Lukasz Hadas

Method of buffering critical resources in make-to-order shop floor control in manufacturing complex products

The article presents the results of research on creating a dedicated planning system and shop floor control in the conditions of make-to-order in manufacturing complex products. The research was carried out at the Marine Diesel Engines Factory of HCP S.A., Poznan. HCP S.A. is the biggest producer of high-power marine engines in Europe. The result of the research is a method for buffering critical resources in shop floor control. These methods of buffering critical resources include procedures of buffer management, (buffer configuration and optimisation), a system of disruption compensation and feedback protecting from the destructive influence of ‘wandering bottlenecks’. The simulations show that this method is more effective than the classical drum-buffer-rope production solution, according to the theory of constraints (TOC), using the first-in-first-out rule. Finally, the lead time and the level of work-in-process were about 20% lower than the solution recommended to TOC. In the final part of the article a place and a method of implementing the solution in a planning system of the enterprise are discussed.

Production planning model with simultaneous production of spare parts

This paper presents, proposed by the authors, application classical models of stock replenishment in production planning model with simultaneous production of identical components for the need of own assembly and as spare parts in machine industry plants. The goal of the thesis was to elaborate a production planning model which would allow to combine all demand sources within one production schedule and to decrease spare parts stock with simultaneous production of identical components (spare parts, subassemblies) for the need of own assembly and as spare parts. The proposed production planning model has been based on the classical stock management theory and material requirement planning methods. It results in merging production management and stock management in a one coherent material flow management system. The research was done in GRUNDFOS POMPY Ltd. Company. GRUNDFOS is one of the biggest pump producers in the world. The model has been verified through its implementation and resulted in a decrease of spare parts stock by nearly 50%.

Decision Making Model in Integrated Assessment of Business-Environment System: a Case Study

The goal of the chapter is to present a business model developed to confront efficiency of processes and their influence on natural environment, combining economic reasons for process reengineering and environmental aspects of business activity. The economic reasons presented are based on the assumption that processes should be cost-efficient to be competitive. Environmental aspects on the other hand assume that limitation of negative influence on natural environment should not result in decreasing enterprises’ competitiveness. The assumptions introduced are integrated in the model developed thanks to analyzing complex relations between assortment, lot size, releases, set ups, energy use, waste, quality providing costs and related processes.

Measuring the Level of Integration in a Sustainable Supply Chain

Abstract This article presents a system for measuring the level of integration of a sustainable supply chain. A supply chain involves both forward and backward flows and is related to S&OP model. The paper features also the methodology for developing a system for evaluating and validating the measurement system along with its application guidelines. A comprehensive list of 19 integration categories subject to evaluation is supplemented with the description of the integration levels pertaining to selected categories.

A Model for a Multidimensional Analysis of the Supply Chain Indicators in the Context of Sustainable Development

Abstract The Authors of this article presents a model for evaluating the supply chain sustainability developed by the authors. The model involves the following levels: a holistic presentation of results, a formal assessment, an informal diagnosis. The first level includes a holistic presentation of the results obtained in the course of the indicator analysis. This analysis has a pyramid form. The second level of the presented evaluation model involves a formal assessment of the supply chain from the point of view of sustainable development. The supply chain effectiveness was reflected in the integrated indicator employed in its evaluation. The third level of the model describes a methodology for an informal diagnosis of the current state of the supply chain from the point of view of sustainable development. The diagnosis methodology is based on the Sustainable Supply Chain Virus Analysis. SSCVA is a practical conceptual process framework for identifying and analyzing problems which occur in a supply chain from the point of view sustainable development. This diagnosis tool is also used to provide feedback for the formal analysis model. SSCVA provides an answer to the question on how to improve the indicator and what is the root cause of its unsatisfactory value.

The hybrid MRP/TOC system in make to order company - case study

This paper presents a building of hybrid MRP/TOC system in make-to-order shop floor control in manufacturing complex products. The research was done in Marine Diesel Engines Factory, HCP S.A. Poznan conditions. HCP S.A. Poznan is the biggest producer of high-power marine engines in Europe. This article presents general idea of hybrid MRP/TOC system and practical aspects of his creation and implementation.

Operational Measurements for Evaluating the Transformation of Production-Logistics System and Their Reflecting in Simulation Software

The aim of the article is to present performance metrics and indicators of a production-logistics system at the operational level and their use for evaluation purposes in simulation experiments carried out in Simulation Software. The authors reviewed logistics and production system performance metrics and indicators as arranged in the category of flow and stock management. A survey questionnaires served as a basis for investigating the evaluation of logistics and performance systems (a system of metrics and indicators) with a view to identifying the ways in which the requirements of companies could be met in this respect, i.e. how they have a real impact on the decision-making process (research sample—372 enterprises surveyed on the operational and tactical level). The final part of the chapter demonstrates the authors’ evaluation system its and modeling in Simulation Software. In the conclusion, the authors offer guidelines on how to capture and analyze the results of simulation experiments to be able to satisfy the requirements of competition-driven market.

The analysis of the effectiveness of computer assistance in the transformation of explicit and tactic knowledge in the course of supplier selection process

The article presents investigations upon the effectiveness of computer assistance in the transformation of explicit and tactic knowledge in the course of supplier selection process in an enterprise. A computer system is oriented towards achieving greater process efficiency than in a traditional procedure based upon expert knowledge of employees. Authors of the article have modeled a multi-variant process of supplier selection providing two options, one with computer assistance and the other without this assistance. The obtained results are used to identify the restrictions and formulate the conclusions as for the requirements that should be met by the systems assisting the decision-making in this area.

Risk Assessment for Potential Failures During Process Implementation Using Production Process Preparation

Production preparation process is one of most important tool which is using during design or redesign of the production process. Production process can be changed by different causes. 3P (production preparation process) is universal tool which can be used in almost all cases of process modernization. 3P is connecting and engaging not only R&D department but also others company departments. The main aim of this research was to identify and assess the risk for potential failures during process implementation using Production Process Preparation (3P). The research was carried out in an enterprise from the automotive industry, which is an international supplier of components to many car brands. The prepared questionnaire contained questions (ordered in the individual categories) selected on the basis of the authors experience and consultations with the experts at least 10 years of experience. The study took into account the seniority of experts as a process engineer and experience as a manager. The results of the surveys were the basis for identifying potential failures with the highest risk in the Production Process Preparation.

Sustainable Transport System Virus: The Conceptual Process Framework of Problems Identification and Analysis in Distribution System

The authors of this chapter proposed their own conceptual process framework of problems occurring in organization of transport processes within distribution systems. The proposed tool is a unique hybrid of well-known solutions, presented in professional literature. This conceptual process framework has been developed and successfully implemented as part of works aimed at facilitating the transportation system in one of the largest market chain operators in Poland. Problem identification and analysis tool of organization of transport processes in distribution companies developed within this project has been called Sustainable Transport System Virus Analysis (STSVA). In this chapter basic assumptions and methodology of the tool developed by the authors have been included.