Manufacturing systems analysis with application to production scheduling:
Saved in:
| Main Author: | |
|---|---|
| Format: | Book |
| Language: | English |
| Published: |
Englewood Cliffs, NJ
Yourdon Press
1990
|
| Edition: | 1. print. |
| Series: | Yourdon Press computing series
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| Subjects: | |
| Online Access: | Inhaltsverzeichnis |
| Physical Description: | XXI, 360 S. graph. Darst. |
| ISBN: | 0135563828 |
Staff View
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| adam_text | CONTENTS
PREFACE XV
Part One — MANUFACTURING SYSTEMS ANALYSIS 1
Chapter 1 — COMPUTERS IN MANUFACTURING 1
1.1. THE STAKES IN MANUFACTURING SYSTEMS ANALYSIS 2
1.2. THE SYSTEMS NIGHTMARE 2
1.2.1. Computer Integrated Manufacturing 2
1.2.2. How Incompatible Systems Proliferate 4
1.3. WHY DO PRODUCTION SCHEDULING SYSTEMS FAIL? 8
1. 3.1. Conflict with Performance Measures 8
1.3.2. Management Commitment — A Double Edged Sword 10
1.3.3. Inadequate Factory Model 11
1.3.4. Scheduling Is not the Problem 12
1.3.5. The System Cannot Model the Factory 13
1.3.6. Poor Software Quality 15
1.4. CONCLUSION AND DIRECTION 15
V
VI CONTENTS
Chapter 2 — MANAGING THE NEEDS ASSESSMENT PROCESS 17
2.1. ORGANIZATION VERSUS TECHNOLOGY 18
2.2. ORGANIZING THE COMMUNICATION 18
2.2.1. The Analysts 18
The Sales Representative 18
The Consultant 19
The Systems Engineer 20
2.2.2. The Manufacturing Organization 21
What It Must Do to Support the Analysts 21
Analysis Paralysis 21
Corporate Culture 22
2.2.3. The Analysis Process 23
2.3. PRAGMATICS 25
2.3.1. Syntax, Semantics, and Pragmatics 25
2.3.2. Comparing a System with a Requirements Document 26
2.3.3. Current Factory versus Future Factory 26
2.4. THE ANALYST S TOOLS 27
2.4.1. Manufacturing Engineering 27
2.4.2. Software Engineering 28
2.5. CONCLUSION 29
Chapter 3 — STRUCTURED ANALYSIS IN MANUFACTURING 30
3.1. INTRODUCTION 31
3.1.1. A Hardware Diagram 31
3.1.2. A Concepts Diagram 3 2
3.1.3. An External Context Diagram 33
3.2. STRUCTURED ANALYSIS 36
3.3. OBSOLETE ALTERNATIVES TO STRUCTURED ANALYSIS 36
3.3.1. Boilerplates 36
3.3.2. How Charts 37
3.4. VARIANTS OF STRUCTURED ANALYSIS 38
3.4.1. Petri Nets 38
3.4.2. Gane and Sarson s SADT 39
3.5. CONCLUSION 39
Chapter 4 — DATA FLOW MODELING 41
4.1. HIERARCHICAL EXPLOSION OF PROCESSORS 42
4.2. DE MARCO S CONVENTIONS 42
4.3. WHEN IS A DATA FLOW DIAGRAM USEFUL? 44
4.3.1. External Context Specification 44
4.3.2. Reports 44
4.3.3. Diagnostic Systems 45
4.3.4. Transactions 45
4.3.5. Administration 46
4.4. DATA FLOW VERSUS CONTROL FLOW 4 7
CONTENTS VII
4.4.1. Why the Distinction Matters 47
4.4.2. Telling Control Flow from Data Flow 48
4.4.3. Relativity of the Meaning of Control Flow 49
4.5. DIAGRAM AESTHETICS AND CROSSED ARROWS 50
Appendix A — Three Houses and Three Utilities 51
Chapter 5 — STATE TRANSITION MODELS IN MANUFACTURING 54
5.1. OBJECT MODELING 5 4
5.1.1. What an Object Is and Isn t 54
5.1.2. State Descriptions 55
5.1.3. Events 58
External Events 58
Temporal Events 59
Internal Events 59
Events Induced by History 59
5.1.4. State Transition Models and the Markov Property 59
5.2. REVIEWING A STATE TRANSITION DIAGRAM 61
5.2.1. Sources and Sinks 61
5.2.2. Reducibility 62
5.3. APPLICATION EXAMPLES 63
5.3.1. A Vehicle 63
Modeling Location by Coordinates 63
Modeling Location by Station 64
Modeling Activity Types 64
5.3.2. Engineering Changes 65
Chapter 6 — MODELING THE FACTORY S MEMORY 68
6.1. MODELING THE SYSTEM MEMORY 69
6.1.1 What the System Remembers 69
6.1.2. Modeling for Retrieval 70
6.2. SETS AND MEMORY MODELS 70
6.2.1. From Sets to Databases 7 0
Foundations 70
Pragmatic Neutrality 71
Database Atoms 72
Properties 72
Tuples 72
Unions and Intersections 73
Subsets and Enumeration 73
Infinite Sets, Factory Models, and Database Size 73
Choice 74
6.2.2. Relations 74
6.2.3. Mappings 76
Definition 76
Rule versus Lookup 76
Many to Many Relationships 76
6.2.4. Relational Algebra 77
VIII CONTENTS
6.2.5. Need for Graphic Notations 78
6.3. GRAPHICS 78
6.3.1. Entity Relationship Diagrams 78
6.3.2. Diagrams for Relations of Arity 2 79
6.3.3. Representing Set Inclusion 80
6.4. SECURITY 81
Appendix A — RELATIONAL ALGEBRA OPERATIONS 81
6.A.I. Selection 81
6.A.2. Projection 82
6.A.3. Join 82
6.A.4. Division 82
Chapter 7 — DATA DICTIONARIES IN MANUFACTURING 83
7.1. DEFINING ATTRIBUTES IN A DATA DICTIONARY 84
7.1.1. Purpose of Data Dictionaries 8 4
7.1.2. De Marco s Conventions 84
7.1.3. Optional Attributes 86
7.1.4. Relations as Attributes 8 7
7.1.5. Textual Explanations 87
7.1.6. Redundancies 88
7.2. DEFINITIONS 88
7.2.1. The Reader s Point of View 88
7.2.2. Defining Primitives 89
7.2.3. Defining Inferred Results 89
7.2.4. Established Usage 90
7.3. LIMITATIONS OF THE DE MARCO CONVENTIONS 92
7.3.1. Variant Structures 92
7.3.2. Bills of Materials and Recursion 93
Appendix A — AN EXCURSION INTO SOFTWARE DESIGN 95
7.A. 1. Variant Types in PASCAL 9 5
7.A.2. First Relational Structure 96
7.A.3. Variants in PROLOG or LISP 97
7.A.4. Variants with No Redundancy 97
7.A.5. Second Relational Structure 98
7.A.6. What Is Actually Done 99
Chapter 8 — MODELING PROCEDURES AND DECISIONS 100
8.1. MODELING PROCEDURES 100
8.2. STRUCTURED NATURAL LANGUAGE 101
8.3. DECISION TREES 103
8.5. ALGORITHMS 106
CONTENTS IX
Chapter 9 — ESSENTIAL SYSTEMS ANALYSIS 108
9.1. THE ESSENTIAL MODEL OF A WORK CELL 108
9.1.1. Event Partitioning 109
9.1.2. Object Partitioning 110
9.1.3. Integration 111
9.1.4. Conclusions on Work Cell Modeling 111
Work Cells as Attributes of Other Objects 112
Work Cells as Independent Data Objects 112
Work Cells in Object Oriented Programming 112
Dedicated Hardware 112
9.2. EXTRACTING THE ESSENCE OF A SYSTEM 112
9.2.1. The Perfect Technology Assumption 112
9.2.2. Fundamental and Custodial Activities 113
9.2.3. Administration 114
9.2.4. Logical Core and Interface Ring 114
Chapter 10 — MATERIAL FLOW MODELING 117
10.1. MATERIAL FLOWS IN FACTORIES 117
10.2. THE ASME SYMBOLS AND THEIR VARIANTS 121
10.2.1. Vocabulary 122
10.2.2. Convergence and Divergence 124
10.2.3. JIS Symbols 125
10.2.4. Representation of Deepening Commitments 126
List of States 126
List of Operations 127
Addition of Inspections, Scrap, and Rework 127
Assignment of Equipment and Transport Steps 128
10.3. TRADITIONAL USES OF MATERIAL FLOW DIAGRAMS 129
10.3.1. Graphic Coding of Documents for Identification 129
10.3.2. Process Analysis 129
10.3.3. Physical Flow Analysis 130
10.4. HIERARCHICAL MATERIAL FLOW MODELING 132
Chapter 11 — MATERIAL FLOW VERSUS DATA FLOW 134
11.1. DIFFERENCES BETWEEN MATERIAL AND DATA FLOWS 13 5
11.2. FROM MATERIAL FLOW TO DATA FLOW 13 7
11.3. TOWARDS A LAYERED MODEL OF MATERIALS HANDLING 143
11.3.1. The ISO OSI Model of Data Communication 143
Layer 7 — Application 144
Layer 6 — Presentation 146
Layer 5 — Session 146
Layer 4 — Transport 146
Layer 3 — Network 146
Layer 2 —Link 147
Layer 1 — Physical 147
X CONTENTS
11.3.2. Ambiguities in the ISO OSI Model 148
11.3.3. Similarities and Differences between the Models 148
11.3.4. A Layered Model for Materials Handling 149
11.4. CONCLUSION 149
Chapter 12 — MANUFACTURING FUNDS FLOW 150
12.1. A MISSING PERSPECTIVE 151
12.1.1. The Triple Flow Model 151
12.1.2. Manufacturing Funds Flow Analysis Issues 152
12.2. THE BUSINESS OF MANUFACTURING 153
12.2.1. Business Performance in General 153
12.2.2. The Paradox of the Blot Line 156
12.3. THE FACTORY AND ITS OPERATING FUNDS FLOWS 156
12.3.1. Effect of Throughput Time Reductions 159
12.3.2. Price Erosion and Experience Curves 161
12.3.3. The Example of a Memory Factory 164
12.4. FINANCIAL ANALYSIS METHODS IN MANUFACTURING 170
12.4.1. Cost Accounting and Manufacturing 170
12.4.2. Payback Period 172
12.4.3. Discounted Cash Flows 173
12.5. RELATION TO DATA FLOWS AND MATERIAL FLOWS 175
Part Two — APPLICATION TO PRODUCTION
SCHEDULING 177
Chapter 13 —COMPONENTS OF PRODUCTION SCHEDULING 177
13.1. TIME 178
13.2. THE PRODUCTION NETWORK 181
13.3. PART AGGREGATES 181
13.3.1. Lot 181
13.3.2. Load 182
13.3.3. Process Batch 182
13.3.4. Transfer Batch 182
13.3.5. Kit 182
13.4. ACTIVITY TYPES 182
13.4.1. Fabrication 183
13.4.2. Assembly 186
13.4.3. Disassembly 186
13.4.4. Inspection. Sorting, and Binning 187
13.4.5. Transport 188
13.4.6. Storage and Retrieval 188
13.5. RESOURCES 189
13.5.1. Hierarchical Model 189
13.5.2. Work Centers versus Work Cells 189
CONTENTS XI
13.5.3. Resource Characterization 189
13.5.4. Little s Law 192
13.5.5. Infinitely Divisible Resources 194
13.5.6. Composite Resources 196
13.5.7. Setup Times and Setup Matrices 197
13.5.8. Interruptions of Service 198
13.6. INVENTORY 199
13.6.1. Schedule Based Buffer Analysis 200
13.6.2. Age Distribution Analysis 200
13.6.3. Batch Size Adjustment Buffers 202
13.6.4. Safety Stocks 204
13.6.5. Queue Organization 205
13.7. PUTTING IT ALL TOGETHER 207
Chapter 14 —THE BACKWARD SCHEDULING LOGIC OF MRP II 209
14.1. MRP S IMPLEMENTATION RECORD 209
14.2. THE PHILOSOPHY OF MRP II 210
14.3. WIGHT S DISCUSSION OF MRP VERSUS REORDER POINT 211
14.4. THE EXTERNAL CONTEXT OF MRP II 212
14.5. MODULAR BREAKDOWN 213
14.5.1. The Master Production Schedule (MPS) 214
14.5.2. Backward Explosion of Demand 217
14.5.3. Net Inventories 218
14.5.4. The Time Zero Spike 219
14.6. CAPACITY CALCULATIONS 221
14.6.1. Capacity Modeling in MRP II 221
14.6.2. Capacity Requirements Planning 221
Chapter 15 —DISPATCHING IN MRP II 224
15.1. FROM PLANNING TO DISPATCHING 225
15.2. REAL TIME, ON LINE, AND OFF LINE DISPATCH 226
15.3. DISPATCHING ALGORITHMS 227
15.3.1. First In First Out (FIFO) 227
15.3.2. Earliest Due Date (EDD) 228
15.3.3. Shortest Processing Time (SPT) 228
15.3.4. Slack 229
15.3.5. Critical Ratio 230
Appendix A. EDD, SPT, AND SLACK FOR N JOBS ON 1 MACHINE 232
15.A.1. EDD Minimizes the Maximum Lateness 232
15.A.2. SPT Minimizes the Average Throughput Time 233
15.A.3. Slack Maximizes the Minimum Lateness 234
Appendix B. WAITING TIMES IN QUEUES WITH POISSON
ARRIVALS 234
XII CONTENTS
Chapter 16 —APPRAISING MRP II 239
16.1. WHY CRP IS RARELY IMPLEMENTED 239
16.2. THE INTERPRETATION OF STANDARD THROUGHPUT
TIMES 240
16.3. INADEQUACY OF SINGLE PARAMETER MODELS 240
16.3.1. Throughput Time Modeling 240
16.3.2. Yield Modeling 242
16.4. THE TIME PERIOD DILEMMA 243
16.5. THE 10.000 KNOB. CONTROL PANEL 245
16.6. RESPONSE TO ACTIVITY LEVEL CHANGES 245
16.7. WHEN DOES MRP WORK? 246
Chapter 17 —THE THEORY OF OPT 248
17.1. OPT IN THE UNITED STATES 248
17.2. FROM BUSINESS ANALYSIS TO SCHEDULES 250
17.3. THE OPT CONCEPT OF BOTTLENECK 250
17.4. FROM BOTTLENECKS TO CAPACITY CONSTRAINT
RESOURCES 252
17.5. THE UNBALANCED PLANT 253
17.5.1. Eli Goldratt s argument 253
17.5.2. External versus Internal Variability 253
17.5.3. The Cost of Capacity 254
17.5.4. Flow Balance and Time 255
17.5.5. Process Batches and Transfer Batches 256
17.5.6. Considering All Constraints Simultaneously 256
17.6. THE SECRET ALGORITHM 256
Appendix A TIME LOST DUE TO BREAKS 256
Chapter 18 —THE OPT PRODUCTION SCHEDULING SOFTWARE 259
18.1. FUNCTIONS OF THE OPT SOFTWARE PRODUCT 259
18.1.1. External Context 259
18.1.2. The OPT Factory Model 260
18.1.3. The Essential Modules of OPT 263
18.1.4. Backward Scheduling with SERVE 265
18.2. GENERATING SCHEDULES WITH OPT 269
18.2.1. Pure SERVE Run 269
18.2.2. Focused Data Cleaning 269
18.2.3. Split OPT Serve Reports 269
18.3. COMMENTS ON THE OPT PRODUCT DESIGN 270
18.3.1. The OPT Software — The Price of Portability 270
18.3.2. OPT s Nonstandard Terminology 272
18.4. CONCLUSION 272
CONTENTS XIII
Chapter 19 — FINITE FORWARD SCHEDULING AND DISCRETE
EVENT SIMULATION 274
19.1. FINITE FORWARD SCHEDULING 275
19.1.1. What is Finite Forward Scheduling ? 275
19.1.2. Job Shop Scheduling versus Production Scheduling 275
19.1.3. Nondelay Schedules 276
19.2. TASK AND RESOURCE MODEL 276
19.3. Producing a Schedule 280
19.4. DISCRETE EVENT SIMULATION 282
Chapter 20 — MATERIAL FLOWS IN JUST IN TIME 283
20.1. JUST IN TIME AS A HOLISTIC APPROACH 284
20.1.1. Just In Time — What s in a Name? 284
20.1.2. Seek Repetitiveness 285
20.1.3. Manufacturing, Marketing, and JIT 287
20.1.4. Job Shops, MRP, and JIT 288
Pros and Cons of Job Shop Layouts 288
JIT and Factory Response to Change 289
20.1.5. Holistic Manufacturing 289
20.2. FUNDAMENTALS OF FLOW LINES 290
20.2.1. Demand Structure Analysis 290
20.2.2. Flow Line Organization 291
Comparison of JIT with Group Technology 292
JIT Cell Structure 292
20.2.3. Setup Time Reduction 294
Dedication by Families 294
Standardization of Procedures and Training 294
Machine Modifications 295
20.3. AUTOMATION 295
20.4. INTEGRATION WITH EQUIPMENT MAINTENANCE 296
20.4.1. Motivation 296
20.4.2. Training and Operation Standards 297
20.4.3. Housekeeping 297
20.5. INTEGRATION WITH QUALITY CONTROL 299
20.5.1. Effects of Flow Lines on Quality 299
20.5.2. Just In Time and SQC 299
20.5.3. Foolproofing the Process with Pokayoke 300
20.6. PEOPLE AS THE MOST CRITICAL RESOURCE 300
20.7. BACK TO PRODUCTION SCHEDULING 302
Chapter 21 —JUST IN TIME PRODUCTION SCHEDULING 303
21.1. DAMPING EXTERNAL VARIABILITY 303
21.1.1. The Overbooking Model 304
21.1.2. Demand and Production Forecasting 305
21.2. GENERATION OF LEVEL SCHEDULES 307
XIV CONTENTS
21.2.1. First Blender Algorithm 308
21.2.2. The Monden Algorithm 309
21.3. FLOW CONTROL ON THE SHOP FLOOR 311
21.3.1. The Kanban system 311
Kanban Flows between Two Cells 311
Exception Handling 313
Kanban State Transitions 313
Data Flow Model 313
21.3.2. The Timetable Planning System 316
Forward Scheduling of Resources 316
Monthly Production Calendars 317
Weekly Production Calendars 317
Scope of Applicability 319
21.4. TO WHAT EXTENT SHOULD JIT BE COMPUTERIZED? 320
Chapter 22 —PERFORMANCE MODELING AND JUST IN TIME 322
22.1. OBJECTIVES AND METHODS 323
22.1.1. Inferring Steady State Throughput Parameters 323
22.1.2. Three Approaches 323
Back of the Envelope Formulas 323
Queueing Network Algorithms 324
Discrete Event Simulation 328
22.2. EFFECT OF LEVELING ON PROCESS BATCHES 329
22.2.1. Run Length in a Multiproduct FIFO Queue 329
22.2.2. Effect of the Service Rate 331
22.2.3. Maximum Run Length in a Level Schedule 332
22.2.4. The Zealots Paradox 333
22.3. PERFORMANCE ANALYSIS OF THE KANBAN SYSTEM 335
22.3.1. What the Literature Says 335
22.3.2. Towards a Queueing Network Model 336
Simplifying Assumptions 336
The Cyclic Queue Model 338
Interpretation 340
Appendix A. RUN LENGTH WITH MULTICLASS SINGLE SERVER 341
Appendix B. EQUILIBRIUM OF A TRUNCATED CYCLIC QUEUE 345
REFERENCES 349
INDEX 353
|
| any_adam_object | 1 |
| author | Baudin, Michel |
| author_facet | Baudin, Michel |
| author_role | aut |
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| dewey-full | 658.5/3 |
| dewey-hundreds | 600 - Technology (Applied sciences) |
| dewey-ones | 658 - General management |
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| dewey-search | 658.5/3 |
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| dewey-tens | 650 - Management and auxiliary services |
| discipline | Wirtschaftswissenschaften |
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| id | DE-604.BV006084873 |
| illustrated | Illustrated |
| indexdate | 2024-07-09T16:40:01Z |
| institution | BVB |
| isbn | 0135563828 |
| language | English |
| oai_aleph_id | oai:aleph.bib-bvb.de:BVB01-003841812 |
| oclc_num | 19126417 |
| open_access_boolean | |
| owner | DE-703 DE-188 |
| owner_facet | DE-703 DE-188 |
| physical | XXI, 360 S. graph. Darst. |
| publishDate | 1990 |
| publishDateSearch | 1990 |
| publishDateSort | 1990 |
| publisher | Yourdon Press |
| record_format | marc |
| series2 | Yourdon Press computing series |
| spelling | Baudin, Michel Verfasser aut Manufacturing systems analysis with application to production scheduling Michel Baudin 1. print. Englewood Cliffs, NJ Yourdon Press 1990 XXI, 360 S. graph. Darst. txt rdacontent n rdamedia nc rdacarrier Yourdon Press computing series Datenverarbeitung Production planning Data processing Production scheduling Data processing System analysis Data processing Fertigungssystem (DE-588)4154150-9 gnd rswk-swf Systemanalyse (DE-588)4116673-5 gnd rswk-swf Produktionsplanung (DE-588)4047360-0 gnd rswk-swf Datenverarbeitung (DE-588)4011152-0 gnd rswk-swf Planung (DE-588)4046235-3 gnd rswk-swf Produktionsplanung (DE-588)4047360-0 s Datenverarbeitung (DE-588)4011152-0 s Systemanalyse (DE-588)4116673-5 s DE-604 Fertigungssystem (DE-588)4154150-9 s Planung (DE-588)4046235-3 s HBZ Datenaustausch application/pdf http://bvbr.bib-bvb.de:8991/F?func=service&doc_library=BVB01&local_base=BVB01&doc_number=003841812&sequence=000002&line_number=0001&func_code=DB_RECORDS&service_type=MEDIA Inhaltsverzeichnis |
| spellingShingle | Baudin, Michel Manufacturing systems analysis with application to production scheduling Datenverarbeitung Production planning Data processing Production scheduling Data processing System analysis Data processing Fertigungssystem (DE-588)4154150-9 gnd Systemanalyse (DE-588)4116673-5 gnd Produktionsplanung (DE-588)4047360-0 gnd Datenverarbeitung (DE-588)4011152-0 gnd Planung (DE-588)4046235-3 gnd |
| subject_GND | (DE-588)4154150-9 (DE-588)4116673-5 (DE-588)4047360-0 (DE-588)4011152-0 (DE-588)4046235-3 |
| title | Manufacturing systems analysis with application to production scheduling |
| title_auth | Manufacturing systems analysis with application to production scheduling |
| title_exact_search | Manufacturing systems analysis with application to production scheduling |
| title_full | Manufacturing systems analysis with application to production scheduling Michel Baudin |
| title_fullStr | Manufacturing systems analysis with application to production scheduling Michel Baudin |
| title_full_unstemmed | Manufacturing systems analysis with application to production scheduling Michel Baudin |
| title_short | Manufacturing systems analysis with application to production scheduling |
| title_sort | manufacturing systems analysis with application to production scheduling |
| topic | Datenverarbeitung Production planning Data processing Production scheduling Data processing System analysis Data processing Fertigungssystem (DE-588)4154150-9 gnd Systemanalyse (DE-588)4116673-5 gnd Produktionsplanung (DE-588)4047360-0 gnd Datenverarbeitung (DE-588)4011152-0 gnd Planung (DE-588)4046235-3 gnd |
| topic_facet | Datenverarbeitung Production planning Data processing Production scheduling Data processing System analysis Data processing Fertigungssystem Systemanalyse Produktionsplanung Planung |
| url | http://bvbr.bib-bvb.de:8991/F?func=service&doc_library=BVB01&local_base=BVB01&doc_number=003841812&sequence=000002&line_number=0001&func_code=DB_RECORDS&service_type=MEDIA |
| work_keys_str_mv | AT baudinmichel manufacturingsystemsanalysiswithapplicationtoproductionscheduling |