Piotr Cyplik

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%.

RANKING OF INTEGRATION FACTORS WITHIN SUPPLY CHAINS OF FORWARD AND BACKWARD TYPES - RECOMMENDATIONS FROM RESEARCHES

Background: Integration trends are one of main determinants of the development of modern logistics. After the period of interest focused mainly on supp ly chains realizing one-way flows only, at present there is a time for supply chains characterized by two-way flows, reali zing at the same time both forward and backward flo ws. The possibility of various configurations of such chain s requires identification of integration factors an d determination of their influence on the results of the whole supply chain. Experiences of the science as well as the practice of supply chains show the urgent need of learning of reasons of the integration within supply chains of the two-way typ e. Material and methods : The researches on modeling and simulation of inte gration processes within supply chains of forward and backward type were carried out in the e nvironment of iGrafx Process 2013 for Six Sigma. The empirical material obtained in these researches was put to th e statistical analysis by the used of Minitab 17. T he identification of the significance of differences was made with the help of analysis of variance ANOVA. Additionally the analysis of differences in form of absolute averages was made. The following measures are main ones for the evalu ation of the integration of a supply chain of forward and backwa rd types: cashflow, profitability, service level. Results : 8 192 simulation experiments were made for 6 inte gration factors: accessibility of recycled material s, production planning, stock management, integration of transpor t, unification of packing materials and optimizatio n of the material flow. Based on the analysis of the significance and values of differences, the results of the influenc e of each integration factor on global results of supply chains of forwar d and backward type were obtained. They were used to prepare the ranking of integration factors. The main factors, f orming the integration shape of two-way supply chai ns were: stock management, production planning and accessibility of recycled materials. Conclusions: The integration offers new possibilities therefore it is the promising option of actions. In complica ted and complex logistic reality, it is more and more diffi cult to function, in economic sense, without starti ng and tightening close cooperation. Sometimes it is even not possible at a ll. The growing popularity of two-way supply chain s opens the dimensions of the possible cooperation. However, bo th science and the practice need the reliable quant itative information covering the conscious creation of the integration in supply chains. Such tool could be a ranking, rec ommended in this paper, of integration factors from the perspective of three measures of evaluation of global level of functioning of the supply chain.

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.

Modelling Integration Process Planning in the Supply Chain Using SOP Approach

This chapter presents the concept behind a simulation model reflecting the functioning of a supply chain in the context Sales and Operations Planning (SOP) working in business in practice. The methodology assumed by the authors was based on: the analysis of integration models of planning processes, with a particular focus on the concept of Sales and Operations Planning, accompanied by the analysis of the surveys findings. Literature on the subject features SOP mainly as a business tool based on a collective decision making on the tactical level. The solution put forward in this article represents a systemic approach to the planning process integration. It includes the mechanisms of coordination put in place in a wide process planning structure, applied both in companies and within the supply chain. The model serves as a point of departure for further works related to the simulation of the material flow within a supply chain in the context of integrated planning. The final results of whole research will be employed in defining the impact of integrated process planning on the functioning of the supply chain, in particular on the coordination of the material flow and achieved results, as measured by economic and logistics metrics.

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 Planning Process Integration Influence on the Efficiency of Material Flow in Production Companies

In the article, the authors present the results of the research on the planning process integration influence on the efficiency of material flow in production companies. In order to identify the influence the authors developed their own planning process integration model based on the Sales and Operations Planning (SOP) approach. Four planning process integration levels were qualitatively defined at the tactical level and were modelled in the simulation environment. The levels were applied to plan material flow in a production company. The flow efficiency was measured by means of the following indicators: customer service level and return on sales. The simulation study results made it possible to confirm that the planning process integration has a positive influence on material flow in production companies.