Flavio Cesar Faria Fernandes

A multi-dimensional classification of production systems for the design and selection of production planning and control systems

A primary requirement for improved understanding of the management of production systems is an appropriate classification of such systems. This paper proposes a classification that facilitates a better understanding of real production systems. It combines all the essential features, e.g. the flow of materials with new classification perspectives with respect to response time, repetitiveness and work organization. As much previous work has influenced the approach proposed here, the paper also presents a review of relevant literature. The classification has four groups of characteristics, comprising eight dimensions of descriptors, encompassing 12 variables. Choosing or designing an appropriate production planning and control system (PPCS) is a difficult task due to the integrative character of the production planning and control area: it tends to interface with all functional areas of the enterprise. An important objective of the classification system proposed here is to provide a tool to assist in undertaking this difficult task. Real production systems are becoming more hybrid in order to be able to cope with change. We show that our classification can successfully deal with such systems.

Manufatura Enxuta: uma revisão que classifica e analisa os trabalhos apontando perspectivas de pesquisas futuras

This work reviews the literature on Lean Manufacturing (LM). Until now, there was no complete literature review regarding this subject in the Operations Management literature. Based on this literature review it is proposed a LM classification system based on 4 main characteristics: methodology, comprehension, principles and enablers. The system is used to classify and to organize the papers. After that a general analyses of LM is performed. The LM analyses is based on 2 main points: i) a quantitative study of the methodology, comprehension, principles and enablers within LM papers; ii) a qualitative study regarding the main subjects and goals accomplished by the papers. The main contributions of this work are to contribute for mental clarification, communication and discovering new fields for research on LM.

A proposal for integrating production control and quality control

Purpose – The purpose of this paper is to present a practical proposal for integrating production control (PC) and quality control (QC) at the shop floor level.Design/methodology/approach – The proposed method is based on three principles which relate PC and QC at the shop floor level. The proposal is applied successfully at the worlds largest pencil factory.Findings – The results show that the proposed method contributes to improve four performance indicators related to PC and QC at the company studied: increase the average throughput in about 28.9 per cent; reduce the average value of work in process (WIP) in about 35.6 per cent, reduce the average lead time by about 45.4 per cent, and reduce the average defect rate by about 71.4 per cent.Research limitations/implications – The proposal (mainly because of principle III) is developed to be applied in repetitive production (RP) systems, i.e. environments characterized by low production volume and low product variety.Practical implications – Some practica...

Pesquisa em gestão da produção na indústria de calçados: revisão, classificação e análise

This paper presents a literature review that intends to be complete including 209 papers on Production Management on footwear industry since 1980. Such a review has not yet been available on the Production Management literature. This review was organized by means of a classification encompassing 5 dimensions: paper origin, area of Production Engineering focused in the paper, sub area of Production Engineering focused, research procedure used, and the paper source. Once classified and organized, the literature review about Production Management on footwear industry was the base of a broad theme analysis. This analysis was based on two basic points: i) a quantitative study on the areas of Production Engineering focused in the papers such as the origin, source, and research procedure used and ii) a qualitative study on the main subjects and objectives discussed and met in those papers. The main contributions of this paper are being useful to increase the amount of literature available on Production Management in the footwear industry and suggestions for future researches.

Systems for coordinating orders: review, classification, operationality and applicability

Ordering systems are the focus of this work. Ordering systems are information systems which schedule or organize requirements in terms of components and materials and/or control the production and purchase orders emission/release being able to restrain or not rules of sequencing orders. Within this context, this paper intends: to present a new nomenclature for ordering systems, Systems for Coordinating purchase and production Orders (SCO); to present a typology that is able to classify all the systems in a rational way; to discuss some systems which have high potential for success applications and that are relatively unknown in Brazil and, to highlight a theme which is highly important to Production Planning and Control (PPC) in the scientific Brazilian literature.

Proposta de um sistema de controle da produção para fabricantes de calçados que operam sob encomenda

This paper presents a proposal for controlling the production in shoe industries. It aims at regulating the material flow in small and medium enterprises operating in a Resources-to-Order (RTO) or Make-to-Order (MTO) product market environment with large variety of final products. For a better understanding of Production Planning and Control (PPC) problems in this context. Seven shoemakers in the city of Birigui-SP, Brasil were investigated. The proposal includes: (a) choosing an ordering system; (b) developing a method for elaborating the master production schedule (MPS); and (c) establishing procedures for sequencing the production orders.

Automação industrial e sistemas informatizados de gestão da produção em fundições de mercado

Fundicao e um processo de fabricacao que vem crescendo em importância. O principal objetivo deste artigo e analisar, em termos de automacao e sistemas informatizados de gestao da producao (SIGP), as fundicoes de mercado (fundicoes que produzem sob encomenda um grande numero de pedidos vindos, em geral, de um grande numero de clientes) no interior do Estado de Sao Paulo pertencentes aos 5 principais polos (Piracicaba, Indaiatuba, Limeira, Sao Carlos e Itu) com 10 a 250 trabalhadores. Das 61 empresas do interior de Sao Paulo, 35 situam-se nesses 5 polos (ou em suas imediacoes); entrevistamos pessoalmente os diretores industriais e visitamos o chao de fabrica de 30 fundicoes dentre essas 35. Analisamos quase 200 tabelas de frequencia e de contingencia e extraimos varias conclusoes, por exemplo: (i) entre os tres principais problemas e necessidades relativos a producao, dois deles estao diretamente relacionados com a automacao industrial e com os SIGP; (ii) sao coincidentes os interesses em automacao e SIGP.

Binary integer programming formulations for scheduling in market-driven foundries

This paper describes the development and solution of binary integer formulations for production scheduling problems in market-driven foundries. This industrial sector is comprised of small and mid-sized companies with little or no automation, working with diversified production, involving several different metal alloy specifications in small tailor-made product lots. The characteristics and constraints involved in a typical production environment at these industries challenge the formulation of mathematical programming models that can be computationally solved when considering real applications. However, despite the interest on the part of these industries in counting on effective methods for production scheduling, there are few studies available on the subject. The computational tests prove the robustness and feasibility of proposed models in situations analogous to those found in production scheduling at the analyzed industrial sector.

Alocação de pedidos em aglomerados industriais calçadistas: modelos e estudo de caso

Este artigo tem como objetivo apresentar propostas de solucao (modelos matematicos) para a alocacao de pedidos em aglomerados industriais calcadistas. Definimos, como base para a sustentacao de tais propostas, uma classificacao dos aglomerados industriais calcadistas e a definicao de uma infra-estrutura tecnologica coordenada por um agente central do cluster. O caso de um cluster exportador tambem e apresentado.

O uso da programação inteira 0-1 para o balanceamento de linhas de montagem: modelagem, estudos de caso e avaliação

This paper deals with the assembly line balancing problem. Within this context, the objective is to show that nowadays, in many practical cases, it is possible, even in large problems, the application of exact solution procedures (in this case, integer programming). This is accomplished by means of two case studies in big companies of Sao Paulo State, which presents large assembly line balancing problems (lines with 80 and 104 tasks). In one of these cases one constraint unpublished on literature was included in the model to adapt the model to the real situation. This constraint accounts to those cases in which the assembly line has both manual and automatic tasks. The results were very good, and a reduction of more than 10% was attained in the number of workstations required on the assembly line.