JPH03196948A - Production planning preparation method - Google Patents
Production planning preparation methodInfo
- Publication number
- JPH03196948A JPH03196948A JP1335812A JP33581289A JPH03196948A JP H03196948 A JPH03196948 A JP H03196948A JP 1335812 A JP1335812 A JP 1335812A JP 33581289 A JP33581289 A JP 33581289A JP H03196948 A JPH03196948 A JP H03196948A
- Authority
- JP
- Japan
- Prior art keywords
- production
- load
- production line
- product
- processes
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Pending
Links
- 238000004519 manufacturing process Methods 0.000 title claims abstract description 62
- 238000002360 preparation method Methods 0.000 title abstract 2
- 238000000034 method Methods 0.000 claims abstract description 123
- 239000000047 product Substances 0.000 description 32
- 238000010586 diagram Methods 0.000 description 5
- 230000000694 effects Effects 0.000 description 3
- 238000003860 storage Methods 0.000 description 3
- 230000003111 delayed effect Effects 0.000 description 2
- 238000009825 accumulation Methods 0.000 description 1
- 239000006227 byproduct Substances 0.000 description 1
- 230000001186 cumulative effect Effects 0.000 description 1
- 238000005520 cutting process Methods 0.000 description 1
- 230000001934 delay Effects 0.000 description 1
- 238000009795 derivation Methods 0.000 description 1
- 238000005553 drilling Methods 0.000 description 1
- 238000003754 machining Methods 0.000 description 1
- 239000000463 material Substances 0.000 description 1
- 238000012261 overproduction Methods 0.000 description 1
Classifications
-
- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
- Y02P—CLIMATE CHANGE MITIGATION TECHNOLOGIES IN THE PRODUCTION OR PROCESSING OF GOODS
- Y02P90/00—Enabling technologies with a potential contribution to greenhouse gas [GHG] emissions mitigation
- Y02P90/02—Total factory control, e.g. smart factories, flexible manufacturing systems [FMS] or integrated manufacturing systems [IMS]
-
- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
- Y02P—CLIMATE CHANGE MITIGATION TECHNOLOGIES IN THE PRODUCTION OR PROCESSING OF GOODS
- Y02P90/00—Enabling technologies with a potential contribution to greenhouse gas [GHG] emissions mitigation
- Y02P90/30—Computing systems specially adapted for manufacturing
Landscapes
- Management, Administration, Business Operations System, And Electronic Commerce (AREA)
- Multi-Process Working Machines And Systems (AREA)
- General Factory Administration (AREA)
Abstract
Description
【発明の詳細な説明】
〔産業上の利用分野〕
FMS生産ライン等の多品種生産を行う生産ラインでの
生産計画の作成方法に関するものである〔従来の技術〕
多品種の生産を行う生産ラインにおける生産計画作成の
従来例としては、例えば、特開昭58−163070号
公報がある。この従来例では与えられた条件(生産数量
、納期等)に基づき、コンピュータを用い累積負荷曲線
法により、日々の作業量が平滑化するように生産計画を
決定する方法が提案されている。この提案によると生産
ラインが素材投入エリア、加工ステージョン、保管エリ
ア、搬送装置、作業待ちエリア、組立ステーションおよ
び完成品エリアから構成されるものと仮定し、その保管
エリアの予め定められた基準仕掛かり量分の作業のみを
行うことにより、後工程が必要とするときに必要な量だ
けを作り、作り過ぎによる無駄な仕掛かりが発生しない
ようにすることができる。[Detailed Description of the Invention] [Industrial Field of Application] This invention relates to a production plan creation method for a production line that produces a wide variety of products, such as an FMS production line. [Prior Art] A production line that produces a wide variety of products. An example of a conventional example of production plan creation in the prior art is Japanese Patent Application Laid-Open No. 163070/1983. In this conventional example, a method has been proposed in which a computer is used to determine a production plan based on given conditions (production quantity, delivery date, etc.) using a cumulative load curve method so as to smooth out the daily workload. According to this proposal, it is assumed that the production line consists of a material input area, a processing station, a storage area, a conveyance device, a work waiting area, an assembly station, and a finished product area, and the storage area has predetermined standard specifications. By performing only the required amount of work, it is possible to produce only the necessary amount when the subsequent process requires it, and to avoid wasteful work in progress due to overproduction.
この従来例はこのような生産ラインで最小限の仕掛かり
で円滑な生産を行うための方法である。This conventional example is a method for performing smooth production on such a production line with a minimum number of work in progress.
もし、加工ステージョンで未完、あるいは遅延部品等が
発生すると、その工程をネック工程としてランプによっ
て表示し警告を出すようにしている。それによって、ネ
ック工程での組立に必要な部品の供給が遅れないように
しようとするものである。If an unfinished or delayed part occurs at a machining station, a lamp indicates that the process is a bottleneck process and a warning is issued. This is intended to prevent delays in the supply of parts necessary for assembly in the bottleneck process.
上述のような従来例においては最小限の仕掛かりで円滑
な生産を行うために、保管エリアに予め定められた量の
仕掛かり等の部品在庫は持たねばならない。又、加工ス
テージョンでの未完、あるいは遅延部品の発生によって
ネック工程が顕在化しそれをランプによる表示で警告す
るようにしているが、このように問題が発生してからの
、しかも警告のみではネック工程へ対応するにあたって
大きな効果を期待することはできない。In the conventional example described above, in order to carry out smooth production with a minimum number of in-process items, a predetermined amount of parts such as in-process items must be kept in the storage area. In addition, when a bottleneck process becomes apparent due to the occurrence of unfinished or delayed parts at the processing station, a lamp is used to warn of this, but it is difficult to solve the bottleneck by only warning after a problem has occurred. It is not possible to expect great effects when responding to processes.
従って、本発明はこれらの課題を解消し、ネックとなる
工程を生産計画段階で予測、対応し、生産性が高く在庫
量の少なくてすむ生産計画の作成方法を提供することを
目的とするものである。Therefore, it is an object of the present invention to solve these problems, predict and deal with bottleneck processes at the production planning stage, and provide a method for creating a production plan that is highly productive and requires less inventory. It is.
上述のような目的を達成するために本発明は次のような
手段を有するものである。In order to achieve the above objects, the present invention has the following means.
即ち、多品種生産を行う生産ラインの各工程の負荷予測
を行い、前記負荷予測から最大負荷量となる工程をネッ
ク工程として選び出す手段と、前記ネック工程の前後の
工程における待ち時間が最も小さくなるような品種投入
の順序を選び出す手段とを有し、前記順序で生産計画を
作成すること特徴とする生産計画作成方法とするもので
ある。That is, there is a means for predicting the load of each process in a production line that performs multi-product production, selecting a process with the maximum load from the load prediction as a bottleneck process, and minimizing waiting time in processes before and after the bottleneck process. and means for selecting the order of inputting the product types, and the production plan is created in the said order.
多品種生産を行う生産ラインの生産計画作成において、
先ず、生産ラインの各工程毎の負荷予測を行う。つまり
、品種別工程負荷データベースおよび生産指示データか
ら工程別負荷データを作成する。そして、その負荷予測
から最大負荷量となる工程をネック工程として選び出す
手段により、最も注目すべき工程を選択し、この工程を
上手に遂行する方法としての生産計画作成法を示したも
のである。その生産計画作成方法とは、その生産ライン
での全ての生産品を合わせたネック工程の前後の工程に
おける待ち時間が最も小さくなるような品種投入の順序
を選び出す手段により生産計画を作成するものであるか
ら、ネックとなる工程に最大の配慮を用いて生産するこ
とになり、それが引いては生産ラインとしての高い生産
性を生み出す素となるものである。When creating a production plan for a production line that produces a wide variety of products,
First, we predict the load for each process on the production line. That is, process-specific load data is created from the product-specific process load database and production instruction data. Then, the method of creating a production plan is shown as a method for selecting the most notable process and skillfully carrying out the process by selecting the process with the maximum load from the load prediction as the bottleneck process. The production plan creation method is to create a production plan by selecting the order of product introduction that minimizes the waiting time in the processes before and after the bottleneck process for all products on the production line. Because of this, we are able to produce with maximum consideration for the processes that are the bottlenecks, which in turn becomes the basis for creating high productivity as a production line.
以下、本発明の実施例につき図面に基づき詳細に説明す
る。Hereinafter, embodiments of the present invention will be described in detail based on the drawings.
本発明における生産ライン11の生産計画作成において
は、第1図に示すように、先ず、各工程A、B、C・・
・の負荷予測を行わねばならない。そのための手順およ
びデータのフローをそれぞれ第1図および第2図に示す
。この時、データ情報として次のデータが必要である。In creating a production plan for the production line 11 according to the present invention, as shown in FIG. 1, first, each process A, B, C...
・The load must be predicted. The procedure and data flow for this purpose are shown in FIGS. 1 and 2, respectively. At this time, the following data is required as data information.
(イ)品種別工程負荷データベース21:品種W1、W
2、W3・・・それぞれの各工程A、ESC・・・での
負荷量を管理しているデータベースで、実績データが登
録されたものである。(b) Product type process load database 21: Product types W1, W
2, W3...A database that manages the load amount in each process A, ESC, etc., in which performance data is registered.
(ロ)生産指示データ22:上位システム(図示せず)
より受は取った生産予定の品種W1、W2、W3・・・
等のデータである。(b) Production instruction data 22: Upper system (not shown)
The varieties W1, W2, W3, etc. that are scheduled to be produced have been received.
etc. data.
(ハ)加工内容別負荷データ23:穴明け、切断等の加
工内容別に加工設備に対する負荷量を登録したデータで
ある。(c) Load data by processing content 23: This is data in which the amount of load on processing equipment is registered for each processing content such as drilling and cutting.
これらのデータから負荷予測を行う手順を次のように行
う。The procedure for predicting load from these data is as follows.
(1)生産指示データ22から生産予定の品種W1、W
2、W3・・・を識別する。(1) Types W1 and W scheduled to be produced from the production instruction data 22
2. Identify W3...
(2)m別した品種W1、W2、W3・・・をキーコー
ドとして品種別工程負荷データベース21より品種別負
荷情報24(第1図での(al)、(a2)、(a3)
はその個々の情報)を引き出す。第1図の個別の品種別
負荷情報(al )(a2)、(a3)において横軸は
工程A。(2) Type-specific load information 24 ((al), (a2), (a3) in Figure 1) from the type-specific process load database 21 using the m-separated types W1, W2, W3...
(individual information). In the individual product type load information (al) (a2) and (a3) in FIG. 1, the horizontal axis is process A.
B、C・・・を、縦軸は負荷量を示したものである(3
)(2)において品種別工程負荷データベース21に未
登録の品種に関しては、その加工内容を分析し加工内容
別負荷データ23から各工程A、B、C・・・に対する
負荷量を算出し個別の品種別負荷情報(al )、(a
2)、(a3)・・・を作成する。B, C..., the vertical axis shows the load amount (3
) In (2), for products that are not registered in the product-specific process load database 21, the processing content is analyzed and the load amount for each process A, B, C, etc. is calculated from the processing content-specific load data 23, and individual Load information by type (al), (a
2), (a3)... are created.
(4)各品種W1、W2、W3・・・の個別の品種別負
荷情報(al )、(a2)、(a3)−より各工程A
、B、C・・・それぞれに負荷量を積み上げ工程別負荷
データ(b)(第2図における25)を作成する。この
時、最大負荷量となる工程をネック工程とする。第1図
の例ではネック工程は工程Bである。(4) Each process A from the individual product load information (al), (a2), (a3) for each product type W1, W2, W3...
, B, C, . . . , to create load data (b) (25 in FIG. 2) for each process by accumulating the load amount. At this time, the process with the maximum load amount is defined as the neck process. In the example of FIG. 1, the neck process is process B.
工程A、B、C・・・それぞれの負荷量の積み上げおよ
びネック工程の決定により負荷予測が完了する。尚、第
2図において26は工程別負荷積み上げ処理を表したも
のである。Load prediction is completed by accumulating the load amounts of processes A, B, C... and determining the bottleneck process. In FIG. 2, numeral 26 represents load accumulation processing for each process.
次に、第3図に示すネック工程20である工程Bと前後
の工程A、Cでの搬出待ち、搬入待ちが全体として最も
少ないような品種W1、W2、W3・・・の生産ライン
11への投入順序で生産計画を作成することにより、生
産性の高い生産計画を得る。その順序付けの方法として
以下に示す方法をとるものである。Next, proceed to the production line 11 for the products W1, W2, W3, etc., which have the least amount of waiting for delivery and delivery in the process B, which is the bottleneck process 20, and the preceding and following processes A and C shown in FIG. 3. By creating a production plan using the input order, a highly productive production plan can be obtained. The ordering method is as follows.
ネック工程20である工程Bと前後の工程A、Cでの待
ちを少なくするには、各工程A、B、Cでの負荷量の差
が少なくならなければいけない。In order to reduce the waiting time between process B, which is the neck process 20, and processes A and C before and after it, the difference in the amount of load between each process A, B, and C must be reduced.
第4図において生産ライン11のネック工程20が工程
Bであるとき、先ず、品種W1が前工程である工程Aに
搬入して加工される(第4図の(a)の状態)。In FIG. 4, when the neck process 20 of the production line 11 is process B, the product type W1 is first carried into process A, which is the previous process, and processed (state in (a) of FIG. 4).
次に、品種W1が工程Bに搬入され、品種W2が工程A
に搬入される。そして、それぞれ加工される(第4図の
(b)の状態)。このとき、品種W1の工程Bでの負荷
量をBl、品種W2の工程Aでの負荷量をA2とすると
工程A、B間の負荷量の差は1A2−Bllとなる。一
方、これを状態で分けて表したのが第3図の(a)、(
b)である。つまり第3図(a)は品種W2の工程Aで
の加工が先に終わり、品種W1の工程Bでの加工がまだ
終わっていない、つまり、工程Aでの搬出待ちの状態を
表したものである。又、第3図(b)は品種W1の工程
Bでの加工が先に終わり、品種W2の工程Aでの加工が
まだ終わっていない、つまり、工程Bの搬入待ちの状態
を表したものである。Next, type W1 is carried into process B, and type W2 is transported to process A.
will be transported to. Then, they are each processed (the state shown in FIG. 4(b)). At this time, if the load amount in process B for product type W1 is Bl, and the load amount in process A for product type W2 is A2, the difference in the load amount between processes A and B is 1A2-Bll. On the other hand, Figure 3 (a) and (
b). In other words, Fig. 3(a) shows a state in which the processing of product W2 has finished in process A first, and the processing of product W1 in process B has not yet been completed, that is, the product is waiting to be carried out in process A. be. Furthermore, Fig. 3(b) shows a state in which the processing of type W1 in process B has been completed first, and the processing of type W2 in process A has not yet been completed, that is, it is waiting for process B to be delivered. be.
更に、品種W1が工程Cに搬入され、続いて品種W2が
工程Bに搬入され、それぞれ加工される(第4図の(c
)の状態)。このとき、品種W1の工程Cでの負荷量を
C1,品種W2の工程Bでの負荷量を82とすると工程
B、C間の負荷量の差はl82−C11となる。一方、
これをこれを状態で分けて表したのが第3図の(C)、
(d)である。つまり第3図(C)は品種W2の工程B
での加工が先に終わり、品種Wlの工程Cでの加工がま
だ終わっていない、工程Bでの搬出待ちの状態を表した
ものである。又、第3図(d)は品種W1の工程Cでの
加工が先に終わり、品種W2の工程Bでの加工がまだ終
わっていない、工程Cの搬入待ちの状態を表したもので
ある。Furthermore, type W1 is carried into process C, and then type W2 is carried into process B, where they are processed ((c in Fig. 4).
) state). At this time, if the load amount in process C for type W1 is C1, and the load amount in process B for type W2 is 82, the difference in load amount between processes B and C is 182-C11. on the other hand,
Figure 3 (C) shows this divided into states.
(d). In other words, Fig. 3 (C) shows process B for type W2.
This figure shows a state in which the product is waiting to be carried out in process B, where the processing in process B has finished first, and the process in process C for product Wl has not yet finished. Further, FIG. 3(d) shows a state in which the product W1 has been processed in process C first, and the product W2 has not yet been processed in process B, and is waiting for delivery to process C.
従って、品種W1、W2に関してのネック工程20であ
る工程Bの前後工程A、Cでの全負荷量の差は、
全負荷量の差=lA2−Bl l+182−CIとな
る。このような全負荷量の差を、負荷予測を行った際に
作成した品種別負荷情報24を基に計算し、全ての生産
指示データ22についてその値の和が最小になるような
品種投入の順序で生産計画を作成する。Therefore, the difference in total load amount between processes A and C before and after process B, which is the bottleneck process 20, for the types W1 and W2 is as follows: Difference in total load amount=lA2-Bl+182-CI. This difference in total load amount is calculated based on the product type load information 24 created when the load was predicted, and the product type input is calculated so that the sum of the values for all production instruction data 22 is minimized. Create a production plan in sequence.
特許請求の範囲第1項記載のように、多品種生産を行う
生産ラインの各工程の負荷予測を行い、前記負荷予測か
ら最大負荷量となる工程をネック工程として選び出す手
段と、前記ネック工程の前後の工程における待ち時間が
最も小さくなるような品種投入の順序を選び出す手段と
を有し、前記順序で生産計画を作成することを特徴とす
る生産計画作成方法としたことにより、最も注目すべき
工程を選択し、この工程を上手に遂行することにより生
産ライン全体として高い生産性を生み出すことになるも
のである。この上手に遂行する方法としてネック工程を
生産計画段階で予測して対応し、この工程の前後での待
ち時間を最小にすることにより、生産性の高い在庫の少
ない生産計画の作成が可能となるものである。As described in claim 1, means for predicting the load of each process of a production line that performs multi-product production, and selecting a process with a maximum load amount from the load prediction as a neck process; The most noteworthy feature is that the production plan creation method is characterized by having a means for selecting the order of product introduction that minimizes the waiting time in the preceding and succeeding processes, and creating a production plan in the said order. By selecting a process and executing this process skillfully, high productivity can be generated for the entire production line. As a way to accomplish this skillfully, by predicting and responding to bottleneck processes at the production planning stage and minimizing the waiting time before and after this process, it is possible to create a production plan with high productivity and low inventory. It is something.
第1図は本発明の生産計画作成のための負荷予測および
ネック工程導出の手順を示した説明図、第2図はそのデ
ータのフローを示したブロック図、第3図はネック工程
の前後の工程間の待ちを説明した工程ブロック図、第4
図は工程での品種の流れを説明するための工程ブロック
図である。
11・・・生産ライン 20・・・ネック工程 2
1・・・品種別工程負荷データベース 22・・・生
産指示データ 23・・・加工内容別負荷データ24
・・・品種別負荷情報 25・・・工程別負荷データFigure 1 is an explanatory diagram showing the procedure for load prediction and derivation of bottleneck processes for creating a production plan according to the present invention, Figure 2 is a block diagram showing the data flow, and Figure 3 is a diagram showing the steps before and after the bottleneck process. Process block diagram explaining waiting between processes, 4th
The figure is a process block diagram for explaining the flow of product types in the process. 11... Production line 20... Neck process 2
1... Process load database by type 22... Production instruction data 23... Load data by processing content 24
...Load information by product type 25...Load data by process
Claims (1)
を行い、前記負荷予測から最大負荷量となる工程をネッ
ク工程として選び出す手段と、前記ネック工程の前後の
工程における待ち時間が最も小さくなるような品種投入
の順序を選び出す手段とを有し、前記順序で生産計画を
作成することを特徴とする生産計画作成方法。(1) Means for predicting the load of each process on a production line that performs multi-product production, and selecting the process with the maximum load from the load prediction as a bottleneck process, and minimizing the waiting time in the processes before and after the bottleneck process. 1. A method for creating a production plan, comprising: means for selecting an order for inputting product types such that the order is such that a production plan is created in the order.
Priority Applications (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| JP1335812A JPH03196948A (en) | 1989-12-25 | 1989-12-25 | Production planning preparation method |
Applications Claiming Priority (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| JP1335812A JPH03196948A (en) | 1989-12-25 | 1989-12-25 | Production planning preparation method |
Publications (1)
| Publication Number | Publication Date |
|---|---|
| JPH03196948A true JPH03196948A (en) | 1991-08-28 |
Family
ID=18292696
Family Applications (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| JP1335812A Pending JPH03196948A (en) | 1989-12-25 | 1989-12-25 | Production planning preparation method |
Country Status (1)
| Country | Link |
|---|---|
| JP (1) | JPH03196948A (en) |
Cited By (6)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| JPH05298339A (en) * | 1992-04-23 | 1993-11-12 | Matsushita Electric Works Ltd | Method for drafting production planning |
| JPH05314143A (en) * | 1991-09-27 | 1993-11-26 | Fujitsu Ltd | Product production planning system in batch plant |
| JPH07192057A (en) * | 1993-12-27 | 1995-07-28 | Sekisui Chem Co Ltd | Production equipment verification simulator |
| US6275744B1 (en) | 1997-08-01 | 2001-08-14 | Kokusai Electric Co., Ltd. | Substrate feed control |
| WO2006137287A1 (en) * | 2005-06-22 | 2006-12-28 | Hitachi Kokusai Electric Inc. | Method for fabricating semiconductor device and equipment for processing substrate |
| JP2013143030A (en) * | 2012-01-11 | 2013-07-22 | Nippon Steel & Sumitomo Metal | Operation schedule preparation method of steel making processes, operation schedule preparation system of the same, operation method of the same and manufacturing method of steel material |
Citations (1)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| JPS60207749A (en) * | 1984-03-30 | 1985-10-19 | Hitachi Ltd | Supply-order determining apparatus |
-
1989
- 1989-12-25 JP JP1335812A patent/JPH03196948A/en active Pending
Patent Citations (1)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| JPS60207749A (en) * | 1984-03-30 | 1985-10-19 | Hitachi Ltd | Supply-order determining apparatus |
Cited By (6)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| JPH05314143A (en) * | 1991-09-27 | 1993-11-26 | Fujitsu Ltd | Product production planning system in batch plant |
| JPH05298339A (en) * | 1992-04-23 | 1993-11-12 | Matsushita Electric Works Ltd | Method for drafting production planning |
| JPH07192057A (en) * | 1993-12-27 | 1995-07-28 | Sekisui Chem Co Ltd | Production equipment verification simulator |
| US6275744B1 (en) | 1997-08-01 | 2001-08-14 | Kokusai Electric Co., Ltd. | Substrate feed control |
| WO2006137287A1 (en) * | 2005-06-22 | 2006-12-28 | Hitachi Kokusai Electric Inc. | Method for fabricating semiconductor device and equipment for processing substrate |
| JP2013143030A (en) * | 2012-01-11 | 2013-07-22 | Nippon Steel & Sumitomo Metal | Operation schedule preparation method of steel making processes, operation schedule preparation system of the same, operation method of the same and manufacturing method of steel material |
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