Journal of Advanced Mechanical Design, Systems, and Manufacturing
Online ISSN : 1881-3054
ISSN-L : 1881-3054
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Bottleneck Oriented Card-Based Production Control for Push Repetitive Manufacturing Systems
Muhammad Haris AZIZErik BOHEZYuichi KANDAHironori HIBINOToru SAKUMA
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2013 Volume 7 Issue 3 Pages 377-397

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Abstract
One of the major problems of the push Repetitive Manufacturing Systems (RMS) is the Work In Process (WIP) buildups between the stations due to the push nature of the flow of material. Card-based pull or push-pull production control systems offered smooth production flow with reduced WIP. But, applying these systems to push production environment requires huge cost for major cultural and operational changes. We propose a solution to WIP buildups, without altering the basic structure of operation of the push production system. We propose a bottleneck oriented card-based production control system for push RMS. In our system parts release on the shop floor according to the customer demand whereas the material flow is constrained with the Production Authorization Cards (PAC). The PAC circulates between the first station and the bottleneck station in the form of a loop, reducing WIP buildups between the stations. We have conducted simulation based case studies to demonstrate the efficacy of our approach.
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© 2013 by The Japan Society of Mechanical Engineers
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