Abstract
Respecting the on-time delivery (OTD) for manufacturing orders is mandatory. However, for non-JIT Batch & Queue Push-manufacturing systems, the compliance of OTD is not intrinsically guaranteed. As an OTD related manufacturing theory is largely missing it is crucial to understand and formalize the necessary conditions of OTD compliance for complex production environments for maximum exploitation of the production capacity. This paper evaluates the conditions of post-optimality while being OTD compliant for production systems, which are characterized by stochastic order rate and a deterministic product-mix. Instead of applying discrete event simulation to explore the real case-by-case order scheduling optimization for OTD compliance, a Cartesian approach is followed. This enables to define theoretically the solution space of order backlog for OTD, which contributes to developing further manufacturing theory. At the base stands the recently defined new concept of virtual manufacturing elasticity by reducing lead-time to increase virtually production capacity. The result has led to defining additional two corollaries to the OTD theorem, which sets up basic OTD theory. Apart from defining the post-optimal requirements to guarantee for orders at least a weak solution for OTD compliance, this paper reveals that for a deterministic product-mix a non-ergodic order arrival rate can be rescheduled into an ergodic order input rate to the shopfloor if the virtual elasticity T is large enough, hence the importance of having fast and flexible production lines.
Highlights
Introduction and Approach to the ProblemAs the fulfillment of customer requirements for product quality, the on-time delivery (OTD), which is the punctual delivery of manufactured products, is essential for a customer-satisfaction sustainable business
Apart from defining the post-optimal requirements to guarantee for orders at least a weak solution for OTD compliance, this paper reveals that for a deterministic product-mix a non-ergodic order arrival rate can be rescheduled into an ergodic order input rate to the shopfloor if the virtual elasticity ∆T is large enough, the importance of having fast and flexible production lines
We have seen that the traditional Western large B & Q manufacturing combined with OTIF deliveries can compromise the OTD requirement for other products
Summary
As the fulfillment of customer requirements for product quality, the on-time delivery (OTD), which is the punctual delivery of manufactured products, is essential for a customer-satisfaction sustainable business. With the present paper we extend the problem setting by developing the post-optimality conditions for OTD of a multi-product manufacturing system showing a predominant non-ergodic stochastic arrival OR characteristic, with a deterministic product-mix. This topic is of high interest in view of forthcoming graph-based and artificial intelligence (AI)-controlled new cyber physical production systems (CPPS). It is important to note that the problem of post-optimality does not represent a topic of interest in TPS-derived perfect lean just-in-time (JIT) production systems, because the product-mix and OR are deterministically known and the manufacturing system can be conceived and implemented to meet the OTD requirement. We have reported here again the OTD theorem, because it is central to the present problem development and is generally one of the most important theorems for manufacturing on which further corollaries can be derived
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