The performance of push and pull systems: a simulation and comparative study

Ideally the just-in-time (pull system) production system holds no buffer inventory so that the production is ‘just in time’. This is achieved only when the stage's operation times are constant and equal; but realistically the variability of operator performance and/or the unequal distribution of task times precludes such an ideal situation. As a result, the production line experiences problems. In this paper we investigate the effects of these variabilities on the performance of push and pull systems and how the manager can decide which production technique to adopt. The implication of the simulation results are reported and openings for future research are identified.

[1]  P. C. Pandey,et al.  The performance analysis of unbalanced automatic transfer lines , 1983 .

[2]  R. Schonberger.  Japanese Manufacturing Techniques , 1982 .

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

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

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

[6]  J. A. Buzacott,et al.  Models of automatic transfer lines with inventory banks a review and comparison , 1978 .

[7]  Norman A. Dudley,et al.  WORK-TIME DISTRIBUTIONS , 1963 .

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

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

[10]  Loren Paul Rees,et al.  An investigation of the factors influencing the number of Kanbans required in the implementation of the JIT technique with Kanbans , 1987 .

[11]  Loren Paul Rees,et al.  Dynamically Adjusting the Number of Kanbans in a Just-in-Time Production System Using Estimated Values of Leadtime , 1987 .

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

[13]  J. Buzacott.  PREDICTION OF THE EFFICIENCY OF PRODUCTION SYSTEMS WITHOUT INTERNAL STORAGE , 1967 .

[14]  Colin L. Moodie,et al.  OPTIMAL BUFFER STORAGE CAPACITY IN PRODUCTION , 1968 .

[15]  Y A Hosni,et al.  Line Of Balance (Lob) Using A Microcomputer , 1981 .

[16]  A. D. Knott,et al.  THE INEFFICIENCY OF A SERIES OF WORK STATIONS—A SIMPLE FORMULA , 1970 .

[17]  S. Panwalkar,et al.  A Predictive Equation for Average Output of K Stage Series Systems with Finite Interstage Queues , 1979 .

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

[19]  N. P. Rao,et al.  A viable alternative to the ‘method of stages’ solution of series production systems with Erlang service times , 1976 .

[20]  C. G. Drury,et al.  THE DEPENDENCE OF THE COEFFICIENT OF VARIATION OF A WORK-TIME DISTRIBUTION ON THE NUMBER OF ELEMENTS IN THE WORK TASK , 1968 .

[21]  G. G. Hitchings,et al.  The effects of performance time variance on a balanced, four-station manual assembly line , 1973 .

[22]  A. Alan B. Pritsker,et al.  Introduction to simulation and SLAM II , 1979 .

[23]  Bhaba R. Sarker,et al.  The effect of imbalance in a just-in-time production system: a simulation study , 1988 .

[24]  Averill M. Law,et al.  Simulation Modeling and Analysis , 1982 .

[25]  William C. Perkins,et al.  Stochastic unpaced line design: Review and further experimental results , 1985 .

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

[27]  Michael J. Magazine,et al.  Heuristics for determining output and work allocations in series flow lines , 1978 .

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

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

[30]  Geoff Buxey,et al.  Simulation studies of conveyor-paced assembly lines with buffer capacity , 1976 .

[31]  Y. Sugimori,et al.  Toyota production system and Kanban system Materialization of just-in-time and respect-for-human system , 1977 .

[32]  Loren Paul Rees,et al.  A SIMULATION ANALYSIS OF THE JAPANESE JUST‐IN‐TIME TECHNIQUE (WITH KANBANS) FOR A MULTILINE, MULTISTAGE PRODUCTION SYSTEM , 1983 .