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Production planning and control in multi-stage assembly systems: an assessment of Kanban, MRP, OPT (DBR) and DDMRP by simulation
International Journal of Production Research ( IF 7.0 ) Pub Date : 2020-12-02 , DOI: 10.1080/00207543.2020.1849847
Matthias Thürer 1 , Nuno O. Fernandes 2, 3 , Mark Stevenson 4
Affiliation  

Multi-stage assembly systems where the demand for components depends on the market-driven demand for end products, are commonly encountered in practice. Production Planning and Control (PPC) systems for this production context include Kanban, Materials Requirement Planning (MRP), Optimised Production Technology (OPT), and Demand Driven MRP (DDMRP). All four of these PPC systems are widely applied in practice and literature abounds on each of these systems. Yet, studies comparing these systems are scarce and remain largely inconclusive. In response, this study uses simulation to assess the performance of all four PPC systems under different levels of bottleneck severity and due date tightness. Results show that MRP performs the worst, which can be explained by the enforcement of production start dates. Meanwhile, Kanban and DDMRP perform the best if there is no bottleneck. If there is a bottleneck then DDMRP and OPT perform the best, with DDMRP realising lower inventory levels. If there is a severe bottleneck, then the performance results for DDMRP and OPT converge. This identification of contingency factors not only resolves some of the inconsistencies in the literature but also has important implications for the applicability of these four PPC systems in practice.



中文翻译:

多级装配系统中的生产计划和控制:通过仿真评估看板、MRP、OPT (DBR) 和 DDMRP

多阶段装配系统的组件需求取决于市场对最终产品的需求,这在实践中很常见。这种生产环境的生产计划和控制 (PPC) 系统包括看板、物料需求计划 (MRP)、优化的生产技术 (OPT) 和需求驱动的 MRP (DDMRP)。所有这四个 PPC 系统都在实践中得到广泛应用,并且关于这些系统中的每一个的文献都比比皆是。然而,比较这些系统的研究很少,而且在很大程度上仍然没有定论。作为回应,本研究使用模拟来评估所有四个 PPC 系统在不同级别的瓶颈严重性和到期日期紧密度下的性能。结果表明,MRP 的表现最差,这可以通过执行生产开始日期来解释。同时,如果没有瓶颈,看板和 DDMRP 表现最好。如果存在瓶颈,则 DDMRP 和 OPT 表现最佳,而 DDMRP 实现了较低的库存水平。如果存在严重瓶颈,则 DDMRP 和 OPT 的性能结果会收敛。这种偶然因素的识别不仅解决了文献中的一些不一致之处,而且对这四种 PPC 系统在实践中的适用性也具有重要意义。

更新日期:2020-12-02
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