Production Management Advanced Models, Tools, and Applications for Pull Systems

Inventory control is an essential task in production management. An effective inventory control can significantly reduce the holding cost and hence, total production cost. Selecting and implementing a suitable production control system plays an important role in inventory reduction and performance improvement of a production system. Since the introduction of Toyota’s just-in-time philosophy, pull control systems have been adopted by numerous companies worldwide, both in the manufacturing and service sectors. This book provides some recent developments in production management and presents modeling and analysis tools for pull production control systems. It contributes by combining theoretical findings and case study analysis results with a practical and contemporary view on how to effectively manage and control production systems. Each chapter in this book focuses on a specific topic in production control systems, allowing readers to identify the chapters that relate to their interests. More specifically, the book is presented in three sections. The first section focuses on the design and implementation aspects of the pull production control systems, as well as performance evaluation approaches for pull systems. The second section presents a recent and comprehensive literature review. Three different case studies on implementation of pull production control systems are presented in the last section. This book can be used as an essential source for students and scholars who need to specifically study the pull control systems. Since the superiority of these systems is controversial, the book can also provide an interesting and informative read for practitioners, managers, and employees who need to deepen their knowledge on pull production management systems.

Contents Preface...................................................................................................................................... vii Editor..........................................................................................................................................ix Contributors...............................................................................................................................xi Part I DESIGN, IMPLEMENTAT ION, AND PERFORMANCE EVALUAT ION 1 Pull Production Control Systems: Selection and Implementation Issues.....................3 YACOB KHOJASTEH 2 Kanban Allocation Policies of Multi-product Production Control Strategies............15 OLADIPUPO OLAITAN, PAUL YOUNG, AND JOHN GERAGHTY 3 BK-CONWIP Adaptive Control Strategies in a Multi-Product Manufacturing System..........................................................................................................................45 PAOLO RENNA 4 Impact of Reworking in Job-Shop Environments Controlled by Kanban System......63 PEDRO L. GONZÁLEZ-R AND MARCOS CALLE 5 Takt Time Grouping: A New Approach to Flow Manufacturing................................85 MITCHELL A. MILLSTEIN AND JOSEPH S. MARTINICH 6 A Framework for Performance Evaluation of Pull Systems.......................................103 S. VINODH, R. BEN RUBEN, AND P. ASOKAN Part II R EVIEW ON PULL SYSTEMS 7 CONWIP and Hybrid CONWIP Production Control Systems: A Literature Review...................................................................................................123 MEHMET BULENT DURMUSOGLU AND CANAN AGLAN Part III PULL SYSTEMS IMPLEMENTAT ION – CASE STUDIES 8 Making CONWIP Scheme in One-of-a-Kind Production: A Case Study.................143 GUODONG HUANG AND JIE CHEN 9 Setting Push–Pull Boundaries: A Case of Textile Manufacturer..............................161 MD SARDER, MOHSEN HOSSEINI, AND MOHAMMAD MARUFUZZAMAN 10 Balancing Flexibility and Lean in Manufacturing Environments............................179 GWENDOLYN HOLOWECKY AND RATNA BABU CHINNAM Index..................................................................................................................................213

Dr. Yacob Khojasteh is an associate professor of operations management at the Graduate School of Global Studies, Sophia University, Tokyo, Japan. He received his PhD in engineering from the University of Tsukuba, Japan. He also received his MSc in policy and planning sciences, and in industrial engineering from the University of Tsukuba and Tarbiat Modares University, respectively. He has several years of professional experience in industry and consulting. His recent books, entitled Production Control Systems: A Guide to Enhance Performance of Pull Systems and Supply Chain Risk Management were published by Springer in 2016 and 2017, respectively. His research interests include production and operations management, supply chain management, systems modeling and optimization, and lean production systems.