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A large number of researchers have addressed social aspects in hierarchical production planning. This article responds to research gaps identified in our previous literature review. Accordingly, consideration of social aspects and the economic implications of social improvements are required in a longer term planning approach. For this, we integrate work intensity as employee utilization in a general mixed-integer programming model for master production scheduling. Following existing fatigue functions, we represent the relationship between work intensity and exhaustion through an employee-utilization-dependent exhaustion function. We account for the economic implications through exhaustion-dependent capacity load factors. We solve our model with a CPLEX standard solver and analyze a case study based on a realistic production system and numerical data. We demonstrate that the consideration of economic implications is necessary to evaluate social improvements. Otherwise, monetary disadvantages are overestimated, and social improvements are, thus, negatively affected. Moreover, from a certain level of work-intensity reduction, demand peaks are smoothed more by pre-production, which requires more core employees, while temporary employment is reduced. Further potential may arise from considering and quantifying other interdependencies, such as employee exhaustion and employee days off. In addition, the relationship between social working conditions and employee turnover can be integrated.
Companies often use specially-designed production systems and change them from time to time. They produce small batches in order to satisfy specific demands with the least tardiness. This imposes high demands on high-performance scheduling algorithms which can be rapidly adapted to changes in the production system. As a solution, this paper proposes a generic approach: solutions were obtained using a widely-used commercially-available tool for solving linear optimization models, which is available in an Enterprise Resource Planning System (in the SAP system for example) or can be connected to it. In a real-world application of a flow shop with special restrictions this approach is successfully used on a standard personal computer. Thus, the main implication is that optimal scheduling with a commercially-available tool, incorporated in an Enterprise Resource Planning System, may be the best approach.
Sustainable production includes economic, environmental, and social aspects. However, social sustainability has received less attention, especially compared to the economic aspects. Next to technical and organizational measures, social improvements within supply chains can also be achieved through suitable production planning. Within production planning, production programs are determined, and the assignment of available resources (e.g., employees) is specified. Thus, the utilization and workload of employees are defined. This systematic literature review investigates to what extent such employee-related social aspects are reflected in production planning and discusses whether economic aspects dominate them. For this, a Scopus database search was carried out and 76 identified approaches were analyzed and categorized regarding the occurring employee-related social aspects and their implementation. Thus far, the approaches mainly consider single aspects on single planning levels. A consideration of a broad set of aspects along the entire production planning has rarely been studied. In particular, health and safety aspects are considered on the levels of assembly line balancing and job rotation. However, their impact is primarily determined by the specific settings of the decision-maker. To support decision-makers, only a few studies have investigated the effects based on real application scenarios. Further potential might be an extended modeling of social and economic interdependencies and a consideration of employee-related social aspects in medium- to long-term production planning.
Final assembly at Krones AG must make the best possible use of its production space and meeting the specified customer due dates is critical. Via a self developed simulation tool, the present scheduling procedure is compared with the one by priority rule shortest slack. As a consequence slack should have a higher importance in the planning
Scarcity of resources, structural change during the further development of renewable energy sources, and their corresponding costs, such as increasing resource costs or penalties due to dirty production, lead industrial firms to adapt ecological actions. In this regard, research on energy utilization in production planning has received increased attention in the last years, resulting in a large number of research articles so far. With the paper at hand, we review the literature on energy-oriented production planning. The aim of this study is to derive similar core issues and related properties along energy-oriented models within hierarchical production planning. For this, we carry out a systematic literature review and analyze and synthesize 375 research articles. We classify the underlying literature with a novel two-dimensional classification scheme and identify three key topics and five frequently found characteristics, which are presented in detail throughout this article. Based on these results, we state several potentials for further research.
Companies use special designed flow shops, in order to satisfy specific demands. Products need to be transported (from one station to the next station) by a crane and the way of working of this crane excludes the intermediate storage (of a work piece). In addition, the way of working restricts the set of feasible schedules even more than the no-buffer restriction discussed in the literature in the case of limited storage. Since this scheduling problem is integrated in the usual hierarchical planning, the tardiness is minimised. A linear optimisation model is presented to provide a formal description of this NP-hard problem. It is also used to explain the performance of priority rule based heuristic solutions on small test problems. In detail, priority rules as well as a priority rule based branch and bound procedure are analysed; priority rules are regarded, because a priority rule is still the standard procedure for on-line scheduling in industrial practise. Out of successful priority rules in the literature the best one is identified by an extensive simulative investigation. An improved look-ahead is realised by a restricted search over all possible schedules.
Folgender Beitrag untersucht die Notwendigkeit einer Berücksichtigung von Mitarbeiterauslastungen und davon abhängiger Bearbeitungszeiten in der Hauptproduktionsprogrammplanung. Zudem wird aufgezeigt, dass dieses Themengebiet aktuell eine Forschungslücke darstellt. Aus diesem Grund wird ein selbst entwickeltes lineares Optimierungsmodell für die Hauptproduktionsprogrammplanung vorgestellt, welches soziale Kriterien und eine geeignete Fallstudie enthält. Die Ergebnisse verdeutlichen, dass erhebliche Abweichungen durch eine Ignoranz von Mitarbeiterauslastungen und davon abhängiger Bearbeitungszeiten entstehen. Deshalb ist eine Integration zu empfehlen. Allerdings wird auch deutlich, dass weitere Forschungen notwendig sind, speziell für die Bestimmung geeigneter Erschöpfungsfunktionen, so wie beispielsweise Funktionen für Lerneffekte existieren.
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.
Companies often use specially-designed production systems and change them from time to time. They produce small batches in order to satisfy specific demands with the least tardiness. This imposes high demands on high-performance scheduling algorithms which can be rapidly adapted to changes in the production system. As a solution, this paper proposes a generic approach: solutions were obtained using a widely-used commercially-available tool for solving linear optimization models, which is available in an Enterprise Resource Planning System (in the SAP system for example) or can be connected to it. In a real-world application of a flow shop with special restrictions this approach is successfully used on a standard personal computer. Thus, the main implication is that optimal scheduling with a commercially-available tool, incorporated in an Enterprise Resource Planning System, may be the best approach.
In this paper, the risks of a Smart Factory are to be examined and structured in order to be able to evaluate the status of the Smart Factory. This thesis thus serves as an overview of the technical components of a Smart Factory and the associated risks. The study takes a holistic view of the smart factory. The results show that the greatest need for action lies in the technological field. Thus, the topics of standardization, information security, availability of IT infrastructure, availability of fast internet and complex systems were prioritized. The organizational and financial risks, which also play an important role in a Smart Factory transformation, are addressed.