Professional Documents
Culture Documents
Amit Sahu2
2
Assistant Professor
M. Tech Student
ssm@nitrkl.ac.in
amit_sahu@hotmail.com
Abstract: The successful enterprises deliver products and services in shorter throughput time and
turnover inventory as quickly as possible. Three important approaches to achieve these goals are
Materials Requirements Planning (MRPI, MRPII), Just-in-Time (JIT), and Theory of Constraints
(TOC). TOC seems to be a viable proposition because it does not require costly affair of system
change; rather it is simply based on scheduling of the capacity constraint resources. The scheduling
system of theory of constraints (TOC) is often referred as drum-buffer-rope (DBR) system. DBR
systems operate by developing a schedule for the systems primary resource constraint. Based on
simulation of a flow shop operation considering non-free goods, this study suggests that the
performance of DBR results in lower in process inventory compared to conventional production
system. In addition, the behavior of the system when bottleneck shifts its position has been studied. A
methodology has been proposed using neural networks based on back propagation algorithm for
accurate prediction of throughput considering mean processing time, coefficient of variation, buffer
size, number of stations and signal buffer.
Keywords: TOC; DBR; Primary Resource Constraint; Simulation
1.0 INTRODUCTION
Todays businesses are competing increasingly on
time and quality. Companies can not survive if they
fail to obtain competitive advantages by producing
high quality products and services in shorter
throughput time and quicker inventory turnover.
Since the early 1970s, three important approaches
have evolved for companies to achieve competitive
advantages, each challenging old assumptions and
ways of doing things. These are Materials
Requirements Planning (MRP I and MRP II), Just-inTime (JIT), and Theory of Constraints (TOC).
Developed by Eli Goldratt in the mid-1980s [1], TOC
evolved from the OPT (Optimized Production
Timetable) system and was later known under the
commercial name of Optimized Production
Technology (OPT). As part of a marketing tool for
the OPT system, Goldratt illustrated the concepts of
OPT in the form of a novel in which the theory is
gradually unraveled through the context of an
everyday production situation. It presented a
logistical system for the material flow called the
Proceedings of the International Conference on Global Manufacturing and Innovation July 27-29, 2006 - 2 -
Proceedings of the International Conference on Global Manufacturing and Innovation July 27-29, 2006 - 3 -
Proceedings of the International Conference on Global Manufacturing and Innovation July 27-29, 2006 - 4 -
count
use
demand
change
f x
D D 1 Ex
E x e
* D
if x ! 0
1 2
1 2
down
D
machine 1
Rand
T
F
L W
buf f er 1
1 2
T
F
L W
buf f er 2
Rand
1 2 3
T
F
Exit
down
D
machine 5
Clear
On
Statistics Clearing
Update
L W
buf f er 4
Update
V 1
Exit
a
Exit
D
down
machine 5
Eqn
Of f
1790
On
Statistics Clearing
Update
Queue
Stats
V 1
Sl.
No.
Throughput
calculated from
Bluemenfields
Formula (B)
Throughput
calculated
from the
model (S)
Percentage
Difference
((BS)/B)*100
1
2
0.098366
0.099034
0.098365
0.099033
0.01
0.01
0.099028
0.099027
0.01
0.097213
0.097212
0.01
0.096200
0.096200
0.00
0.096423
0.096423
0.00
0.094231
0.094213
0.00
0.098612
0.098612
0.00
0.99867
0.99867
0.00
10
0.99500
0.99500
0.00
select
start
Queue
Stats
V 1
Activ ity
Stats
Random
Seed
select
start
Of f
1764
Rand
1 2
Exit
a
1 2 3
D
down
machine 4
Rand
V 1
L W
buf f er 4
Rand
T
F
L W
buf f er 3
Activ ity
Stats
down
D
machine 4
L W
buf f er 3
Update
(1)
down
D
machine 3
1 2
D
down
machine 3
Rand
Random
Seed
otherwise
down
D
machine 2
Rand
T
F
L W
buf f er 2
1 2
ev ent
1 2
Rand
count
D
down
machine 2
Rand
change
F
L W
buf f er 1
1 2
use
D
down
machine 1
Rand
Clear
Proceedings of the International Conference on Global Manufacturing and Innovation July 27-29, 2006 - 5 -
6500.00
Throughput
6000.00
5500.00
5000.00
4500.00
4000.00
3500.00
0.00
Value
0.50
CV
0.3
1.00
0.225
Flow Shop
DBR
0.15
0.075
0
0
Utilization
22500
Red
45000
Time
Green
67500
90000
Black
Throughput
6500.00
6000.00
5500.00
5000.00
4500.00
4000.00
3500.00
0.00
0.20
0.40
0.60
CV
Flow Shop
0.80
1.00
DBR
Proceedings of the International Conference on Global Manufacturing and Innovation July 27-29, 2006 - 6 -
FLOW SHOP
Avg
Avg Wait
Length
DBR
Avg Length
1
2
3
4
1.840.045
1.610.040
1.370.029
1.110.02
0.6540.0162
0.3130.0025
0.3820.014
0.3830.009
19.20.484
16.80.424
14.40.308
11.60.30
Avg
Wait
7.590.18
3.360.02
4.430.16
4.450.1
6000
5950
5900
SFL
5850
5800
DBR
5750
5700
5650
5600
1
10
B u f f e r Si z e
1206
1204
6500
1202
1200
1198
SFL
5500
DBR
3500
1196
SFL
4500
DBR
2500
1500
500
1194
1192
1
10
15
20
25
30
35
M e a n P r oc e s s i ng T i me
B ot t l eneck M / C P osi t i on
Proceedings of the International Conference on Global Manufacturing and Innovation July 27-29, 2006 - 7 -
T hr o ug hp ut vs C hang ein N o . o f M / C
5950
5850
SFL
DBR
5750
5650
5550
3
N o. of M a c hi ne s
X i norm
X i X i min
X i max X i min
------------- (1)
Proceedings of the International Conference on Global Manufacturing and Innovation July 27-29, 2006 - 8 -
Utilization
Throughput
Avg. Length of
corresponding buffer
Avg. Wait of
corresponding buffer
0.99984.8950
1205186.8
0.9980.0002
49.60.2490
0.99900.0001
1203186.0
0.9980.0003
49.60.3450
0.99930.0001
1199186.2
0.9970.0003
49.90.2580
0.99300.0001
1201186.0
0.9970.0004
49.70.3220
Position of bottleneck
machine in the line
2
Utilization
3
4
5
0.99810.001
0
0.99967.946
0
0.99940.000
0
0.99910.000
0
DBR System
Avg. Length of
corresponding buffer
1204186.7
0.7990.0020
Throughput
Avg. Wait of
corresponding buffer
39.80.2850
1205185.7
0.9930.0010
49.30.3550
1194185.0
0.9930.0010
49.80.3270
1198184.9
0.9930.0010
49.70.2840