Modeling just-in-time production systems: a critical review

Kanban-controlled serial manufacturing systems have recently received considerable attention. A large proportion of the literature on the topic is devoted to success stories. There is also an important model- based effort in gaining insight into the behavior of such systems, in identifying important success factors, and ultimately in optimizing various aspects of systems' performance. This paper focuses exclusively on model-based approaches in studying pull systems. Even though analytic models such as linear programming formulations or queueing approximations exist, the inherent complexity of pull systems makes simulation an essential tool in studying them. The objective of this paper is therefore to critically review selected papers that have recently appeared in refereed journals, highlight their approach, point out deficiencies, where appropriate, re-emphasize their message, and suggest new directions for research.

[1]  Peter O'Grady,et al.  Kanban controlled pull systems: an analytic approach , 1989 .

[2]  Chin-Sheng Chen,et al.  Flexible manufacturing systems: An overview and bibliography , 1986 .

[3]  Loren Paul Rees,et al.  A mathematical programming approach for determining workcentre lotsizes in a just-in-time system with signal Kanbans , 1990 .

[4]  Y. Monden.  Toyota Production System: Practical Approach to Production Management , 1983 .

[5]  Gordon C. Hunt,et al.  Sequential Arrays of Waiting Lines , 1956 .

[6]  John Miltenburg,et al.  Designing and phasing in just-in-time production systems , 1991 .

[7]  Harry G. Perros,et al.  On equivalencies of blocking mechanisms in queueing networks with blocking , 1986 .

[8]  Loren Paul Rees,et al.  A comparative analysis of an MRP lot-for-lot system and a Kanban system for a multistage production operation , 1989 .

[9]  Kut C. So,et al.  Allocating buffer storages in a pull system , 1988 .

[10]  Osamu Kimura,et al.  Desiǵn and analysis of Pull System, a method of multi-staǵe production control , 1981 .

[11]  Rajan Suri,et al.  Getting from “just-in-case” to “just-in-time”: Insights from a simple model , 1986 .

[12]  A. N. Poo,et al.  Periodic pull: a modified approach to Just-In-Time production , 1993 .

[13]  Paul Glasserman,et al.  Gradient Estimation Via Perturbation Analysis , 1990 .

[14]  Shiramura Shingo,et al.  A Study of the Toyota Production System From an Industrial Engineering Viewpoint , 1989 .

[15]  B. J. Berkley,et al.  A Decomposition Approximation for Periodic Kanban‐Controlled Flow Shops* , 1992 .

[16]  S. Tayur.  Structural properties and a heuristic for kanban-controlled serial lines , 1993 .

[17]  M. Garetti,et al.  Design of a control system for a flexible manufacturing cell , 1985 .

[18]  S. Tayur.  Structural properties of a Kanban controlled serial manufacturing system , 1990 .

[19]  Mahesh Gupta,et al.  A system dynamics model for a multi-stage multi-line dual-card JIT-kanban system , 1989 .

[20]  Bernard J. Schroer,et al.  Just-In-Time (JIT), with Kanban, manufacturing system simulation on a microcomputer , 1985 .

[21]  Phillip S. Mitchell.  Japanese Manufacturing Techniques: Nine Hidden Lessons in Simplicity , 1983 .

[22]  William L. Berry,et al.  Manufacturing Planning and Control Systems , 1984 .

[23]  S. Jordan.  Analysis and Approximation of a JIT Production Line , 1988 .

[24]  Harry G. Perros,et al.  Open Networks of Queues with Blocking: Split and Merge Configurations: , 1986 .

[25]  Paul H. Zipkin,et al.  Production control in a kanban-like system with defective outputs , 1992 .

[26]  Debasis Mitra,et al.  Analysis of a Kanban discipline for cell coordination in production lines , 1990 .

[27]  Harry G. Perros,et al.  Approximate analysis of open networks of queues with blocking: Tandem configurations , 1986, IEEE Transactions on Software Engineering.

[28]  Andrew B. Whinston,et al.  Towards an adaptive Kanban system , 1990 .

[29]  Lee J. Krajewski,et al.  Kanban, MRP, and Shaping the Manufacturing Environment , 1987 .

[30]  Wayne J. Davis,et al.  Configuring a Kanban system using a discrete optimization of multiple stochastic responses , 1987 .

[31]  Stanley B. Gershwin,et al.  An Efficient Decomposition Method for the Approximate Evaluation of Tandem Queues with Finite Storage Space and Blocking , 1987, Oper. Res..

[32]  Hanan Luss,et al.  A Lot-sizing Model for Just-in-time Manufacturing , 1990 .

[33]  Richard J. Schonberger.  Applications of Single-Card and Dual-Card Kanban , 1983 .

[34]  Herbert J. Grünwald,et al.  Many steps towards zero inventory , 1992 .

[35]  B. J. Berkley.  Analysis and Approximation of a JIT Production Line: A Comment , 1990 .

[36]  Maling Ebrahimpour,et al.  Dynamic Simulation of a Kanban Production Inventory System , 1985 .

[37]  Willard I. Zangwill,et al.  Variance Effects in Cyclic Production Systems , 1991 .

[38]  Debasis Mitra,et al.  Analysis of a Kanban Discipline for Cell Coordination in Production Lines, II: Stochastic Demands , 1991, Oper. Res..

[39]  Hsu-Pin Wang,et al.  Determining the number of kanbans: a step toward non-stock-production , 1990 .

[40]  Damodar Y. Golhar,et al.  The just-in-time philosophy : a literature review , 1991 .

[41]  Ian Graham.  Comparing trigger and kanban control of flow-line manufacture , 1992 .

[42]  David L. Woodruff,et al.  CONWIP: a pull alternative to kanban , 1990 .

[43]  Frederick S. Hillier,et al.  Finite Queues in Series with Exponential or Erlang Service Times - A Numerical Approach , 1966, Oper. Res..

[44]  Henry C. Co,et al.  A dynamic programming model for the kanban assignment problem in a multistage multiperiod production system , 1991 .

[45]  W. Zangwill.  From EOQ Towards ZI , 1987 .

[46]  Yves Dallery,et al.  A unified modeling of Kanban systems using petri nets , 1991 .

[47]  Rick L. Wilson,et al.  Describing processing time when simulating JIT environments , 1992 .

[48]  Lee W. Schruben,et al.  An experimental procedure for simulation response surface model identification , 1987, CACM.

[49]  Jonathan F. Bard,et al.  Determining the number of kanbans in a multiproduct, multistage production system , 1991 .

[50]  Gary S. Wasserman,et al.  Simulation constructs for JIT modelling , 1992 .

[51]  William L. Maxwell,et al.  The Role of Work-in-Process Inventory in Serial Production Lines , 1988, Oper. Res..

[52]  Bhaba R. Sarker,et al.  The performance of push and pull systems: a simulation and comparative study , 1989 .

[53]  Kenjiro Okamura,et al.  A heuristic algorithm for the assembly line model-mix sequencing problem to minimize the risk of stopping the conveyor , 1979 .

[54]  R. Schonberger.  Japanese manufacturing techniques : nine hidden lessons simplicity , 1982 .

[55]  Elsayed A. Elsayed,et al.  Analysis of two-stage manufacturing systems with buffer storage and redundant machines , 1986 .

[56]  Milton L. Smith,et al.  Increasing the production rate of a just-in-time production system with variable operation times , 1988 .

[57]  Gabriel R. Bitran,et al.  A mathematical programming approach to a deterministic Kanban system , 1987 .

[58]  Blair J. Berkley,et al.  A Simulation Study of Sequencing Rules in a Kanban‐Controlled Flow Shop* , 1991 .

[59]  新郷 重夫,et al.  A study of the Toyota production system from an industrial engineering viewpoint , 1989 .

[60]  Michael A. Zazanis,et al.  Push and Pull Production Systems: Issues and Comparisons , 1992, Oper. Res..

[61]  D. Yao,et al.  The Optimal Input Rates To A System Of Manufacturing Cells , 1987 .

[62]  Yih-Long Chang,et al.  An Approximate Solution to Deterministic Kanban Systems , 1990 .

[63]  Chao-Hsien Chu,et al.  Simulation studies in JIT production , 1992 .

[64]  Bhaba R. Sarker.  Some Comparative and Design Aspects of Series Production Systems , 1984 .

[65]  Sheldon Howard Jacobson,et al.  Discrete event computer simulation response optimization in the frequency domain , 1988 .

[66]  J. Miltenberg,et al.  Level schedules for mixed-model assembly lines in just-in-time production systems , 1989 .

[67]  Mark L. Spearman,et al.  Customer Service in Pull Production Systems , 1992, Oper. Res..

[68]  John S. Morris,et al.  A simulation analysis of factors influencing the attractiveness of group technology cellular layouts , 1990 .

[69]  Bhaba R. Sarker.  Simulating a just-in-time production system , 1989 .

[70]  Gary S. Wasserman,et al.  Basic concepts of JIT modelling , 1992 .

[71]  Tayfur Altiok,et al.  Approximate Analysis of Queues in Series with Phase-Type Service Times and Blocking , 1989, Oper. Res..

[72]  Abraham Seidmann,et al.  Regenerative pull (Kanban) production control policies , 1988 .

[73]  B. J. Berkley,et al.  Tandem queues and kanban-controlled lines , 1991 .

[74]  Didier Dubois,et al.  A mathematical model of a flexible manufacturing system with limited in-process inventory , 1983 .