Fundamentals of Production Logistics

by ; ;
Edition: CD
Format: Hardcover
Pub. Date: 2008-12-04
Publisher(s): Springer Verlag
List Price: $192.58

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Summary

This book comprehensively encapsulates for the first time the fundamentals of modeling Logistic Operating Curves for production and storage processes including how they can be derived and calculated based on standard operating data. In doing so, the authors clearly demonstrate the mutual dependencies between the often contradictory logistic objectives, i.e. on the one hand low throughput times and high delivery reliability and on the other hand low WIP levels and high rates of utilization. Moreover, they also explain how these objectives can be improved using the Logistic Operating Curve Theory and why this method thus provides an interesting alternative to simulations. Logistic Operating Curves open up the frequently hidden potential of the throughput time and WIP without requiring excessive restructuring or capital expenditures. Through numerous industry based examples this well structured book first provides a thorough introduction to the essentials of the Logistic Operating Curve Theory including the Nine Basic Laws of Production Logistics. Based on this knowledge a variety of useful tools and practical applications are presented and discussed. Finally using the Excel-based program provided on the accompanying CD-ROM, the reader can then calculate various Production, Storage and Scheduling Operating Curves using their own data. The Fundamentals of Production Logistics is thus a theoretical substantiated but practice oriented guideline for improving a production company's logistic quality.

Author Biography

Univ.-Prof. Dr.-Ing. habil. Peter Nyhuis, born in 1957, studied mechanical engineering at the Leibniz University of Hannover, Germany. He completed his PhD at the university's Institute of Production Systems and Logistics (IFA) in 1991 and his habilitation there in the field of production logistics in 1999. In the same year, he began working as a project manager and partner at Siemens SPLS Supply Chain Consulting in Munich. Since 2003, he has been appointed both as a professor for Production Systems, Logistics and Work Sciences as well as the director of the Institute of Production Systems and Logistics at the Leibniz University of Hannover. Since 2008 he is a managing partner of the Institute for Integrated Production Hannover (IPH). Professor Nyhuis is the author of numerous book contributions and articles on manufacturing and production planning and control, Logistic Operating Curves, shortening setup times and procurement logistics. Univ.-Prof. Dr.-Ing. Dr. h.c. mult. Hans-Peter Wiendahl, born in 1938, studied mechanical engineering at the RWTH Aachen University, Germany. After studies at MIT and Cambridge, he completed his PhD in 1970 and his habilitation in 1972 at RWTH Aachen. Later he transferred over to the industry, heading first the Department for Planning and Quality at Sulzer Escher Wyss in Ravensburg and since 1975, their department of paper machinery design and technology. In 1979 he was appointed as a professor at the Leibniz University of Hannover and became the director of the university's Institute of Production Systems and Logistics (IFA). He led the institute until 2003. From 1988 to 1992 Professor Wiendahl was also the vice-president of the Leibniz University of Hannover. From 1988 to 2007 he was a managing partner of the Institute for Integrated Production Hannover (IPH). Professor Wiendahl is the author and editor of numerous articles and books including "Load-Oriented Manufacturing Control" (published in English also by Springer).

Table of Contents

Introductionp. 1
Logistic Key Performance Indicators for Manufacturersp. 1
Dilemma of Operations Planningp. 4
Model Based Problem Solving Processp. 6
Objectives of Production Logisticsp. 9
Logistic Operating Curves - an Explanatory Model for Production Logisticsp. 11
Goals and Structure of the Bookp. 13
Basic Principles of Modeling Logistic Operating Curvesp. 17
Funnel Model as a Universal Model for Describing Production Processesp. 17
Work Content and Operation Timesp. 17
Throughput Timep. 21
Latenessp. 23
Logistic Objectives in a Throughput Diagramp. 24
Output Rate and Utilizationp. 25
Work in Process (WIP)p. 27
Weighted Throughput Time and Rangep. 28
Little's Lawp. 31
Logistic Operating Curves for Production Processesp. 35
Traditional Models of Production Logisticsp. 39
Queuing Modelsp. 40
M/G/1 Modelp. 42
Using Queuing Theory to Determine Logistic Operating Curvesp. 45
A Critical Review of the Queuing Theory Approachp. 46
Simulationp. 48
PROSIM III Simulation Systemp. 49
Simulation as an Aid in Determining Logistic Operating Curvesp. 50
A Critical Review of Simulationp. 52
Deriving the Logistic Operating Curves Theoryp. 59
Ideal Logistic Operating Curvesp. 60
Ideal Minimum WIP Levelp. 60
Maximum Possible Output Ratep. 63
Constructing Ideal Logistic Operating Curves for the Output Rate and Time Parametersp. 64
Deriving an Approximation Equation for Calculating an Output Rate Operating Curvep. 66
C[subscript norm] Function as the Basic Function for a Calculated Output Rate Operating Curvep. 68
Transforming the C[subscript norm] Functionp. 70
Parametrizing the Logistic Operating Curves Equationp. 72
Calculating Output Rate Operating Curvesp. 77
Calculating Operating Curves for the Time Parametersp. 80
Normalized Logistic Operating Curvesp. 85
Logistic Operating Curves Theory and Little's Law - a Model Synthesisp. 88
Verifying the Logistic Operating Curves Theoryp. 91
Simulation Based Model Validationp. 91
Validating the Model Based on Field Analysesp. 96
Underload Operating Zonep. 97
Transitional Operating Zonep. 99
Overload Operating Zonep. 100
Extending the Logistic Operating Curves Theoryp. 101
Hierarchically Aggregating Logistic Operating Curvesp. 101
Manufacturing System Operating Curvesp. 104
Workstations with Common WIP Buffersp. 110
Considering Overlapping Productionp. 111
Prerequisites for Applying Calculated Logistic Operating Curvesp. 113
Schedule Reliability Operating Curvesp. 115
Mean Relative Lateness Operating Curvep. 115
Deriving an Operating Curve for Describing the Schedule Reliabilityp. 118
Summarizing the Derivation of the Logistic Operating Curves Theoryp. 123
Basic Laws of Production Logisticsp. 127
First Basic Law of Production Logisticsp. 127
Second Basic Law of Production Logisticsp. 128
Third Basic Law of Production Logisticsp. 129
Fourth Basic Law of Production Logisticsp. 130
Fifth Basic Law of Production Logisticsp. 131
Sixth Basic Law of Production Logisticsp. 132
Seventh Basic Law of Production Logisticsp. 133
Eighth Basic Law of Production Logisticsp. 134
Ninth Basic Law of Production Logisticsp. 135
Applications of the Logistic Operating Curves Theoryp. 137
Developing and Analyzing Calculated Logistic Operating Curvesp. 137
Calculating the Logistic Operating Curvesp. 138
Applying Logistic Operating Curves for Analyzing a Simulated Manufacturing Processp. 140
Evaluating Alternative Methods for Developing Potential for Logistic Improvementp. 143
Varying the Work Content Structurep. 145
Varying the Capacity Structurep. 147
Calculating Logistic Operating Curves with Missing or Incorrect Operating Datap. 148
Incorrect Work Content and Transport Time Datap. 148
Case 1: WC[subscript m] incorrect; WC[subscript v] correct; TTR[subscript m] correctp. 149
Case 2: WC[subscript m] correct; WC[subscript v] incorrect; TTR[subscript m] correctp. 150
Case 3: WC[subscript m] correct; WC[subscript v] correct; TTR[subscript m] incorrectp. 151
Missing or Incorrect Data for the Maximal Possible Output Ratep. 152
An Incorrect Stretch Factor [alpha subscript 1]p. 155
Impact of an Unsteady Process State on Developing and Interpreting Logistic Operating Curvesp. 157
Time Related Changes to the Work Content Structurep. 157
Time Related Changes in the WIP Levelp. 159
Possibilities for Employing Logistic Operating Curves in Designing and Controlling Production Processesp. 163
Logistic Positioningp. 165
Implementing Logistic Operating Curves in Production Controlp. 169
Logistic Oriented Design and Parameterization of Planning and Control Strategiesp. 171
Throughput Oriented Lot Sizingp. 172
Flow Rate Oriented Schedulingp. 173
Integrating the Logistic Operating Curves Theory in Load Oriented Order Releasep. 175
Logistic Oriented Production Designp. 177
Employing the Logistic Operating Curves in Factory Planningp. 177
Logistic Oriented Evaluation of Supply Chainsp. 178
Practical Applications of Bottleneck Oriented Logistic Analysesp. 181
Conducting a Bottleneck Oriented Logistic Analysisp. 181
Determining Key Figuresp. 182
Key Work Content Figuresp. 182
Key Throughput Figuresp. 183
Key Output Rate Figuresp. 183
Key Work in Process Figuresp. 183
Key Lateness Figuresp. 183
Determining Logistically Relevant Workstationsp. 184
Goal: Reducing the Order's Mean Throughput Timep. 185
Goal: Increasing Scheduling Adherencep. 185
Goal: Reducing Loss of Utilizationp. 186
Goal: Reducing the WIPp. 186
Determining Measuresp. 187
Bottleneck Oriented Logistic Analysis in a Circuit Board Manufacturerp. 190
Analysis' Objectivesp. 190
Data Compilationp. 191
Order Throughput Analysisp. 191
Workstation Analysisp. 196
Analysis of Key Performance Figuresp. 196
Identifying Throughput Time Determining Workstationsp. 198
Detailed Analysis of Chosen Work Stationsp. 199
The Resist Coating Workstationp. 199
The Hot Air Leveling Workstationp. 203
Drilling Workstationp. 206
Quantifying the Potential for Logistic Improvementp. 207
Experiences in Applying Bottleneck Oriented Logistic Analysesp. 210
Applying the Bottleneck Oriented Logistic Analysis in a Circuit Board Insertion Departmentp. 211
Determining Throughput Time Relevant Workstationsp. 212
Estimating Existing Potential for Logistic Improvementp. 213
Deriving and Implementing Workstation Specific Measuresp. 214
Manual Insertion Workstationp. 214
SMD Workstationp. 216
HF Testing Workstationp. 218
Summary of Application Experiencesp. 220
Strategies for Implementing the Bottleneck Oriented Logistic Analysisp. 221
Applying the Logistic Operating Curves Theory to Storage Processesp. 223
Throughput Diagram as a Model for the Logistic Procurement Process Chainp. 224
Storage Operating Curvesp. 226
Determining Storage Operating Curves Using Simulationsp. 229
Determining Storage Operating Curves Using an Approximation Equationp. 230
Ideal Storage Operating Curvep. 231
Integrating Plan Deviationsp. 233
Parametrizing the Approximation Equationp. 239
Verifying Storage Operating Curves Using Simulationsp. 241
Possible Applicationsp. 241
Fields and Limits of Applicationp. 245
Examples of Applying Storage Operating Curves in order to Evaluate Suppliersp. 248
Applying the Logistic Operating Curves Theory to Supply Chainsp. 253
Supply Chain Objectivesp. 253
Weighted Service Levelp. 254
An Approximation Equation for a Service Level Operating Curvep. 255
Correlations between the Supply Chain's Logistic Parametersp. 257
Example of a Supply Chain Logistic Analysisp. 259
Logistic Oriented Storage Analysis of the Manufacturer's Finished Goods Storep. 260
Calculating Potential Based on Logistic Operating Curvesp. 260
Deriving Measuresp. 264
Conducting a Bottleneck Oriented Logistic Analysis of the Manufacturer's Productionp. 265
Logistic Oriented Storage Analysis of the Manufacturer's Input Storesp. 268
Bottleneck Oriented Logistic Analysis of the Supplier's Productionp. 268
Supply Chain's Total Potentialp. 269
Summary of Applying Operating Curves to the Supply Chainp. 271
Conclusionsp. 273
Software Documentationp. 277
Bibliographic Referencesp. 301
Indexp. 309
Table of Contents provided by Ingram. All Rights Reserved.

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