Shusaku Hiraki

Pull-Push integration in production ordering systems

Abstract In this paper, we study Pull-Push integration in production ordering for multistage production inventory systems. In Pull-Push integration, the succeeding stages are ordered by a pull-type production ordering system and the other stages are ordered by a push-type production ordering system. After reviewing the previous literature, we develop a mathematical model of an integrated production ordering system. As performance measures, we analyzed the amplifications of production quantities and inventory levels, and we show that the proposed production ordering system makes the performance of preceding stages much better than a pure push-type or pull-type production ordering system.

Flexibility of production ordering systems

The flexibility of production ordering systems as medium range production control systems are studied. The changes affecting flexibility, production ordering systems as responses to changes, and the performance measures of flexibility are clarified. On the basis of this framework, mathematical models of production system and production ordering systems are developed to evaluate their flexibility. Two types of changes are considered: demand fluctuation and downtime fluctuation due to machine breakdown, and two models for ‘push-type’ and ‘pull-type’ production ordering systems are investigated. By simulating the models, the amplifications of production quantities and inventory levels as flexibility measures for each type of production ordering system are analysed and the flexibility compared.

A mathematical model to minimize the inventory and transportation costs in the logistics systems

Abstract In this paper we consider a logistics system for parts manufacturer distribution center(depot) to supply the parts to the parent company. And we formulate the mathematical model to minimize the sum of inventory holding costs at the depot, and the transportation and inventory costs at parts manufacturer. We apply the model to an actual automobile parts manufacturer to demonstrate the effectiveness of the proposed model.

LOW-INVENTORY ORDERING SYSTEMS FOR THE INTERNATIONAL CO-OPERATIVE KNOCKDOWN PRODUCTION SYSTEMS

SUMMARY This paper aims to clarify the properties of the ordering systems of the international co-operative knockdown production systems (ICKDPS) for mutual countrys development. The ICKDPS consists of a three-stage production, inventory and transportation system. Two types of ordering models based on the pull-type ordering system are formulated, and the relations between the transportation lead time and variations of ordering quantity and inventory quantity are analysed in an attempt to improve the productivity and reliability of the ICKDPS.

Designing a pull-type parts procurement system for international co-operative knockdown production systems

In this paper, a conceptual framework for designing a parts procurement system for international co-operative knockdown production systems is proposed. Two types of pull-type parts procurement models that contain both a backorder function which modifies the backlog carried over from the last period and emergency delivery compensating for component part shortages, are formulated, and the effects of emergency delivery on the probability of stock out and the mean value of shortage quantity is analysed. Using these results, a computational procedure for determining an economic buffer stock level and emergency delivery rate or level which assures system reliability for a given performance level and minimizes the sum of inventory and emergency procurement costs, is presented.

Comparative analysis of ordering models for an international co-operative global complementary production system

Abstract In recent years, international co-operative global complementary production systems (ICGCPS), especially in the automobile industry, have been widely developed in order to improve the international coordination and division of labor in the developing countries. ICGCPS is a global production system with several production bases located in several countries. In order to get the advantages of scale merit, each production base produces only special kinds of components and machining parts for the total demand required in all the participating countries, and supplies them to the other production bases. This paper aims to design a production, inventory and transportation system to realize high productivity and low inventory in the ICGCPS for the mutual development of all the countries. We will propose two types of ordering models based on the concept of the pull-type ordering system in the form of a mathematical model. One is a product-oriented ordering model and the other is a component-oriented ordering model. We make a comparative analysis of these two ordering models with respect to the distribution properties of ordering, withdrawal and inventory quantities at each stage and stock point for determining adequate buffer stock in the system.

Trade-off analysis of buffer stock versus emergency delivery in the knockdown production systems

Abstract In the international co-operative knockdown production systems (ICKDPS), the transportation lead time to procure component parts is much longer than actual production lead time. Therefore, in designing an ordering system for the ICKDPS, it is necessary to decide an adequate buffer capacity in order to improve the system reliability for the transportation lead time. In this paper, we develop a new pull type ordering system, based on the concepts of just-in-time production systems, which incorporates a backorder function which modifies the back-log carried over from the last period, and includes two types of buffer capacities, that is, safety stock and emergency delivery for the ICKDPS. By trading off these two types of buffer capacities, we develop a way of determining an economical safety stock level and emergency delivery rate which will assure system performance reliability to any pre-determined level.

A framework for the management system model to create new value of business output

A model that aims at measuring the comparative advantage of a management system is proposed in this paper. The model consists of leadership, management resources, business process, and value of business output for stakeholders such as stockholders, employees, customers, suppliers, and corporate companies. We designed a questionnaire based on the proposed model and used it to compare Japanese industries with those in Asia, Europe, and the USA. One hundred answers were collected, and the results were analysed. This paper shows the strengths and weaknesses of the Japanese industry in terms of competitive edge and suggests future research directions that may help in increasing the overall capacity for the management system.

Japanese offshore manufacturing in Thailand: its difficulties and future prospects

During the past decade, the market for consumer and industrial goods in South‐East Asia has grown at a rapid rate and industrial countries in this region have been trying to advance their national plans to stimulate economic take‐off. However, in the middle of 1997, the ASEAN bubble economy started to collapse after devaluation of the baht. In this paper the current status and future direction of Japanese manufacturers in Thailand are discussed through facts investigations and a survey execution. The results from this investigation indicate that the Japanese offshore manufacturers in Thailand are at an earlier stage than their domestic counterparts in Japan, in terms of manufacturing strategies and action programmes. Therefore, offshore manufacturers are in a much more severe situation than domestic firms, although one of their major reasons for joining the Thai manufacturing industry was to recover from the ending of Japan’s own bubble economy.

A modeling approach to a JIT-based ordering system

In this paper, we consider a multi-stage multi-product production, inventory and transpor-tation system and develop a mathematical model for a pull type ordering system based on the concept of a Just-In-Time (JIT) production system. Our model considers a manufacturing system in which the setup action is improved and can deal with the number of setups required. We also propose two approximate solution procedures to rapidly obtain a suboptimal solution of the formulated integer programming problem using a mathematical programming modeling language. The approximate procedures are realized utilizing post-optimal analysis which can be performed by the modeling language. Finally, we show a numerical example of the model applied to an actual manufacturing system of an automo-bile parts manufacturer in order to verify the effectiveness of the approximate procedures and to clarify the applicability of our modeling approach.