Paulina Rewers

A Study of Priority Rules for a Levelled Production Plan

This paper looks as initial results of research into the validity of application of selected priority rules in the development of a levelled production plan. The development of a levelled production plan is the key stage of the authors’ own methodology of levelling production to mitigate the adverse impact of variable demand. A levelled production plan permits to maximize effects, defined as being able to deliver diverse products in a timely manner and at the same time reduce stocks and optimize efficient use of manufacturing resources. Application of an appropriate priority rule in the development of a levelled production plan is the key factor determining the effectiveness of the developed methodology. Initial research has been conducted for twenty automatically generated task sets. One hundred manufacturing schedules have been developed in total—five schedules for each set, according to the selected priority rules (shortest task time, longest task time, shortest processing time, longest processing time, first in first out). The schedules have been assessed in terms of meeting the selected key criteria for the objectives of levelled production.

Data Analysis in Production Levelling Methodology

The article describes an original computer program developed by the authors to aid data analysis for the purposes of production levelling methodology. Individual stages of the methodology are connected with analysis of multiple types of data. The program AnaPro enables analysis of manufacturing process data to separate product families, specify the demand for products and implement production. Functions of the program are described along with examples of data analysis.

The Impact of Task Balancing and Sequencing on Production Efficiency

The paper contains an evaluation of the impact of assembly-line balancing and scheduling on production efficiency. It describes issues connected with assembly-line balancing and the rules of scheduling production tasks. Some problems are indicated connected with the functioning of assembly line before the improving actions began, which have been eliminated by means of the assembly-line balancing and a new method of scheduling. Results connected with improved productivity and production efficiency are shown.

Computer Aided Data Acquisition and Analysis for Value Stream Mapping

The article presents original computer software designed to assist in data acquisition and analysis for the purpose of value stream mapping for one of tools of lean manufacturing concept. The AnaPro program uses the collected data about manufacturing processes to analyse product demand, material supplies or manufacturing processes, which is then used as a basis for creating current state maps. Furthermore, the program allows for preparing variants of future state maps through an analysis of turnover classification, product demand and methods of production flow control. The article describes functions of AnaPro with regard to value stream mapping and a practical example of the software application is provided.

Classification of Products in Production Levelling

The article focuses on the issue of production levelling (jap. Heijunka). The article contains an analysis of literature and presents the author’s methodology of production levelling. The methodology consists of 5 steps. The first stage is the selection of products for which the production levelling will be carried out. The article presents the author’s scheme for defining product groups, consisting of two main steps, from which 6 product groups are selected. Criteria that were taken into account in the creation of the scheme are primarily the rotation of products, sales of products (volume and value) and the minimum, economic production batch. The example of the use of product classification in an enterprise from the automotive industry is also presented. Separated product groups accounted for 28% of all manufactured products and approximately 88% of the company’s total turnover.