufacturing & Assembly System) 형태의 모형공장이며, 현재 세 종류의 모터 등을 생산할 수 있다. 본 연구에서는 고려한 부품투입시점 전략으로는 고정 WIP(Work-in-process)유지전략 , 병목기계 전략, 일정비율 투입전략 등이며, 부품 투입순서 전략으로는 크게 주기적 투입전략과 비주기적 투입전략을 고려하였다. 또한 이러한 부품 투입정책들이 시스템 내에서 적용할 수 있는 여러 가지 우선순위규칙 등과 함께 사용될 때, 나타나는 상호관계를 파악하기 위한 연구가 수행되었다. 아울러 병목기계 추가도입, 물류운반시간의 감소 등과 같이 가능한 범위에서 현재의 시스템 조건이 바뀐 상황에 대해서도 시뮬레이션을 수행함으로써, 추후 변경된 시스템에서도 본 연구의 결과가 적응될 수 있도록 하였다.

• Journal of the Korean Operations Research and Management Science Society
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• v.18 no.3
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• pp.151-157
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• 1993

In this paper, we investigate the effects of yield randomness for lot-sizing in a multi-stage production system. The practical importance of incorporating yield randomness into production models has been emphasized by many researchers. Yield randomness, especially in semiconductor manufacturing, poses a mojor challenge for production planning and control. The task becomes even more difficult if the demand for final product is uncertain. An attempt to meet the demand with a higher level of confidence forces one to release more input in the fabrication line. This leads to excessive work-in-process (WIP) inventories which cause jobs to spend unpredictably longer time waiting for the machines. The result is that it is more difficult to meet demand with exceptionally long cycle time and puts further pressure to increase the safety stocks. Due to this spiral effect, it is common to find that the capital tied in inventory is the msot significant factor undermining profitability. We propose a policy to determine the quantity to be processed at each stage of a multi-stage production system in which the yield at each stage may be random and may need rework.

• Journal of Korean Institute of Industrial Engineers
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• v.40 no.3
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• pp.283-290
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• 2014

In the flat panel display industry, to meet production target quantities and the deadline of production, the scheduler and dispatching systems are major production management systems which control the order of facility production and the distribution of WIP (Work In Process). Especially the delivery time is a key factor of the dispatching system for the time when a lot can be supplied to the facility. In this paper, we use survival analysis methods to identify main factors of the delivery time and to build the delivery time forecasting model. To select important explanatory variables, the cox proportional hazard model is used to. To make a prediction model, the accelerated failure time (AFT) model was used. Performance comparisons were conducted with two other models, which are the technical statistics model based on transfer history and the linear regression model using same explanatory variables with AFT model. As a result, the mean square error (MSE) criteria, the AFT model decreased by 33.8% compared to the statistics prediction model, decreased by 5.3% compared to the linear regression model. This survival analysis approach is applicable to implementing the delivery time estimator in display manufacturing. And it can contribute to improve the productivity and reliability of production management system.