Asbj0rn Rolstadas (Ed.) Computer-Aided Production Management With 169 Figures Springer-Verlag Berlin Heidelberg New York London Paris Tokyo
Professor Dr. Asbjern Ro1stadas Production Engineering Laboratory NTH-SINTEF Richard Birke1andsv. 2b N-7034 Trondheim-NTH, Norway ISBN -13: 978-3-642-73320-8 e-isbn -13: 978-3-642-73318-5 DOl: 10.1007/978-3-642-73318-5 Library of Congress Cataloging-in-Publication Data. Computer-aided production management! A. Rolstadas (ed.). p. cm. Includes index. ISBN-13:97S-3-642-73320-S 1. Production management - Data processing. 2. Computer integrated manufacturing systems. 3. Flexible manufacturing systems. I. Rolstadas, A. (Asbj0rn), 1944-. TS 155.6.C646 1988 658.5'0028'5-dc19 88-6627 CIP This work is subject to copyright. All rights are reserved, whether the whole or part of the material is concerned, specifically the rights of translation, reprinting, re-use of illustrations, recitation, broadcasting, reproduction on microfilms or in other ways, and storage in data banks. Duplication of this publication or parts thereof is only permitted under the provisions of the German Copyright Law of September 9, 1965, in its version of June 24, 1985, and a copyright fee must always be paid. Violations fall under the prosecution act of the German Copyright Law. 1988 IFIP International Federation for Information Processing, 16 place Longemalle, CH-1204 Geneva, Switzerland Softcoverreprint of the hardcover 1st edition 1988 The use of registered names, trademarks, etc. in this publication does not imply, even in the absence of a specific statement, that such names are exempt from the relevant protective laws and regulations and therefore free for general use. 1)rpesetting: K + V Fotosatz GmbH, Beerfelden; 2145/3140-543210 - Printed on acid free paper
Preface The purpose of this book is to discuss the state of the art and future trends in the field of computerized production management systems. It is composed of a number of independent papers, each presented in a chapter. Some of the widely recognized experts in the field around the world have been asked to contribute. lowe each of them my sincere gratitude for their kind cooperation. I am also grateful to Peter Falster and Jim Browne for their kind support in helping me to review topics to be covered and to select the authors. This book is a result of the professional work done in the International Federation of Information Processing Technical Committee IFIP TC5 "Computer Applications in Technology" and especially in the Working Group WG5.7 "Computer-Aided Production Management". This group was established in 1978 with the aim of promoting and encouraging the advancement of the field of computer systems for the production management of manufacturing, offshore, construction, electronic and similar and related industries. The scope of the work includes, but is not limited to, the following topics: 1) design and implementation of new production planning and control systems taking into account new technology and management philosophy; 2) CAPM in a CIM environment including interfaces to CAD and CAM; 3) project management and cost engineering; 4) knowledge engineering in CAPM; 5) CAPM for Flexible Manufacturing Systems (FMS) and Flexible Assembly Systems (F AS); 6) methods and concepts in CAPM; 7) economic and social implications of CAPM. The Working Group has the following specific tasks in furthering the area of its scope: a) maintaining liaison with the other appropriate national and international organizations and IFIP's TCs and WGs working in related fields; b) conducting working conferences and symposia as deemed appropriate in furthering its scope; c) stimulating and sponsoring research investigations and social studies into the various aspects of the topics of its scope. This book is one of the ways in which the Working Group 5.7 can meet its objectives.
VI Preface The book is divided into six parts. Each part contains a number of papers. Part I covers stages of development in production management and is intended as an introduction. Recently various PM concepts or philosophies have received a great deal of attention, and Part II contains papers on the most interesting ones, like MRP, nt, OPT, period batch control, and all-embracing production control. The fundamental techniques that are used in production management are discussed in Part III. These cover graph theory, simulation, operations research, and artificial intelligence. Parts II and III form the theoretical foundation of PM. Part IV addresses computerization of PM systems. It contains papers on databases, user interfaces, systems analysis, fourth generation languages, etc. In Part V some important aspects are further discussed. Scheduling, planning in FMS, forecasting, stock control, and integration of PM into elm are discussed. In the last part, Part VI, some industrial applications are discussed. Different industries are covered, such as small companies, the car industry, the aircraft industry, job shops, the electromechanical industry, and the electronic industry. IFIP WGS.7 has been working with a Glossary of Production Management that has been published. A short summary of this is presented as an appendix. The viewpoints in this book are those of the authors as individuals and not necessarily those of their companies/organizations. It is my sincere hope that this book will be of interest to production planners and computer experts as well as to academicians and industrial people. Trondheim, Norway, February 1988 Asbj0fll Rolstadas
Contents Part I Stages of Development in Production Management Chapter 1. Production Management Systems Asbjl2lrn Rolstadas... 3 Part II Production Management Philosophies Chapter 2. MRP IMRP II John Harhen... 23 Chapter 3. Just-in-Time Production - A New Formulation and Algorithm of the Flow Shop Problem Hajime Yamashina... 37 Chapter 4. The Drum-Buffer-Rope (DBR) Approach to Logistics Oded Cohen... 51 Chapter 5. Period Batch Control John L. Burbidge... 71 Chapter 6. All-Embracing Production Control Gideon Halevi... 77 Part III Fundamental Techniques Chapter 7. Graph Theoretical Approaches Peter Falster... 97 Chapter 8. Simulation and Simulation Models Jim Browne... 123 Chapter 9. Operations Research Models and Techniques Wing S. Chow, Sunderesh Heragu, and Andrew Kusiak... 135 Chapter 10. Artificial Intelligence Approach to Production Planning Andrew Kusiak... 149
VIII Contents Part IV The Computerized Production Management System Chapter 11. Databases Johan C. Wortmann... 169 Chapter 12. User Interface Eero Eloranta........................................... 181 Chapter 13. Systems Analysis Techniques Guy Doumeingts... 201 Chapter 14. Fourth Generation Languages J arle Aaram... 225 Chapter 15. Design of a Generalized Job Shop Control System and PM Packages Harinder Jagdev... 233 Chapter 16. Validation of Job Shop Control Software - A Case Study Harinder Jagdev... 253 Part V Some Important Aspects of Production Management Functions Chapter 17. Production Scheduling John R. King... :.. 267 Chapter 18. Production Planning and Scheduling in Flexible Manufacturing Systems Kathryn E. Stecke... 281 Chapter 19. Forecasting and Stock Control Birger Rapp... 289 Chapter 20. Integration of PM into CIM Gideon Halevi... 303 Part VI Industrial Applications Chapter 21. Multi-Product Batch Production on a Single Machine A Problem Revisited Samuel Eilon... 319 Chapter 22. Production Control in Small Companies Kai Mertins.................................................. 345 Chapter 23. Production Control in the Car Industry Wolfgang D. Thurow... 355 Chapter 24. Production Control in the Aircraft Industry Bernd Hirsch apd Gustav Humbert... 363 Chapter 25. Job Shop Production Control Oddmund Oterhals... 375 Chapter 26. Production Control in the Electromechanical Industry Siegfried Augustin... 385 Chapter 27. Production Control in the Electronics Industry Ichiro Inoue... 393
Contents IX Appendix A Drafted PM Glossary John L. Burbidge... 399 Address List of Authors... 403