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This article describes a systematic literature search of research articles on the topics of ecological sustainability and production planning. Over 900 research articles deal intensively with these topics. These articles were catalogued and included in a database. They can be evaluated with an analysis tool, developed by the research group. The tool is available free of charge via a website of the research group.
A simulation analysis of Independent Requirements Consumption in Master Production Scheduling
(2012)
This poster presents purpose and function of the Independent Requirements Consumption in Master Production Scheduling and gives recommendations for its application. The approach of hierarchical production planning and its planning problems are explained. The problem of new customer requirements information between planning periods and solving options are shown. The solving option of Independent Requirements Consumption is focus of this poster. The algorithm of the Independent Requirements Consumption that is implemented in commercial Enterprise Resource Planning (ERP) systems like the SAP system is analyzed. The methods for analyzing the effects of the Independent Requirements Consumption are outlined. The scenarios for simulation studies are stated and compared to similar investigations. The simulation studies were performed on a simulation system at IPF that contains both a production planning and control system and a production. The extent of simulation analyses outreaches similar investigations, especially because of the variety of scenarios. For scenarios in which capacity is available to a sufficient extent, advice for setting the Independent Requirements Consumption parameters is given. It is pointed out that with production constrained scenarios, the necessity to level out production leads to problems. An algorithm to determine necessary inventory levels is presented. It is stated that straight advice for Independent Requirements Consumption parameter settings might not be possible with production constrained scenarios. Further analyses with production constrained scenarios as well as investigations concerning safety stocks in combination with Independent Requirements Consumption are current and future research topics at the Innovation Center for Production Logistics and Factory Planning.
In this paper, we propose a micro-periodic inventory replenishment policy for quickly perishable goods with fixed and known lifetime of items, deterministic lead time, fixed given order cycle, mixed issuing policies (FIFO and LIFO), age-based stock, imperfect items and target customer service level under random demand. The inventory policy is based on time of day (morning, midday, afternoon or evening). The results of our simulation study show that the proposed micro-periodic inventory policy leads to waste reduction of 66% as well as a partial decrease in cost compared to inventory policy with planning on a daily basis.
The sustainable development of processes is currently an important topic in industry and science. Various interest groups and other factors like resource shortages or a lack of skilled workers drive this trend. In the area of Production and Operation Management, the integration of sustainable aspects is also becoming more and more important. However, mainly ecological aspects are considered. Thus, this contribution expands the previous research by the integration of social aspects. For this, we limit our research to the Master Production Scheduling as part of operational production planning. In the context of sustainability, the Global Reporting Initiative (GRI) Standard has established itself for companies and other organisations to report on their sustainability activities. It is the first and most widely adopted global standards for sustainability reporting. The aim of this standard is to measure the sustainable performance and in this way, sustainability activities can be oriented to specific performance indicators. Accordingly, the GRI standard enables concrete initiatives to improve social, environmental and economic conditions for everyone. The modular standard comprises 36 standard modules. For this paper, the 19 social modules were analysed and relevant indicators that could be influenced by the Master Production Scheduling were identified. One of the important indicators from the GRI standard for our research question is the use of employees, measured in terms of hiring and employee turnover. The long-term employee commitment and thus low fluctuation will become a competitive advantage in the future, which is enhanced by the demographic change and the lack of skilled workers. In order to integrate these aspects based on the GRI standard, the classic formulation of Master Production Scheduling is extended. For this a control of the employee utilization within concrete utilization intervals as well as dependent processing times due to different exhaustion effects were integrated. Additionally, in order to take into account the requirements of a flexible production and to model the use of employees, aspects of personnel requirements planning are considered as well, which enable the build-up and reduction of capacity. As a result, social and economic consequences of related production scenarios are presented. In this context, a conflict of targets arises especially with macroeconomic fluctuations. On the one hand, shortages and inventories should be avoided from an economic point of view. On the other hand, a low and constant work intensity as well as a constant number of staff should be preferred for long-term employee commitment. Accordingly, the ability of the model to examine these questions, which will become more and more important for industrial enterprises in the future, becomes clear. Furthermore, it can be seen that it is possible to improve social aspects by adapted production planning without neglecting economic targets.
This article illustrates the problem of deficient working conditions like high work intensity and underlines the possibilities of production planning and control to improve them. However, an included literature search presents that previous approaches have predominantly considered social aspects within a short planning horizon and that there is a need for a long-term consideration. To address this research gap a linear optimization model for Master Production Scheduling is presented, which has been extended by basic aspects of personnel requirements planning and a control of personnel work intensity. The results show that improvements in working conditions can be achieved through adapted production planning without an automatically increase in costs. However , challenges in quantifying the corresponding social correlations are identified as well.
In diesem Beitrag wird anhand einer Fallstudie die Bedeutung der Hauptproduktionsprogrammplanung (HPPLAN) für die hierarchische Produktionsplanung herausgearbeitet werden. Dazu wird versucht das Ergebnis der aggregierten Gesamtplanung (AGGRPLAN) durch Veränderung einzelner Paramater so zu verbessern, dass es dem Ergebnis der HPPLAN entspricht. Im Rahmen der Untersuchungen konnten dabei Verbesserungen für einzelne Planungssituationen erzielt werden, eine generelle Lösung konnte jedoch nicht gefunden werden. Insbesondere der Einsatz eines geeigneten Kapazitätsreduktionsfaktors in Verbindung mit der Berücksichtigung der Durchlaufzeit führt zu einer Verbesserung der Lösung. Bei der Planung von mehr als einem Produkt ist allerdings schwierig einen geeigneten Kapazitätsreduktionsfaktor zu finden, da dieser abhängig von der Nachfrage ist.
Single-stage capacitated lot-sizing problems (CLSP) are essential for manyplanning tasks in production systems. Due to the hierarchical planning approach, which is widely used in industrial practice and implemented in commercial enterprise resource planning as well as production planning and controlsystems, a subsequent scheduling is necessary to gain executable productionplans. Capacity consumption depends on many factors as, for example, systems workload, machine availability, or yield. Thus, a feasible and optimalsolution of the CLSP may lead to unplanned delays after sequencing and processing the orders on the shop floor. Using a so called clearing function (CF),which represents the relationship between the workload and the output of a production system, this capacity consumption in a CLSP is improved in various ways and tested on a real-world application.
This paper introduces a novel chaotic flower pollination algorithm (CFPA) to solve a tardiness-constrained flow-shop scheduling problem with simultaneously loaded stations. This industrial manufacturing problem is modeled from a filter basket production line in Germany and has been generally solved using standard deterministic algorithms. This research develops a metaheuristic approach based on the highly efficient flower pollination algorithm coupled with different chaos maps for stochasticity. The objective function targeted is the tardiness constraint of the due dates. Fifteen different experiments with thirty scenarios are generated to mimic industrial conditions. The results are compared with the genetic algorithm and with the four standard benchmark priority rule-based deterministic algorithms of First In First Out, Raghu and Rajendran, Shortest Processing Time and Slack. From the obtained results and analysis of the relative difference, percentage relative difference and t tests, CFPA was found to be significantly better performing than the deterministic heuristics and the GA algorithm.