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Pull based production systems: performance, modelling and analysis
Luleå tekniska universitet.
2010 (English)Doctoral thesis, comprehensive summary (Other academic)
Abstract [en]

This doctoral thesis addresses performances, modelling and analyses of pull based production systems. The thesis consists of four main parts: a literature review, a comparison study of Kanban and CONWIP, an industrial practical case study, and the development of a new tool used for presentation and analysis of simulated performance results. Through a literature review existing performance measures, modelling techniques and analysing approaches were discovered and discussed. The literature review revealed a lack of performance measures regarding the variation in system performances. To compensate for this a new variation measure for analysing pull based production systems was found. Simulation was chosen as an analysing tool, because of the dynamic nature of practical production systems and the desire to analyse complex real systems not fitting other approaches.A comparison of Kanban and CONWIP, the two most basic pull based control methods, has been conducted through a simulation study. A five machine line system for production of a single product was used as a case. The result was seven rather general observations. A main finding is that Kanban and CONWIP systems need to be analysed due to variation measures and not only average measures, Kanban and CONWIP perform equally in terms of throughput due to average work in process (WIP), but unequally due to maximum storage capacity. An industrial practical case of a mass-produced single product have been studied and analysed with simulation. A new production line consisting of several chemical and mechanical processes was to be designed and installed. The design was tested for sensitivity to the experts' estimated parameters down time and required buffer capacities. The down times were categorized in five groups due to length, and three of these were analysed further. The system was sensitive to changes in all three groups but due to different performance measures and with different results of variations. The study also showed that the variations of the flow differed in the system from input to output. Based on performed simulations a new tool for presentation and analysis of performance data related to the system configurations has been invented. The result is a 3D Performance Surface method. Here, the performance's lead time, WIP and throughput are plotted into a three dimensional geometrical space. In this model the relation between different system settings and performances is analysed. Variation measures can also be included. The advantage with this geometrical tool is that the performances of not simulated configurations can be estimated.

Abstract [no]

Dette doktorgradsarbeidet fokuserer på egenskaper, modellering og analyse av sug baserte produksjonssystemer. Gjennom et omfattende litteratur studie er eksisterende prestasjonsmål, modelleringsmetoder og analysemetoder avdekket og diskutert. Et nytt variasjonsmål for bruk under analyse av sug baserte produksjonssystemer er definert og simulering ble valgt som modelleringsverktøy. Simulering ble valgt fordi virkelige produksjonssystemer er utpreget dynamiske og det var et ønske å kunne analysere komplekse systemer som ikke passer for analyse med andre metoder.En sammenlikning av Kanban og CONWIP, de to mest grunnlegende sug kontroll metodene, er gjennomført gjennom simulering. En produksjonslinje med fem maskiner ble brukt som eksempel. Resultatet ble syv observasjoner. Hovedfunnene er at Kanban og CONWIP systemer må analyseres med både variasjons- og gjennomsnittsmål, Kanban og CONWIP presterer likt når gjennomstrømming måles mot gjennomsnittlig produkter i systemet, men ulikt målt mot behovet for maksimalt lager kapasitet.Et simuleringsbasert case-studie er gjennomført med et firma som masseproduserer et produkt. En ny produksjonsline bestående av flere kjemiske og mekaniske prosesser skulle designes og implementeres. Designet ble testet for sensitivitet til de ekspertestimerte parameterne nede tid og behovet for mellom lager. Nede tiden ble kategorisert i fem grupper. Tre av disse ble analysert videre. Systemet var sensitivt til variasjon i alle tre gruppene, men relatert til forskjellige prestasjonsmål. Resultatet viser at variasjonsmål må inkluderes i prestasjonsanalyser. Studiet viser at variasjonen i strømmen av produkter er forskjellig inn og ut av systemet.Basert på behov avdekket i tidligere simuleringer ble et nytt verktøy for analyse av prestasjonsmål relatert til system innstillinger definert. Resultatet er 3D Prestasjon Overflate metoden. Her er prestasjonene ledetid, varer i arbeid, og gjennomstrømning angitt i et tre dimensjonalt geometrisk rom. I denne modellen kan sammenhengen mellom prestasjonene og systeminnstillingene analyseres. Variasjonsmål kan også inkluderes og prestasjoner av ikke simulerte systeminnstillinger kan bli estimert ved hjelp av geometriske verktøy.

Place, publisher, year, edition, pages
Luleå: Luleå tekniska universitet, 2010. , 144 p.
Series
Doctoral thesis / Luleå University of Technology 1 jan 1997 → …, ISSN 1402-1544
National Category
Production Engineering, Human Work Science and Ergonomics
Research subject
Industrial Logistics
Identifiers
URN: urn:nbn:se:ltu:diva-26663Local ID: f62f8310-e101-11df-8b36-000ea68e967bISBN: 978-91-7439-160-2 (print)OAI: oai:DiVA.org:ltu-26663DiVA: diva2:999830
Note
Godkänd; 2010; 20101026 (ysko); DISPUTATION Ämnesområde: Industriell logistik/Industrial Logistics Opponent: Professor Jose M. Framinan, University of Seville, Spanien Ordförande: Professor Anders Segerstedt, Luleå tekniska universitet Tid: Måndag den 13 december 2010, kl 10.30 Plats: D770, Luleå tekniska universitetAvailable from: 2016-09-30 Created: 2016-09-30Bibliographically approved

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Production Engineering, Human Work Science and Ergonomics

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