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Order Review/Release in a Job Shop

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Title: Order Review/Release in a Job Shop


1
Order Review/Release in a Job Shop
  • 1998? 9? 10?
  • ????? ????????
  • ? ? ?

2
Order review and release strategies in a job shop
environment a review and a classification
  • Bergamaschi, D., Cigolini, R., Perona, M.
    and Portioli, A.,
  • IJPR, 1997, 35(2), 399-420.
  • Former student of Politecnico di Milano, Milano,
    Italy
  • Dipartimento di Economia e Produzione,
    Politecnico di Milano, Milano, Italy

3
Contents
  • Objectives of this paper
  • Order Review/Release System? ??
  • Order Review/Release System? ??
  • Literature Review
  • Analysis and Classification
  • Conclusion and Further Research Paths

4
Objectives of this paper
  • A review and a classification framework of the
    main research work carried out to date
  • A better understanding of ORR strategies and the
    most promising research paths

5
Order Review/Release System? ??
  • Planning ???? ??? ?? ????? shop floor? ?? ????
    ??? ??
  • Decision which order, at what time, under what
    conditions to release
  • WIP control? workload balance? ?? shop?
    utilization? ???, ????? ?? delivery performance?
    ????? ?? ???? ?
  • both filtering mechanism and capacity management
    tool

6
Order Review/Release System? ??
  • Order Entry Phase
  • Routing Check, Pick List Check, Due/Delivery Date
    Assignment
  • Pre Shop Pool Management Phase
  • Sequencing orders according to their priority
  • EDD, ERD, CR, Capacity slack based rule
  • Order Release Phase
  • ?? order? ?? shop? release? ???? ??(triggering or
    input control mechanism)
  • employ three types of information current
    pre-shop pool status, current shop status,
    planned shop performance (manufacturing lead
    time, delivery timeliness)

7
Position of ORR within PPC
8
Literature Review (1/6)
  • Wight(1970)
  • first to understand and describe the importance
    of controlled release
  • The interactions between ORR and dispatching
    rules
  • Nicholson et al.(1971), Bechte(1988) if job
    release is carefully controlled, sophisticated
    dispatching rules might be replaced by a simple
    FCFS
  • Bertrand(1983) even with an effective order
    release procedure, such rules as tSPT can yield
    to better shop performance than FCFS
  • Ragatz et al.(1988) the greatest advantage from
    the use of ORR appears to be achieved with non
    due date related sequencing rules
  • Ahmed et al.(1992) an interaction does exist
    among three activities of a job scheduling policy
    (due-date assignment, ORR and dispatching)
  • Perona et al.(1996) the impact of an ORR
    procedure should be evaluated while considering
    all the relevant scheduling decisions

9
Literature Review (2/6)
  • The relationship between WIP, MLT and throughput
    rate
  • Little (1961) from a theoretical point of view
  • Shimoyashiro (1984) simulation approach
  • A strong indication towards the existence of a
    critical level of WIP inventory that should be
    kept in the system.
  • These conclusions led researchers to look for an
    effective way of controlling both lead time and
    WIP inventory through the control of work input
    to the shop

Utilization
MLT
Desired WIP level
WIP
10
Literature Review (3/6)
  • Basic mechanisms to control the shop's workload
  • the limitations of load released to the shop
  • Wiendahl (1995), Bechte(1988, 1994), Ragatz et
    al. (1988), Bobrowski (1989), Philipoom et al.
    (1993)
  • the balancing of workload among different work
    centers of the shop
  • Irastorza and Deane (1974) MILP
  • LIMITE by Portioli (1991) loosening the rigid
    limitation of workload for improving overall
    workload balance

11
Literature Review (4/6)
  • Application of workload control
  • Input control
  • A feedback tool to control and reduce lead times
    through shop load limitations and balancing
  • Output control
  • The regulation of the shop production capacity
    with a feed-forward approach
  • Hendry and Kingsman (1991) input? output? ???
    control
  • Onur and Fabrycky (1987) an combined
    feed-forward/back control procedure
  • To prevent specific work center from being idle
  • Glassey and Resende (1988) Starvation Avoidance
  • Melnyk and Ragatz (1989) WCEDD, AGGWNQ
  • may prove ineffective whenever multiple
    bottleneck work centers are dynamically changing
    over time, subject to the particular order mix
    processed

12
Literature Review (5/6)
  • Broadening ORR time-wise workload smoothing
  • Melnyk Ragatz (1991)
  • the effects of broadening the range of ORR
    functions, by smoothing workload over time
  • Fredendall and Melnyk (1995)
  • ORRs potential is greatly improved by providing
    for a time-wise workload balancing with an
    extended schedule visibility
  • Contributions to OE and PSP phases
  • Bobrowski (1989) loading exchange heuristics in
    OE phase
  • Philipoom and Fry (1992) consider rejecting
    customer orders
  • Philipoom et al. (1993) demonstrated the choice
    of an appropriate PSP priority rule plays a
    leading role in a ORR procedure effectiveness and
    thus has a significant impact on overall shop
    performance

13
Literature Review (6/6)
  • Order Review/Release? ?? ??? ??
  • Positive view reduced stock carrying cost, shop
    congestion and flow times
  • Negative view
  • Bertrand(1983), Baker(1984), Kanet (1988), Melnyk
    and Ragatz(1988), Melnyk et al.(1994) long delay
    in the pool, overall MLT may increase
  • Bechte(1988), Perona and Portioli(1996)
  • above authors might have undervalued the
    possibility offered by an appropriate ORR
    strategy to better balance workloads both over
    time and among the work centers of the shop, thus
    achieving better utilization and throughput rate,
    together with improved MLTs and delivery
    performance.

14
Analysis and Classification (1/8)
  • Eight dimensions of OR methodologies
  • Order release mechanism
  • Timing convention
  • Workload measure
  • Aggregation of workload measure
  • Workload accounting overtime
  • Workload control
  • Capacity planning
  • Schedule visibility

15
Analysis and Classification (2/8)
  • Order release mechanism mechanism that triggers
    the release of one or more orders
  • Load limited methodologies decide which orders
    should be released based upon their distinctive
    features and the existing workload in the shop
  • Time phased methodologies computing a release
    time for each order based on information about
    jobs in the pool such as due date, job work
    content and job routing (MIL, CMS)

16
Analysis and Classification (3/8)
  • Timing convention determines when an order
    release can take place
  • Discrete periodic interval
  • Continuous MIL, SA, AGGWNQ, WCEDD, ORM, CMS
  • Workload measure
  • number of jobs MIL(Ragatz), MNJ, CMS
  • work content (hours or percentage of the planned
    capacity)
  • A logic which looks after more than the simple
    number of jobs on the shop floor is needed at the
    release stage

17
Analysis and Classification (4/8)
  • Aggregation of workload measure
  • total shop load AGGWNQ, MNJ, MAX
  • bottleneck work center load SA, ORM
  • load by each work center
  • In a job shop environment a workload control
    methodology seems to be fully effective only if
    the workload distribution among work centers is
    considered (Melnyk et al. 1989)

18
Analysis and Classification (5/8)
  • Workload accounting over time
  • load? ?? load on hand, load in transit, released
    load
  • Attemporal (total shop load ? ?? ??? attemporal)
  • Time bucketing SCOPE2, BFL, FFL
  • requires a pre-processing scheduling activity
  • Probabilistic LOMC, LIMITE
  • a greater robustness against the typical
    industrial perturbations
  • authors disagree the way by which workload
    accounting should be accounted over time

19
Analysis and Classification (6/8)
  • Workload control
  • Upper bound only BFL, LOMC, FFL, PBB, MNJ, ORM,
    MAX
  • control the WIP level and therefore the
    statistical distribution of MLTs result in a
    reduced mean with a smaller coefficient of
    variation
  • Upper and lower bounds JSSWC
  • trying to ensure that each work center is
    provided with an appropriate buffer
  • Lower bound only SA, AGGWNQ, WCEDD
  • potential drawback the assumption of a fixed
    bottleneck
  • Workload balancing Irastorza-Deane, SCOPE 2,
    DI/OCS
  • selective release of orders to the shop on
    condition that the sum of deviations from
    aggregate balance of each machine center is
    reduced
  • Authors disagree about the way in which workload
    should be limited

20
Analysis and Classification (7/8)
  • Capacity planning controlling/adjusting capacity
  • Passive feedback logic
  • Active Irastorza-Deane, SCOPE 2, DI/OCS, JSSWC
  • Onur and Fabrycky(1987) if the feedback input
    control is combined with a feed-forward control
    mechanism through which the amount of production
    capacity available is adjusted, better shop
    performances can be adjusted.

21
Analysis and Classification (8/8)
  • Schedule visibility
  • Limited oriented at controlling the workload
    level in the shop during the next closest
    planning period
  • workload is actually smoothed over time, but only
    in order to optimize the next period, regardless
    how following periods could be affected
  • Extended (Irastorza-Deane, DI/OCS, MAX) oriented
    at achieving a more general optimization of the
    shop performances along a time horizon longer
    than a single time horizon (look-ahead module)
  • In time phased release mechanism, the schedule
    visibility is absent.

22
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23
Conclusion and Further Research Paths
  • Further Research Paths
  • To combine an upper lower bounds approach with
    a continuous timing convention
  • The analysis of the workload control strategy by
    means of load balancing
  • A formalized investigation of the dimension
    related to workload accounting over time
  • Designing new techniques for capacity and
    workload planning in order to achieve good
    performances, while keeping them simple enough to
    be effectively implemented in a real-life
    industrial context
  • The adjustment of production capacity and the
    ability to optimize the order release over an
    extended time horizon
  • Time bucketing approach with schedule visibility

24
References (1/4)
  • Ahmed, I. and Fisher, W. W., 1992, Due date
    assignment, job order release and sequencing
    interaction in job shop scheduling. Decision
    Sciences, 23, 633-647.
  • Baker, K. R., 1984, The effects of input control
    on the performance of a simple scheduling model.
    Journal of Operations Management, 4(2), 99-112.
  • Bechte, W., 1988, Theory and practice of
    load-oriented manufacturing control. IJPR, 26,
    375-395.
  • Bergamaschi, D., Cigolini, R., Perona, M. and
    Portioli, A., 1997, Order review and release
    strategies in a job shop environment a review
    and a classification. IJPR, 35(2), 399-420.
  • Bertrand, J. W. M., 1983, The use of workload
    information to control job lateness in controlled
    and uncontrolled release production systems.
    Journal of Operations Management, 3, 79-92.
  • Bertrand, J. W. M. and van Ooijen, H. P. G.,
    1996, Integrating material coordination and
    capacity load smoothing in multi-product
    multi-phase production systems. IJPE, 46-47,
    1-12.
  • Bobrowski, P. M., 1989, Implementing a loading
    heuristic in a discrete release job shop. IJPR,
    27, 1935-1948.

25
References (2/4)
  • Fredendall, L. D. and Melnyk, S. A., 1995,
    Assessing the impact of reducing demand variance
    through improved planning on the performance of a
    dual resource constrained job shop. IJPR, 27,
    1935-1948.
  • Glassey, C. R. and Resende, M. G., 1988,
    Closed-loop job release control for VLSI circuit
    manufacturing. IEEE Transactions on Semiconductor
    Manufacturing, 1, 36-46.
  • Hendry, L. and Wong, S. K., 1994, Alternative
    order release mechanisms a comparison by
    simulation. IJPR, 32, 2827-2842.
  • Lingayat, S., Mittenthal, J. and O'Keefe, R. M.,
    1995, An order release mechanism for a flexible
    flow system. IJPR, 33, 1241-1256.
  • Melnyk, S. A. and Ragatz, G. L., 1989, Order
    review/release research issues and perspectives.
    IJPR, 27, 1081-1096.
  • Melnyk, S. A. and Ragatz, G. L. and Fredendall,
    L., 1991, Load smoothing by the planning and
    order review/release systems a simulation
    experiment. Journal of Operations Management,
    10(4), 512-523.
  • Melnyk, S. A., Tan, K. C., Denzler, D. R., 1994,
    Evaluating variance control, order review/release
    and dispatching a regression analysis. IJPR,
    32(5), 1045-1061.

26
References (3/4)
  • Park., P. S. and Salegna, G. J., 1995, Load
    smoothing with feedback in a bottleneck job shop.
    IJPR, 33(6), 1549-1568.
  • Perona, M. and Portioli, A., 1996, An Enhanced
    loading model for the probabilistic workload
    control under imbalance. Production Planning and
    Control, 7(1), 68-78.
  • Philipoom, P. R. and Fry, T. D., 1992,
    Capacity-based order review/release strategies to
    improve manufacturing performance. IJPR, 30(11),
    2259-2572.
  • Philipoom, P. R., Malhotra, M. K. and Jensen, J.
    B., 1993, An evaluation of capacity sensitive
    order review and release procedures in a job
    shops. Decision Sciences, 24(6), 1109-1133.
  • Shimoyashiro, S., Isoda, K. and Awane, H., 1984,
    Input scheduling and load balance control for a
    job shop. IJPR, 22(4), 597-605.
  • Roderick, L. M., Phillips, D. T. and Hogg, G. L.,
    1992, A comparison of order release strategies in
    production control systems. IJPR, 30(3), 611-626

27
References (4/4)
  • Irastorza, J. C. and Deane, R. H., A loading and
    balancing methodology for job shop control. AIIE
    Transactions, 6, 302-307.
  • Melnyk, S. A. and Ragatz, G. L., 1988, Order
    review/release and its impact on the shop floor.
    Production and Inventory Management, 29, 13-17.
  • Onur, L. and Fabrycky, W. L., 1987, An
    input/output control system for the dynamic job
    shop. IIE Transactions, 19(1), (March), 88-97.
  • Ragatz, G. and Mabert, V. A., 1988, An evaluation
    of order release mechanisms in a job shop
    environment. Decision Sciences, 19, 167-189.
  • Wight, O. W., 1970, Input/Output control a real
    handle on lead times. Production and Inventory
    Management, 11, 9-30.
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