Fundamentals of Production Logistics
by Nyhuis, Peter; Wiendahl, Hans-Peter; Rossi, RettRent Textbook
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Summary
Author Biography
Table of Contents
| Introduction | p. 1 |
| Logistic Key Performance Indicators for Manufacturers | p. 1 |
| Dilemma of Operations Planning | p. 4 |
| Model Based Problem Solving Process | p. 6 |
| Objectives of Production Logistics | p. 9 |
| Logistic Operating Curves - an Explanatory Model for Production Logistics | p. 11 |
| Goals and Structure of the Book | p. 13 |
| Basic Principles of Modeling Logistic Operating Curves | p. 17 |
| Funnel Model as a Universal Model for Describing Production Processes | p. 17 |
| Work Content and Operation Times | p. 17 |
| Throughput Time | p. 21 |
| Lateness | p. 23 |
| Logistic Objectives in a Throughput Diagram | p. 24 |
| Output Rate and Utilization | p. 25 |
| Work in Process (WIP) | p. 27 |
| Weighted Throughput Time and Range | p. 28 |
| Little's Law | p. 31 |
| Logistic Operating Curves for Production Processes | p. 35 |
| Traditional Models of Production Logistics | p. 39 |
| Queuing Models | p. 40 |
| M/G/1 Model | p. 42 |
| Using Queuing Theory to Determine Logistic Operating Curves | p. 45 |
| A Critical Review of the Queuing Theory Approach | p. 46 |
| Simulation | p. 48 |
| PROSIM III Simulation System | p. 49 |
| Simulation as an Aid in Determining Logistic Operating Curves | p. 50 |
| A Critical Review of Simulation | p. 52 |
| Deriving the Logistic Operating Curves Theory | p. 59 |
| Ideal Logistic Operating Curves | p. 60 |
| Ideal Minimum WIP Level | p. 60 |
| Maximum Possible Output Rate | p. 63 |
| Constructing Ideal Logistic Operating Curves for the Output Rate and Time Parameters | p. 64 |
| Deriving an Approximation Equation for Calculating an Output Rate Operating Curve | p. 66 |
| C[subscript norm] Function as the Basic Function for a Calculated Output Rate Operating Curve | p. 68 |
| Transforming the C[subscript norm] Function | p. 70 |
| Parametrizing the Logistic Operating Curves Equation | p. 72 |
| Calculating Output Rate Operating Curves | p. 77 |
| Calculating Operating Curves for the Time Parameters | p. 80 |
| Normalized Logistic Operating Curves | p. 85 |
| Logistic Operating Curves Theory and Little's Law - a Model Synthesis | p. 88 |
| Verifying the Logistic Operating Curves Theory | p. 91 |
| Simulation Based Model Validation | p. 91 |
| Validating the Model Based on Field Analyses | p. 96 |
| Underload Operating Zone | p. 97 |
| Transitional Operating Zone | p. 99 |
| Overload Operating Zone | p. 100 |
| Extending the Logistic Operating Curves Theory | p. 101 |
| Hierarchically Aggregating Logistic Operating Curves | p. 101 |
| Manufacturing System Operating Curves | p. 104 |
| Workstations with Common WIP Buffers | p. 110 |
| Considering Overlapping Production | p. 111 |
| Prerequisites for Applying Calculated Logistic Operating Curves | p. 113 |
| Schedule Reliability Operating Curves | p. 115 |
| Mean Relative Lateness Operating Curve | p. 115 |
| Deriving an Operating Curve for Describing the Schedule Reliability | p. 118 |
| Summarizing the Derivation of the Logistic Operating Curves Theory | p. 123 |
| Basic Laws of Production Logistics | p. 127 |
| First Basic Law of Production Logistics | p. 127 |
| Second Basic Law of Production Logistics | p. 128 |
| Third Basic Law of Production Logistics | p. 129 |
| Fourth Basic Law of Production Logistics | p. 130 |
| Fifth Basic Law of Production Logistics | p. 131 |
| Sixth Basic Law of Production Logistics | p. 132 |
| Seventh Basic Law of Production Logistics | p. 133 |
| Eighth Basic Law of Production Logistics | p. 134 |
| Ninth Basic Law of Production Logistics | p. 135 |
| Applications of the Logistic Operating Curves Theory | p. 137 |
| Developing and Analyzing Calculated Logistic Operating Curves | p. 137 |
| Calculating the Logistic Operating Curves | p. 138 |
| Applying Logistic Operating Curves for Analyzing a Simulated Manufacturing Process | p. 140 |
| Evaluating Alternative Methods for Developing Potential for Logistic Improvement | p. 143 |
| Varying the Work Content Structure | p. 145 |
| Varying the Capacity Structure | p. 147 |
| Calculating Logistic Operating Curves with Missing or Incorrect Operating Data | p. 148 |
| Incorrect Work Content and Transport Time Data | p. 148 |
| Case 1: WC[subscript m] incorrect; WC[subscript v] correct; TTR[subscript m] correct | p. 149 |
| Case 2: WC[subscript m] correct; WC[subscript v] incorrect; TTR[subscript m] correct | p. 150 |
| Case 3: WC[subscript m] correct; WC[subscript v] correct; TTR[subscript m] incorrect | p. 151 |
| Missing or Incorrect Data for the Maximal Possible Output Rate | p. 152 |
| An Incorrect Stretch Factor [alpha subscript 1] | p. 155 |
| Impact of an Unsteady Process State on Developing and Interpreting Logistic Operating Curves | p. 157 |
| Time Related Changes to the Work Content Structure | p. 157 |
| Time Related Changes in the WIP Level | p. 159 |
| Possibilities for Employing Logistic Operating Curves in Designing and Controlling Production Processes | p. 163 |
| Logistic Positioning | p. 165 |
| Implementing Logistic Operating Curves in Production Control | p. 169 |
| Logistic Oriented Design and Parameterization of Planning and Control Strategies | p. 171 |
| Throughput Oriented Lot Sizing | p. 172 |
| Flow Rate Oriented Scheduling | p. 173 |
| Integrating the Logistic Operating Curves Theory in Load Oriented Order Release | p. 175 |
| Logistic Oriented Production Design | p. 177 |
| Employing the Logistic Operating Curves in Factory Planning | p. 177 |
| Logistic Oriented Evaluation of Supply Chains | p. 178 |
| Practical Applications of Bottleneck Oriented Logistic Analyses | p. 181 |
| Conducting a Bottleneck Oriented Logistic Analysis | p. 181 |
| Determining Key Figures | p. 182 |
| Key Work Content Figures | p. 182 |
| Key Throughput Figures | p. 183 |
| Key Output Rate Figures | p. 183 |
| Key Work in Process Figures | p. 183 |
| Key Lateness Figures | p. 183 |
| Determining Logistically Relevant Workstations | p. 184 |
| Goal: Reducing the Order's Mean Throughput Time | p. 185 |
| Goal: Increasing Scheduling Adherence | p. 185 |
| Goal: Reducing Loss of Utilization | p. 186 |
| Goal: Reducing the WIP | p. 186 |
| Determining Measures | p. 187 |
| Bottleneck Oriented Logistic Analysis in a Circuit Board Manufacturer | p. 190 |
| Analysis' Objectives | p. 190 |
| Data Compilation | p. 191 |
| Order Throughput Analysis | p. 191 |
| Workstation Analysis | p. 196 |
| Analysis of Key Performance Figures | p. 196 |
| Identifying Throughput Time Determining Workstations | p. 198 |
| Detailed Analysis of Chosen Work Stations | p. 199 |
| The Resist Coating Workstation | p. 199 |
| The Hot Air Leveling Workstation | p. 203 |
| Drilling Workstation | p. 206 |
| Quantifying the Potential for Logistic Improvement | p. 207 |
| Experiences in Applying Bottleneck Oriented Logistic Analyses | p. 210 |
| Applying the Bottleneck Oriented Logistic Analysis in a Circuit Board Insertion Department | p. 211 |
| Determining Throughput Time Relevant Workstations | p. 212 |
| Estimating Existing Potential for Logistic Improvement | p. 213 |
| Deriving and Implementing Workstation Specific Measures | p. 214 |
| Manual Insertion Workstation | p. 214 |
| SMD Workstation | p. 216 |
| HF Testing Workstation | p. 218 |
| Summary of Application Experiences | p. 220 |
| Strategies for Implementing the Bottleneck Oriented Logistic Analysis | p. 221 |
| Applying the Logistic Operating Curves Theory to Storage Processes | p. 223 |
| Throughput Diagram as a Model for the Logistic Procurement Process Chain | p. 224 |
| Storage Operating Curves | p. 226 |
| Determining Storage Operating Curves Using Simulations | p. 229 |
| Determining Storage Operating Curves Using an Approximation Equation | p. 230 |
| Ideal Storage Operating Curve | p. 231 |
| Integrating Plan Deviations | p. 233 |
| Parametrizing the Approximation Equation | p. 239 |
| Verifying Storage Operating Curves Using Simulations | p. 241 |
| Possible Applications | p. 241 |
| Fields and Limits of Application | p. 245 |
| Examples of Applying Storage Operating Curves in order to Evaluate Suppliers | p. 248 |
| Applying the Logistic Operating Curves Theory to Supply Chains | p. 253 |
| Supply Chain Objectives | p. 253 |
| Weighted Service Level | p. 254 |
| An Approximation Equation for a Service Level Operating Curve | p. 255 |
| Correlations between the Supply Chain's Logistic Parameters | p. 257 |
| Example of a Supply Chain Logistic Analysis | p. 259 |
| Logistic Oriented Storage Analysis of the Manufacturer's Finished Goods Store | p. 260 |
| Calculating Potential Based on Logistic Operating Curves | p. 260 |
| Deriving Measures | p. 264 |
| Conducting a Bottleneck Oriented Logistic Analysis of the Manufacturer's Production | p. 265 |
| Logistic Oriented Storage Analysis of the Manufacturer's Input Stores | p. 268 |
| Bottleneck Oriented Logistic Analysis of the Supplier's Production | p. 268 |
| Supply Chain's Total Potential | p. 269 |
| Summary of Applying Operating Curves to the Supply Chain | p. 271 |
| Conclusions | p. 273 |
| Software Documentation | p. 277 |
| Bibliographic References | p. 301 |
| Index | p. 309 |
| Table of Contents provided by Ingram. All Rights Reserved. |
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