Sadeleştirilmiş kısıt-tampon-bağ (S-DBR) ve yalın-hat dengesi yöntemlerinin simülasyonla kıyaslanması
Year 2023,
Volume: 12 Issue: 4, 1436 - 1451, 15.10.2023
Batuhan Kocaoğlu
,
Utkan Uluçay
Abstract
Geleneksel yaklaşımda işlem süreleri sabitken Yalın-hat dengesiyle gelir artışı sağlanacağı çok kaynakta kabul görmektedir. Bu çalışmanın amacı, işlem süresi değişken olduğunda S-DBR (Simplified Drum Buffer Rope: Sadeleştirilmiş Kısıt Tampon Bağ) yaklaşımının daha iyi sonuç vereceğini göstermektir. Bu amaçla Yalın-hat dengesi ve S-DBR temel kurguları simülasyonla modellenerek işlem sürelerinin değişken olduğu senaryoda kıyaslanmış ve istatistik değerlendirmesi yapılmıştır. İşlem sürelerinde değişkenlik varken Yalın-hat dengesinde gününde teslim oranı %100’ den %82’ ye düşmüştür. S-DBR yöntemiyle değişkenliğe rağmen %84 gününde teslim oranıyla net gelirde %4, üretimde %3 artış elde edilmiştir. Dolayısıyla sadece üretim planlama ve yönetim metodunun değiştirilmesiyle, ilave yatırım gerektirmeden iş ortamındaki değişkenliğe daha dayanıklı ve daha rekabetçi olmak mümkündür. Çalışmanın özgünlüğü, üretim firmaları için Kısıtlar Teorisindeki uygun üretim çözümünün seçimi, S-DBR yönteminin uygulama ve iyileştirme algoritmalarının literatür senteziyle oluşturulması, istatistiksel uygulanabilirlik değerlendirmesi ve gelecek araştırmalar için içgörü oluşturmasıdır.
Supporting Institution
yoktur
References
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- J. H. Blackstone, Ed., APICS Dictionary, 13 ed. APICS-The Association for Operations Management, Chicago, 2010.
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- E. Schragenheim and H. Dettmer, Manufacturing at Warp Speed- Optimizing Supply Chain Financial Performance. Boca Raton: St. Lucie Press/APICS series on constraints management, 2001.
- Ş. Demirkol Akyol, Tip-2 Montaj Hattı Dengeleme ve İşgücü Atama Problemi için Doğrusal Programlama Yaklaşımı: Bir Vaka Çalışması. DEÜ Mühendislik Fakültesi Fen ve Mühendislik Dergisi, 25(73), 121-129, 2023. 10.21205/deufmd.2023257310
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- M. Ritt, A. M. Costa and C. Miralles, The Assembly Line Worker Assignment and Balancing Problem with Stochastic Worker Availability. International Journal of Production Research, 54(3), 9007-922, 2015. 10.1080/00207543.2015.1108534
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- K. G. H. Ağpak, Basit U Tipi Montaj Hattı Dengeleme Problemine Bulanık Programlama Yaklaşımı. Dokuz Eylül Üniversitesi Mühendislik Fakültesi Fen ve Mühendislik Dergisi, 4(2), 29-40, 2002.
- S. Kökhan, Farklı tipte işgücüne sahip maliyet yönelimli paralel montaj hattı dengeleme problemi için modelleme ve çözüm. Doktora Tezi, Gazi Üniversitesi, Ankara, 2020.
- G. Kumar and P. Gowda, An optimal balancing of assembly line using Rpw Technique. International Journal of Engineering Research And Advanced Technology, 1, 469-475, 2016.
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- G. Kılıç, Hazır giyim işletmelerinde üretim hattı dengelemesine yönelik bir uygulama. Yüksek Lisans Tezi, Marmara Üniversitesi Fen Bilimleri Enstitüsü, İstanbul, 2010.
- K. Nahar, A. Habib, A. A. Nayon and M. Hossain, Assembly line balancing using ACO Algorithm and RPW Method: A Comparative case study. Journal of Modern Science and Technology, 6(3), 13-24, 2018.
- K. Ağpak, H. Gökçen, N. N. Saray and S. Özel, Stokastik görev zamanlı tek modelli U tipi montaj hattı dengeleme problemleri için bir sezgisel. Gazi Üniversitesi Mühendislik Mimarlık Fakültesi Dergisi, 17(4), 115-124, 2002.
- S. T. Ghutukade and S. M. Sawant, Use of ranked position weighted method for assembly line balancing. International Journal of Advanced Engineering Research and Studies / II / IV / July-Sept, 1(3), 2013.
- M. S. Khan and J. P. Saurabh, Evaluation of standard time with the application of rank positional weighted method in the production line. International Journal of Mechanical and Production Engineering Research and Development (IJMPERD), 7(2), 73-80, 2017.
- A. Ş. Uyanık, Bir traktör fabrikasında karışık modelli montaj hattı dengeleme–deterministik ve stokastik ölçümlere göre analizler. Yüksek Lisans Tezi, TOBB ETÜ Fen Bilimleri Enstitüsü, Ankara, 2020.
- T. C. Lopes, A. S. Michelsa and C. G. S. Sikorab, Balancing and cyclically sequencing synchronous, asynchronous, and hybrid unpaced assembly lines. International Journal of Production Economics, 203, 216-224, 2018. 10.1016/j.ijpe.2018.06.012
- A. Portioli-Staudacher, F. Costa and M. Thürer, The use of labour flexibility for output control in workload controlled flow shops A simulation analysis. International Journal of Industrial Engineering Computations, 11, 429-442, 2020. 10.5267/j.ijiec. 2019.11.004
- S. Yoon and S. Jeong, Line Balancing Strategy for Re-Entrant Manufacturing. IEEE Transactions on Semiconductor Manufacturing, 31(1), 42-51, 2018. 10.1109/tsm.2017.2768242
- N. Zheng and L. Xiaochun, Comparative study on push and pull production system based on Anylogic. in International Conference on Electronic Commerce and Business Intelligence, 2009. 10.1109/ecbi.2009.26
- B. Mendenhall, Creating Perfect Harmony - How to Solve the Discords of TOC and LSS. 2008.
- M. Rother and J. Shook, Görmeyi Öğrenmek, Ver 1.2- değer yaratmak ve israfı ortadan kaldırmak için değer akışı haritalama. The Lean Enterprise Institute, Massachusetts, 1999.
- E. M. Goldratt and J. Cox, Amaç-Sürekli İyileştirme Süreci. Optimist Yayınları-İstanbul: North River Press, 1984.
- H. W. Dettmer, The Logical Thinking Process. Milwaukee, USA: ASQ Quality Press, 2007.
- E. M. Goldratt and R. E. Fox, The Race. New York: North River Press, 1986.
- C. Roser, All About Lean-Organize your Industry!, 2014. https://www.allaboutlean.com/drum-buffer-rope /. Accessed Mayıs 2023.
- Z. Sardar and I. Abrams, Kaos: Düzensizlikteki Düzen., İstanbul: NTV Yayınları, 1998.
- J. H. Holland, Signals & Boundaries: Building Blocks For Complex Adaptive Systems., Londra: The MIT Press, 2012.
- M. Gökçen, A. Boru and A. T. Dosdoğru, İki Aşamalı Tedarik Zincirinde Eş Zamanlı Stok Kontrolünün ve Tedarikçi Seçiminin Simülasyon Optimizasyonu Yaklaşımı ile Analizi. Karaelmas Fen ve Mühendislik Dergisi, vol. 8, no. 1, pp. 1-10, 2018. 10.7212 %2Fzkufbd.v8i1.617
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- B. Scholz-Rieter, K. Windt and H. Liu, (DET2009) Modelling Dynamic Bottlenecks in Production Networks. International Journal of Computer Integrated Manufacturing, no. 1, 2010. 10.1080/0951 192x.2010.511655
- M. Thürer, M. Stevenson, C. Silva and T. Qu, Drum-buffer-rope and workload control in high-variety flow and job shops with bottlenecks: An assessment by simulation. International Journal of Production Economics, no. 188, pp. 116-127, 2017. 10.1016/j.ijpe.2017.03.025
- A. Lizarralde-Aiastui, U. Apaolaza-Perez de Eulate and M. Mediavilla-Guisasola, A Strategic Approach for Bottleneck Identification in Make-To-Order Environments: A Drum-Buffer-Rope Action Research Based Case Study. Journal of Industrial Engineering and Management, vol. 13, no. 1, pp. 18-37, 2020. 10.3926/jiem.2868
- A. Gonzales-Romero, I. J. Huamani-Martinez, J. C. Quiroz-Flores and B. H. Diaz-Garay, Production management model based on Lean and DDMRP tools to increase the rate of project compliance in manufacturing SMEs in the metalworking sector. in 8th International Engineering, Sciences and Technology Conference (IESTEC), 2022. 10.1109/IESTEC545 39.2022.00015
- F. Tanhaie, Comparison Between the Performances of Pull and Push Systems Using Discrete Event Simulation. Journal of Systems Thinking in Practice, vol. 1, no. 2, pp. 44-55, 2022. 10.22067/JST INP.2022.77835.1015
- U. Apaolaza, A. Orue, A. Lizarralde and A. Oyarbide-Zubillaga, Competitive Improvement through Integrated Management of Sales and Operations. Sustainability, no. 14-2722, 2022. 10.3390/su14052 722
- Yalın-hat dengeli model erişim adresi: https://clo ud.anylogic.com/model/194f3e34-bc74-4289-9577-239 4cea5d0c5?mode=SETTINGS&tab=GENERAL
- S-DBR model erişim adresi: https://cloud.any logic.com/model/3d090860-dae8-4f75-92d7-20415cc2 0a03?mode=SETTINGS&tab=GENE RAL
Benchmarking of S-DBR and lean-line balancing methods by simulation
Year 2023,
Volume: 12 Issue: 4, 1436 - 1451, 15.10.2023
Batuhan Kocaoğlu
,
Utkan Uluçay
Abstract
It is common in the literature that a lean-line balance with fixed process times is a good way to achieve higher throughput. This study aims to demonstrate that S-DBR (Simplified Drum Buffer Rope) approach would produce higher returns when process times are not fixed. Lean-line balancing and S-DBR methods were modeled in a basic structure and benchmarked by simulation. Results were statistically assessed. The on-time delivery rate of the Lean-line balancing method decreased from 100% to 82% with varying process times. Meanwhile, the S-DBR method yielded 84% on-time delivery, resulting in increased net income by 4%, and shipments by 3%. It is possible to become more resilient and more competitive to the variability in the business environment without requiring additional investment by simply changing the production planning and management method. This study sets a guide for choosing the proper TOC (Theory Of Constraints) method for a certain business environment as well as disposing S-DBR algorithm synthesized by literature and statistically tested for adaptability. Additionally, an insight for future research is also presented.
References
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- R. Pirasteh and R. Fox, Profitability With No Boundaries. American Society for Quality, Quality Press, Milwaukee, 2011.
- T. Ohno, Toyota Ruhu- Toyota Üretim Sistemi. Scala Yayıncılık, İstanbul, 2018.
- J. H. Blackstone, Ed., APICS Dictionary, 13 ed. APICS-The Association for Operations Management, Chicago, 2010.
- M. Rother and R. Harris, Sürekli Akış Yaratmak-Yöneticiler, Mühendisler ve Üretim Çalışanları İçin Bir Eylem Kılavuzu. The Lean Enterprise Institute, Massachusetts, 2001.
- D. Smith, The Measurement Nightmare-How the TOC Can Resolve Conflicting Strategies, Policies and Measures. The St. Lucie Press/APICS Series on Constraints Management, Boca Raton, 2000.
- E. M. Goldratt, Introduction to TOC-My Perspective. in Theory of Constraints Handbook, J. F. Cox III and J. G. Schleier, Eds., McGraw-Hill, pp. 3-9, New York, 2010.
- E. M. Goldratt, Standing on the Shoulders of Giants. The Manufacturer, 2009.
- E. M. Goldratt, The Unbalanced Plant. Twenty-fourth Annual International Conference Proceedings, Boston, 1981.
- J. Bicheno, The New Lean Toolbox-Towards Fast, Flexible Flow, Production and Inventory Control. Systems and Industrial Engineering Books, Buckingham, 2004.
- O. Cohen, Ever Improve- A Guide to Managing Production the TOC Way. Ivancna: TOC Strategic Solutions, 2010.
- E. Schragenheim, From DBR to Simplified-DBR for Make-to-Order. in Theory of Constraints Handbook, J. F. Cox III and J. G. J. Schleier, Eds., McGraw-Hill, pp. 211-238, New York, 2010.
- J. H. J. Blackstone, A Review of Literature on Drum-Buffer-Rope, Buffer Management and Distribution. in Theory Of Constraints Handbook, J. F. Cox III and J. G. Schleier, Eds., McGraw-Hill, pp. 145-173, New York, 2010.
- E. Schragenheim and H. Dettmer, Manufacturing at Warp Speed- Optimizing Supply Chain Financial Performance. Boca Raton: St. Lucie Press/APICS series on constraints management, 2001.
- Ş. Demirkol Akyol, Tip-2 Montaj Hattı Dengeleme ve İşgücü Atama Problemi için Doğrusal Programlama Yaklaşımı: Bir Vaka Çalışması. DEÜ Mühendislik Fakültesi Fen ve Mühendislik Dergisi, 25(73), 121-129, 2023. 10.21205/deufmd.2023257310
- A. Corominas, A. Garcia-Villoria and R. Pastor, Improving the Resolution of the Simple Assembly Line Balancing Problem Type E. Statistics and Operations Research Transactions, 40(2), 227-242, 2016.
- M. C. A. Ritt, Improved Integer Programming Models for Simple Assembly Line Balancing and Related Problems. International Transactions in Operational Research, 25, 1345-1359, 2015. 10.1111/itor.12206
- M. Ritt, A. M. Costa and C. Miralles, The Assembly Line Worker Assignment and Balancing Problem with Stochastic Worker Availability. International Journal of Production Research, 54(3), 9007-922, 2015. 10.1080/00207543.2015.1108534
- Z. Zhang and W. Cheng, Teaching assembly line balancing problem by using Lingo Software. Second International Workshop on Education Technology and Computer Science, pp. 663-666, 2010. 10.1109/ETCS.2010.456
- B. N. Şahin and E. Kahya, Hedef programlama problemi ile ergonomik kısıtlar altında montaj hattı dengelemesi. Mühendislik Bilimleri ve Tasarım Dergisi, 6(ÖS: Ergonomi2017), 188-196, 2018. 10.21923/jesd.358709
- K. G. H. Ağpak, Basit U Tipi Montaj Hattı Dengeleme Problemine Bulanık Programlama Yaklaşımı. Dokuz Eylül Üniversitesi Mühendislik Fakültesi Fen ve Mühendislik Dergisi, 4(2), 29-40, 2002.
- S. Kökhan, Farklı tipte işgücüne sahip maliyet yönelimli paralel montaj hattı dengeleme problemi için modelleme ve çözüm. Doktora Tezi, Gazi Üniversitesi, Ankara, 2020.
- G. Kumar and P. Gowda, An optimal balancing of assembly line using Rpw Technique. International Journal of Engineering Research And Advanced Technology, 1, 469-475, 2016.
- G. Çalışkan, Bir tekstil işletmesinde simülasyon optimizasyon yaklaşımı ile hat dengeleme çalışması. Yüksek Lisans Tezi, Pamukkale Üniversitesi Fen Bilimleri Enstitüsü, Denizli, 2020.
- G. Kılıç, Hazır giyim işletmelerinde üretim hattı dengelemesine yönelik bir uygulama. Yüksek Lisans Tezi, Marmara Üniversitesi Fen Bilimleri Enstitüsü, İstanbul, 2010.
- K. Nahar, A. Habib, A. A. Nayon and M. Hossain, Assembly line balancing using ACO Algorithm and RPW Method: A Comparative case study. Journal of Modern Science and Technology, 6(3), 13-24, 2018.
- K. Ağpak, H. Gökçen, N. N. Saray and S. Özel, Stokastik görev zamanlı tek modelli U tipi montaj hattı dengeleme problemleri için bir sezgisel. Gazi Üniversitesi Mühendislik Mimarlık Fakültesi Dergisi, 17(4), 115-124, 2002.
- S. T. Ghutukade and S. M. Sawant, Use of ranked position weighted method for assembly line balancing. International Journal of Advanced Engineering Research and Studies / II / IV / July-Sept, 1(3), 2013.
- M. S. Khan and J. P. Saurabh, Evaluation of standard time with the application of rank positional weighted method in the production line. International Journal of Mechanical and Production Engineering Research and Development (IJMPERD), 7(2), 73-80, 2017.
- A. Ş. Uyanık, Bir traktör fabrikasında karışık modelli montaj hattı dengeleme–deterministik ve stokastik ölçümlere göre analizler. Yüksek Lisans Tezi, TOBB ETÜ Fen Bilimleri Enstitüsü, Ankara, 2020.
- T. C. Lopes, A. S. Michelsa and C. G. S. Sikorab, Balancing and cyclically sequencing synchronous, asynchronous, and hybrid unpaced assembly lines. International Journal of Production Economics, 203, 216-224, 2018. 10.1016/j.ijpe.2018.06.012
- A. Portioli-Staudacher, F. Costa and M. Thürer, The use of labour flexibility for output control in workload controlled flow shops A simulation analysis. International Journal of Industrial Engineering Computations, 11, 429-442, 2020. 10.5267/j.ijiec. 2019.11.004
- S. Yoon and S. Jeong, Line Balancing Strategy for Re-Entrant Manufacturing. IEEE Transactions on Semiconductor Manufacturing, 31(1), 42-51, 2018. 10.1109/tsm.2017.2768242
- N. Zheng and L. Xiaochun, Comparative study on push and pull production system based on Anylogic. in International Conference on Electronic Commerce and Business Intelligence, 2009. 10.1109/ecbi.2009.26
- B. Mendenhall, Creating Perfect Harmony - How to Solve the Discords of TOC and LSS. 2008.
- M. Rother and J. Shook, Görmeyi Öğrenmek, Ver 1.2- değer yaratmak ve israfı ortadan kaldırmak için değer akışı haritalama. The Lean Enterprise Institute, Massachusetts, 1999.
- E. M. Goldratt and J. Cox, Amaç-Sürekli İyileştirme Süreci. Optimist Yayınları-İstanbul: North River Press, 1984.
- H. W. Dettmer, The Logical Thinking Process. Milwaukee, USA: ASQ Quality Press, 2007.
- E. M. Goldratt and R. E. Fox, The Race. New York: North River Press, 1986.
- C. Roser, All About Lean-Organize your Industry!, 2014. https://www.allaboutlean.com/drum-buffer-rope /. Accessed Mayıs 2023.
- Z. Sardar and I. Abrams, Kaos: Düzensizlikteki Düzen., İstanbul: NTV Yayınları, 1998.
- J. H. Holland, Signals & Boundaries: Building Blocks For Complex Adaptive Systems., Londra: The MIT Press, 2012.
- M. Gökçen, A. Boru and A. T. Dosdoğru, İki Aşamalı Tedarik Zincirinde Eş Zamanlı Stok Kontrolünün ve Tedarikçi Seçiminin Simülasyon Optimizasyonu Yaklaşımı ile Analizi. Karaelmas Fen ve Mühendislik Dergisi, vol. 8, no. 1, pp. 1-10, 2018. 10.7212 %2Fzkufbd.v8i1.617
- informs: Simulation Software Survey, 2017. https://www.informs.org/ORMS-Today/OR-MS-Toda y-Software-Surveys/Simulation-Software-Survey. Ace ssed Mayıs 2023.
- B. Scholz-Rieter, K. Windt and H. Liu, (DET2009) Modelling Dynamic Bottlenecks in Production Networks. International Journal of Computer Integrated Manufacturing, no. 1, 2010. 10.1080/0951 192x.2010.511655
- M. Thürer, M. Stevenson, C. Silva and T. Qu, Drum-buffer-rope and workload control in high-variety flow and job shops with bottlenecks: An assessment by simulation. International Journal of Production Economics, no. 188, pp. 116-127, 2017. 10.1016/j.ijpe.2017.03.025
- A. Lizarralde-Aiastui, U. Apaolaza-Perez de Eulate and M. Mediavilla-Guisasola, A Strategic Approach for Bottleneck Identification in Make-To-Order Environments: A Drum-Buffer-Rope Action Research Based Case Study. Journal of Industrial Engineering and Management, vol. 13, no. 1, pp. 18-37, 2020. 10.3926/jiem.2868
- A. Gonzales-Romero, I. J. Huamani-Martinez, J. C. Quiroz-Flores and B. H. Diaz-Garay, Production management model based on Lean and DDMRP tools to increase the rate of project compliance in manufacturing SMEs in the metalworking sector. in 8th International Engineering, Sciences and Technology Conference (IESTEC), 2022. 10.1109/IESTEC545 39.2022.00015
- F. Tanhaie, Comparison Between the Performances of Pull and Push Systems Using Discrete Event Simulation. Journal of Systems Thinking in Practice, vol. 1, no. 2, pp. 44-55, 2022. 10.22067/JST INP.2022.77835.1015
- U. Apaolaza, A. Orue, A. Lizarralde and A. Oyarbide-Zubillaga, Competitive Improvement through Integrated Management of Sales and Operations. Sustainability, no. 14-2722, 2022. 10.3390/su14052 722
- Yalın-hat dengeli model erişim adresi: https://clo ud.anylogic.com/model/194f3e34-bc74-4289-9577-239 4cea5d0c5?mode=SETTINGS&tab=GENERAL
- S-DBR model erişim adresi: https://cloud.any logic.com/model/3d090860-dae8-4f75-92d7-20415cc2 0a03?mode=SETTINGS&tab=GENE RAL