Article

Using system dynamics simulations to compare capacity models for production planning

Authors:

Karl KempfAuthors Info & Claims

WSC '06: Proceedings of the 38th conference on Winter simulation

Pages 1855 - 1862

Published: 03 December 2006 Publication History

Abstract

While a variety of optimization formulations of production planning problems have been proposed over the last fifty years, the majority of these are based on simple models of capacity that fail to reflect the nonlinear relationship between workload and lead times induced by the queuing behavior of capacitated production resources. We use system dynamics simulations of a simple capacitated production system to examine the performance of several different capacity models that yield load-dependent lead times, and relate these models to those used in system dynamics models of production systems.

References

[1]

Asmundsson, J. M., R. L. Rardin, C. H. Turkseven, and R. Uzsoy (2006). "Tractable Nonlinear Capacity Models for Production Planning." Research Report, Laboratory for Extended Enterprises, Purdue University.

[2]

Asmundsson, J. M., R. L. Rardin, and R. Uzsoy (2006). "Tractable Nonlinear Production Planning Models for Semiconductor Wafer Fabrication Facilities." IEEE Trans, on Semiconductor Mfg. 19: 95--111.

[3]

Atherton, R. W. and J. E. Dayhoff (1986a) "Signature analysis: Simulation of inventory, cycle time, and throughput trade-offs in wafer fabrication," IEEE Trans, on Components, Hybrids, and Manuf. Tech., vol. CHMT-9, no. 4, pp. 498--507.

[4]

Atherton, R. W. and J. E. Dayhoff (1986b). "Signature analysis of dispatch schemes in wafer fabrication," IEEE Trans. on Components, Hybrids, and Manuf. Tech., vol. CHMT-9, no. 4, pp.518--525.

[5]

Billington, P. J., J. O. McClain, and L. J. Thomas (1983). "Mathematical Approaches to Capacity-Constrained MRP Systems: Review, Formulation and Problem Reduction." Management Science 29(10): 1126--1141.

Digital Library

[6]

Buzacott, J. A. and J. G. Shanthikumar (1993). Stochastic Models of Manufacturing Systems. Englewood Cliffs, NJ, Prentice-Hall.

[7]

Dauzere-Peres, S. and J. B. Lasserre (1994). An Integrated Approach in Production Planning and Scheduling. Berlin, Springer-Verlag.

[8]

Elmaghraby, S. E. (1991). "Manufacturing Capacity and its Measurement: A Critical Evaluation." Computers and Operations Research 18(17): 615--627.

Digital Library

[9]

Ettl, M., G. Feigin, G. Y. Lin, and D. D. Yao (2000). "A Supply Chain Network Model with Base-Stock Control and Service Requirements." Operations Research 48: 216--232.

Digital Library

[10]

Fine, C. H. and S. C. Graves (1989). "A Tactical Planning Model for Manufacturing Subcomponents of Mainframe Computers." Journal of Manufacturing and Operations Management 2: 4--34.

[11]

Forrester, J. W. (1962). Industrial Dynamics, MIT Press.

[12]

Graves, S. C. (1986). "A Tactical Planning Model for a Job Shop." Operations Research 34: 552--533.

Digital Library

[13]

Graves, S. C. (1988). "Safety Stocks in Manufacturing Systems." Journal of Manufacturing and Operations Management 1: 67--101.

[14]

Hackman, S. T. and R. C. Leachman (1989). "A General Framework for Modeling Production." Management Science 35: 478--495.

Digital Library

[15]

Holt, C. C., F. Modigliani, and J. F. Muth (1956). "Derivation of a Linear Rule for Production and Employment." Mgmt. Science 2(2): 159--177.

[16]

Hopp, W. and M. L. Spearman (2001). Factory Physics, Irwin.

[17]

Hung, Y. F. and M. C. Hou (2001). "A Production Planning Approach based on Iterations of Linear Programming Optimization and Flow Time Prediction." Journal of the Chinese Institute of Industrial Engineers 18(3): 55--67.

[18]

Hung, Y. F. and R. C. Leachman (1996). "A Production Planning Methodology for Semiconductor Manufacturing Based on Iterative Simulation and Linear Programming Calculations." IEEE Transactions on Semiconductor Manufacturing 9(2): 257--269.

[19]

Johnson, L. A. and D. C. Montgomery (1974). Operations Research in Production Planning, Scheduling and Inventory Control. New York, John Wiley.

[20]

Karmarkar, U. S. (1989). "Capacity Loading and Release Planning with Work-in-Progress (WIP) and Lead-times." Journal of Manufacturing and Operations Management 2(105--123).

[21]

Karmarkar, U. S. (1993). Manufacturing Lead-times, Order Release and Capacity Loading. Handbooks in Operations Research & Management Science Vol. 4: Logistics of Production and Inventory. S. C. Graves, A. H. G. Rinnooy Kan and P. H. Zipkin.

[22]

Kekre, S. (1984). Some Issues in Job Shop Design. Simon Graduate School of Business Administration. Rochester, NY, University of Rochester.

[23]

Lautenschlager, M. and H. Stadtler (1998). Modelling Lead Times Depending on Capacity Utilization. Research Report, Technische Univ. Darmstadt.

[24]

Modigliani, F. and F. E. Hohn (1955). "Production Planning Over Time and the Nature of the Expectation and Planning Horizon." Econometrica 23: 46--66.

[25]

Orlicky, J. (1975). Material Requirements Planning. New York, McGraw-Hill.

Digital Library

[26]

Pahl, J., S. Voss and D. L. Woodruff (2005). "Production Planning with Load Dependent Lead Times." 4OR: A Quarterly Journal of Operations Research 3: 257--302.

[27]

Pritsker, A. A. B. and K. Snyder (1997). Production Scheduling Using FACTOR. The Planning and Scheduling of Production Systems. A. Artiba and S. E. Elmaghraby, Chapman and Hall.

[28]

Riano, G. (2003). Transient Behavior of Stochastic Networks: Application to Production Planning with Load-Dependent Lead Times. School of Industrial and Systems Engineering. Atlanta, GA, Georgia Institute of Technoogy.

[29]

Riano, G., R. Serfozo, S. Hackman, S. H. Ng, L. P. Chan, and P. Lendermann (2003). Benchmarking of a Stochastic Production Planning Model in a Simulation Testbed. Winter Simulation Conference.

Digital Library

[30]

Srinivasan, A., M. Carey, and T. E. Morton (1988). Resource Pricing and Aggregate Scheduling in Manufacturing Systems. Graduate School of Industrial Administration, Carnegie-Mellon University. Pittsburgh, PA.

[31]

Sterman, J. D. (2000). Business Dynamics: Systems Thinking and Modeling for a Complex World. New York, McGraw-Hill.

Digital Library

[32]

Tardif, V. and M. L. Spearman (1997). "Diagnostic Scheduling in Finite-Capacity Production Environments." Computers and Industrial Engineering 32: 867--878.

Digital Library

[33]

Uzsoy, R., C. Y. Lee and L. A. Martin-Vega (1992). "A Review of Production Planning and Scheduling Models in the Semiconductor Industry Part I: System Characteristics, Performance Evaluation and Production Planning." IIE Transactions on Scheduling and Logistics 24(47--61).

[34]

Voss, S. and D. L. Woodruff (2003). Introduction to Computational Optimization Models for Production Planning in a Supply Chain. Berlin, Springer-Verlag.

Digital Library

Cited By

Durmuşoğlu ADurmuşoğlu Z(2018)An Analysis on the Technological Capacity Distribution for TurkeyProceedings of the 2nd International Conference on Business and Information Management10.1145/3278252.3278257(141-144)Online publication date: 20-Sep-2018
https://dl.acm.org/doi/10.1145/3278252.3278257
Orcun SÇetinkaya SUzsoy RTew J(2007)Determining safety stocks in the presence of workload-dependent lead timesProceedings of the 39th conference on Winter simulation: 40 years! The best is yet to come10.5555/1351542.1351846(1691-1698)Online publication date: 9-Dec-2007
https://dl.acm.org/doi/10.5555/1351542.1351846

Using system dynamics simulations to compare capacity models for production planning
1. Applied computing

Recommendations

Models and solution techniques for production planning problems with increasing byproducts

We consider a production planning problem where the production process creates a mixture of desirable products and undesirable byproducts. In this production process, at any point in time the fraction of the mixture that is an undesirable byproduct ...
Optimal production planning in a petrochemical industry using multiple levels

Proposed mixed integer programming formulation for production planning.Proposed formulation incorporates production through multiple levels.Proposed formulation is expressive and can be solved to global optimality.Proposed formulation overcomes the ...
Capacity-driven production planning
Highlights
- Combination of MRP, capacity planning and capacity adjustment.
- (Semi-)automatic ...
Abstract
Traditional material requirements planning systems (MRP) schedule production orders for on-demand items without considering limited capacities of production resources. This article introduces a production planning approach which also ...

Comments

Information & Contributors

Information

Published In

cover image ACM Conferences

WSC '06: Proceedings of the 38th conference on Winter simulation

December 2006

2429 pages

ISBN:1424405017

Editors:
L. Felipe Perrone
Bucknell University
,
Barry G. Lawson
University of Richmond
,
Jason Liu
Colorado School of Mines
,
Frederick P. Wieland
Sensis Corporation
,
General Chair:
David Nicol
University of Illinois, Urbana-Champaign
,
Program Chair:
Richard Fujimoto
College of Computing, Georgia Tech

Sponsors

IIE: Institute of Industrial Engineers
ASA: American Statistical Association
IEICE ESS: Institute of Electronics, Information and Communication Engineers, Engineering Sciences Society
IEEE-CS\DATC: The IEEE Computer Society
SIGSIM: ACM Special Interest Group on Simulation and Modeling
NIST: National Institute of Standards and Technology
(SCS): The Society for Modeling and Simulation International
INFORMS-CS: Institute for Operations Research and the Management Sciences-College on Simulation

Publisher

Winter Simulation Conference

Publication History

Published: 03 December 2006

Check for updates

Qualifiers

Article

Conference

WSC06

Sponsor:

IIE
ASA
IEICE ESS
IEEE-CS\DATC
SIGSIM
NIST
(SCS)
INFORMS-CS

WSC06: Winter Simulation Conference 2006

December 3 - 6, 2006

California, Monterey

Acceptance Rates

WSC '06 Paper Acceptance Rate 177 of 252 submissions, 70%;

Overall Acceptance Rate 3,413 of 5,075 submissions, 67%

Contributors

Other Metrics

View Article Metrics

Bibliometrics & Citations

Bibliometrics

Article Metrics

2
Total Citations
View Citations
572
Total Downloads

Downloads (Last 12 months)2
Downloads (Last 6 weeks)1

Reflects downloads up to 07 Mar 2025

Other Metrics

View Author Metrics

Citations

Cited By

Durmuşoğlu ADurmuşoğlu Z(2018)An Analysis on the Technological Capacity Distribution for TurkeyProceedings of the 2nd International Conference on Business and Information Management10.1145/3278252.3278257(141-144)Online publication date: 20-Sep-2018
https://dl.acm.org/doi/10.1145/3278252.3278257
Orcun SÇetinkaya SUzsoy RTew J(2007)Determining safety stocks in the presence of workload-dependent lead timesProceedings of the 39th conference on Winter simulation: 40 years! The best is yet to come10.5555/1351542.1351846(1691-1698)Online publication date: 9-Dec-2007
https://dl.acm.org/doi/10.5555/1351542.1351846

View Options

Login options

Check if you have access through your login credentials or your institution to get full access on this article.

Full Access

Get this Publication

View options

PDF

View or Download as a PDF file.

eReader

View online with eReader.

Figures

Tables

Media

View Table of Conten