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This work is a supplement to earlier literature reviews of research on the production control scheme known as CONWIP. In this paper, we chronicle the origins of CONWIP and address many of the issue...

Studies on the performance of production control systems typically assume that materials are continuously available at stations, thereby neglecting the potential impact of inventory stockouts. Contrarily, this study assesses the performance behavior of two of the most known production control systems, namely POLCA (Paired-cell Overlapping Loops of Cards with Authorization) and WLC (Workload Control) under inventory stockouts, in an assembly-to-order system. For a better understanding of such behavior, Load-Based POLCA (LB-POLCA), i.e. a variant of the POLCA system that takes into account the workload of jobs, is also considered in the study. The study is carried out using discrete event simulation. Results show that stockouts induce loss of system performance, as expected, but the relative performance of the production control systems tested does not change in relation to the situation of continuous availability of materials. Moreover, delivery performance is best using WLC followed first by LB-POLCA and after by POLCA.

In the face of challenges such as limited resources and climate change, aerospace companies strive for efficiency and sustainability in their manufacturing processes. By means of Additive Manufacturing (AM), new dimensions in terms of cost-effective and bionic lightweight structures are achievable. Even though AM results in the direct manufacturing of components, a variety of post-processing steps has to be implemented in the manufacturing line. By selecting a suitable automatic identification and data capture (Auto-ID) system, a production control system is capable of responding in real time to unforeseen events, while reducing waste caused, for exemple, through unnecessary processing steps. Thus, this paper focuses on an approach for a production control system for a manufacturing line including metal-based AM process.

Production control systems (PCSs) control the flow of jobs in a production system. The selection of a suitable PCS in the context of make-to-order (MTO) is challenging, due to the characteristics of MTO businesses and the number of parameters or factors that comprise a PCS. The literature that compares PCSs in the MTO context reported contradictory results. In fact, there is a gap in the literature concerning which factors or parameters explain a PCS performance. This paper presents an analysis of comparative studies on PCS in the MTO context, using a systematic literature review, to reveal which control factors and manufacturing conditions influence a PCS performance. The analysis concentrates on studies that use simulation to assess the performance of PCSs. Our results indicate that the main difference in PCSs performance is the design of the control loops. Other important factors that must be considered in the choice of a PCS are the order release mechanism, the workload aggregation approach, and the workload estimation method used on control loops. A framework for choosing a suitable PCS for MTO companies is presented, considering these factors.

Supply chain system experiences variance amplification in order replenishment and inventory level, leading to severe inefficiencies of the system. Information distortion is universally known as a fundamental reason for the variance amplification phenomenon. The purpose of this paper is to study the effect of demand information sharing in reducing bullwhip effect and improving the robustness of supply chain systems. The “automatic pipeline inventory and order-based production control system, APIOBPCS” is adopted to model supply chains with different information-sharing strategies. The stochastic factors in the supply chain system lead to poor performance in system robustness. Taguchi design is adopted to find out the optimal setting of ordering parameters in the APIOBPCS model for a robust supply chain. An extension of Taguchi design is adopted to solve the multi-response problems. The weighted signal-to-noise ratio is used as the performance index of the overall performance of the supply chain, including inventory cost, customer service level, and inventory variance amplification. The results show that full demand information transparency helps to improve the overall performance of supply chain. Furthermore, the sensitivity analysis of stochastic lead times verifies the results. This research gives some insights to improve the overall performance of supply chain via information sharing.

Matrix production refers to a highly flexible production system based on independent production cells that are linked by a flexible transportation system. The production control system decides on the sequence of the production steps of each order and their allocation to specific time slots on the available machines. This paper presents an approach based on deep Q-learning that is able to cope with the dynamic events of the system. The performance of the machine learning-based production control is compared to a static rule-based approach. Additionally, the effects of coordination between the independent agents on throughput time is shown.

This project was carried out at a company in the electric mobility sector, which manufactures chargers for electric vehicles, specifically in the wiring section. The main objective of the developed work was to improve the production processes in order to enhance responsiveness to the growing demand. After analyzing the processes in the section, the objectives were outlined to enable the improvement of some practices in the production department, such as the ones related to the organization of the raw material supermarket, as well as the calculation of the wiring consumption by chargers, and the implementation of a production control system. After the improvement actions were implemented, it was possible to observe a 14,9% reduction in the changeover process of the cable cutting process; weekly wiring consumptions were estimated, and procedures were defined to generate orders of raw material and supply to the workstation, which led to the elimination of stock shortages. In addition, worker autonomy increased and production downtime was reduced.

PurposeThe purpose of this paper is to contribute to the lean manufacturing literature by providing a roadmap for pull production control system (PCS) implementation.Design/methodology/approachAxiomatic Design (AD) methodology is used to develop the proposed pull PCS transformation roadmap.FindingsThe proposed design methodology is validated in a real-life manufacturing system. The results show that the proposed methodology significantly reduces the design efforts. The methodology effectively helps to choose the most appropriate pull PCS and determine its operational settings with respect to the manufacturing system characteristics.Research limitations/implicationsThis study presents only one case study to test the proposed methodology. In future studies, the validity of the proposed method can be further generalized in different manufacturing sectors by real-life implementations.Practical implicationsIn many real-life lean production projects, companies do not know where to start or how to proceed, which leads to repetitive design efforts and inefficient designs. The developed roadmap of this study minimizes incorrect or imperfect design trials and increases the success of pull production transformation projects.Originality/valueThe implementation of pull PCS requires extensive design knowledge and expertise. Therefore, many real-life applications fail due to costly and time-consuming trial-and-error-based design efforts. In the literature, there is no comprehensive guideline or roadmap for pull PCS implementation. To address this issue, this study provides a novel holistic roadmap to transform an existing push PCS to pull. The proposed methodology uses AD principles and combines fragmentary studies of the pull production literature.

The problem of designing a system for optimal operational control of random deviations in the productivity of technological equipment is considered. The synthesized control ensures the synchronization of the productivity of the technological equipment of the production line and asymptotic stability of the given planned state of the flow parameters of the production line for the steady and transient mode of operation., {"references":["1. Pihnastyi O.M. Statistical theory of control systems of the flow production / O.M. Pihnastyi. –LAP LAMBERT Academic Publishing. – 2018. - 436 p. –ISBN: 978-613-9-95512-1","2. Pihnastyi O.M. Target function of a production system with mass production of products P. Demutsky, O. M. Pignasty, V. D. Khodusov, M. N. Azarenkova // - Bulletin of the Kharkov National University. - Kharkiv: KhNU. - 2006. - N746. - P.95-103","3. Pihnastyi O.M. Issues of stability of macroscopic parameters of technological processes of mass production / V. P. Demutskiy, O.M.Pihnastyi // Dopovidi of the National Academy of Sciences of Ukraine. - Kiev: Vidavnichy dim \"Akademperiodika\". - 2006. -№ 3. - S. 63-67","4. Pihnastyi O. M. Overview of models of controlled production processes of production line production lines / О.M.Pihnastyi // Scientific bulletins of the Belgorod State University. Belgorod: BSU. - 2015. - No. 34/1. P.137-152"]}

The problem of designing a system for optimal operational control of random deviations in the productivity of technological equipment is considered. To construct an algorithm for optimal control of the performance of technological equipment, a PDE model of a production flow line was used. The Lyapunov functions method was used to determine the value of the optimal control of the technological equipment performance. The production line is considered by a distributed dynamic system. Equations are written for the flow parameters of the production line in small perturbations. A criterion for the quality control of the performance of technological equipment of a production flow line has been introduced. Based on this criterion, the Lyapunov function is determined for the considered production system. Taking into account the form of the Lyapunov function, control actions are obtained that correct the performance of the technological equipment. The introduced control made it possible to ensure the synchronization of the productivity of the technological equipment of the production line and the asymptotic stability of the given planned state of the flow parameters of the production line for the steady and transient operation mode., {"references":["Pihnastyi O. M. Overview of models of controlled production processes of production line production lines / О.M.Pihnastyi // Scientific bulletins of the Belgorod State University. Belgorod: BSU. - 2015. - No. 34/1. P.137-152. http://doi.org/10.5281/zenodo.2647598","Pihnastyi O.M. Statistical theory of control systems of the flow production / O.M. Pihnastyi. –LAP LAMBERT Academic Publishing. – 2018. - 436 p. ISBN: 978-613-9-95512-1","Malkin I.G. The theory of stability of motion / I.G. Malkin. - Moscow: Nauka, 1966 .- P. 531","Pihnastyi O. M. Analysis of models of transition processes controlled manufacturing / O. M. Pihnastyi / Scientific Bulletins of the Belgorod State University. Belgorod: BSU. - 2015. - No. 35/1. - P. 133-144 https://doi.org/10.5281/zenodo.2595561","Lyapunov A.M. General problem of motion stability / A.M. Lyapunov. - M .: Gostekhizdat, 1950 .-- P. 395","Pihnastyi O. M. On the relationship between micro-and macro-description of production and technical systems / O.M. Pihnastyi, V. Zaruba // Management of large systems: proceedings of the International Scientific and Practical Conference (Moscow, November 17-19, 2009). - Moscow: IPU RAN, 2009.- P. 255-258. http://doi.org/10.5281/zenodo.4731141","Sinitsa L.M. Organization of production. / L.M. Tit. - Minsk: UP IVC Minfin, 2003. –C. 512","Pihnastyi O.M. Analytical methods for designing technological trajectories of the object of labour in a phase space of states / O.M.Pihnastyi // Scientific bulletin of National Mining University. – Dnipro: State Higher Educational Institution «National Mining University». –2017. n.4. P. 104–111. http://nvngu.in.ua/index.php/en/component/jdownloads/viewdownload/69/8679","Khodusov V.D. The use of physical kinetics methods for studying oscillations of the parameters of a production line / V.D. Khodusov, O.M. Pihnastyi // East european journal of physics. - 2014. - Vol. 1, Num. 4. - S. 88-95. http://nbuv.gov.ua/UJRN/eejph_2014_1_4_12","Korobetsky Yu.P. Simulation models in flexible systems. / Yu.P. Korobetsky, S.K. Ramazanov. - Lugansk: Ed. VNU, 2003. - P. 280","Kempf K. Optimization models for production planning. Planning Production and Inventories in the Extended Enterprise: A State of the Art Handbook. / K.Kempf, P.Keskinocak, R.Uzsoy –Springer-Verlag, New York, 2010. – P. 587","Pihnastyi O.M. To the question of similarity of technological processes of production and technical systems / NA Azarenkov, OM Pihnastiy, VD Khodusov // Reports of the National Academy of Sciences of Ukraine. -Kiev: Akademperiodika Publishing House. - 2011. –№2–P. 29-35. doi.org/10.13140/RG.2.2.13585.53600"]}

Considering a Flow Shop production line in an Industry 4.0 setting where the Cyber-Physical System (CPS) and Internet of Things (IoTs) can be deployed, a newly Performance-based Decentralised Dispatching Rule (PDDR) is proposed. It combines known dispatching rules with the knowledge of the monitored production system state. The goal is to provide a novel dispatching rule based on production line performance oversight. The governance system considers the machine condition in terms of machine utilisation. Regarding the assessment scenario, the proposed rule has been tested and compared with the well-known Short Processing Time (SPT) and the First-In-First-Out (FIFO) rule in a higher generality way by taking into account unforeseen events that may occur in production (such as breakdowns, potential rework, micro-stops, and unplanned machine setups). The simulation results showed interesting results where the flexibility of this rule, as well as its practical use with real hypotheses are its main advantages.

This paper describes examples of functionality and equipment limitations encountered during the subsea field operational phase, and practical solutions to eliminate the limitations. It addresses changes and upgrades required to hydraulic, chemical and electric infrastructure. Modifications and upgrades, such as retrofit sensors, retrofit electric actuators, bypass connections and digital soutions are described. How a holistic obsolescence strategy can modernize the subsea functionality and let different generation systems coexist is further described.

PurposeThis study aims to examine the interrelationship between resilience, robustness and bullwhip effect using an inventory- and order-based production control system being subjected to operational disruption in the customer demand process.Design/methodology/approachControl engineering techniques and simulation are employed for the supply chain dynamics study.FindingsThe results show that resilience and robustness are two conflicting performance characteristics and therefore, a tradeoff can be established between them. It is also observed that improvement in resilience and reduction of bullwhip effect can be achieved simultaneously through a proper selection of control parameters.Originality/valueThe work establishes a relationship between the resilient behavior of a supply chain and bullwhip effect.

Sand production is a crucial problem during the process of extracting natural gas from hydrate reservoirs. To deal with sand-production problems systematically, a sand-production control system (SCS) is first proposed in this paper, specialized for pore-distributed clayey silt hydrate reservoirs. Secondly, a nodal system analysis method (NSAM) is applied to analyze the sand migration process during hydrate exploitation. The SCS is divided into three sub-systems, according to different sand migration mechanisms, and three key scientific problems and advances in SCS research in China Geological Survey are reviewed and analyzed. The maximum formation sanding rate, proper sand-control gravel size, and borehole blockage risk position were provided for clayey hydrate exploitation wells based on the SCS analysis. The SCS sub-systems are closely connected via bilateral coupling, and coordination of the subsystems is the basis of maintaining formation stability and prolonging the gas production cycle. Therefore, contradictory mitigation measures between sand production and operational systems should be considered preferentially. Some novel and efficient hydrate exploitation methods are needed to completely solve the contradictions caused by sand production. © 2019 China Geology Editorial Office.

The arrival of the industry 4.0 era has made the intelligentization and informationization of manufacturing become the mainstream trend. The workshop production control system needs to be more intelligent to meet the needs of real-time control and dynamic coordination. This paper proposes a production instruction service system based on graphical deduction model, constructs the structural framework of production instruction service system, establishes a graphical deduction model of smart job shop production process, and briefly describes the key enabling technology for realizing production instruction service system.

Goal: Although card-based systems are a mature topic in literature, studies have focused mainly on how to optimize parameter of each system. The influential of human factors in the implementation of those systems have rarely been evaluated. Therefore, this study aims to understand what are the critical soft factors for a successful card-based systems implementation. Design / Methodology / Approach: A multi-method study is used in this research, combining systematic literature review, longitudinal case study, content analysis, interviews with experts and validations with two different groups. Results: The paper proposes a list of 15 soft factors critical to a successful implementation of card-based systems categorized in a “house framework” according to the level of analysis each factor is included. Limitations of the investigation: A single case study, although longitudinal, was conducted to proposed the list of factors. Therefore, further studies should be conducted to adapt the list to other organizations and contexts. Practical implications: Following the proposed list of factors, managers can increase the success in implementing a card-based system in their organizations. Originality / Value: This study combines different research methods in a unique way, since in the researchers' view, an individual method was not sufficient to answer the proposed research question. Moreover, the case study reported a failure implementation of a card-based system, a rare addition to literature which mainly presented success cases.