Production Control in Practice

Henny van Ooijen, PhD, is assistant professor in Production and Operations Management at the School of Industrial Engineering of Eindhoven University of Technology, The Netherlands. He received his PhD in 1996 for research on workload control. He teaches the courses Introduction to Industrial Engineering, Analyses of Production, Warehousing and Transportation Systems, Control of Dynamic Processes in Production, Modeling and Analysis of Manufacturing Systems, Design of Operational Planning and Control Systems. Corné Dirne, PhD, is currently lector for Operational Excellence at the Fontys University of Applied Sciences, The Netherlands. He received his PhD in 1990 for research on the production control of flexible manufacturing systems. He has been senior lecturer and curriculum coordinator for Industrial Engineering at Avans University of Applied Sciences; during that period he has contributed to the development of a new four-year English-language university program focused on Maintenance Management.

Part 1

1. PRODUCTION CONTROL- A LOGISTIC CONTROL FUNCTION
1.1 Logistics
1.2 Logistics Planning and Control
1.3 Logistic concepts in production
1.4 Terminology for Production Control

2. HORIZONTAL AND VERTICAL DECOMPOSITION
2.1 Horizontal decomposition
2.2 Vertical decomposition
2.3 Types of release triggers
2.4 An Example of Decomposition

3. PLANNING AND CONTROL IN PRODUCTION UNITS
3.1 Production Control in general
3.2 Basic forms of production

4. FRAMEWORK FOR LOGISTIC PLANNING AND CONTROL IN PRODUCTION SYSTEMS
4.1 General framework
4.2 Position of this book

Part 2

5. DECOUPLING POINT CONTROL
5.1 Decoupling Point Control - an introduction
5.2 Performance Measures for Decoupling Point Control
5.3 Demand and Forecasting
5.4 Order Size
Appendix 5.A The Wagner-Whitin algorithm
Appendix 5.B Example impact advanced and optimal approach for determining batch sizes
Appendix 5.C Newsvendor Problem

6. ROP (SIC) DECOUPLING POINT CONTROL SYSTEMS
6.1 General discussion of ROP Control systems
6.2 When to order?
6.3 How much to order?
Appendix 6.A Table of the one-sided Standard Normal distribution
Appendix 6.B Table Standard Normal Loss Function
Appendix 6.C Reorder level determination in case of a general distributed distribution

7. MRP DECOUPLING POINT CONTROL SYSTEMS
7.1 General discussion of MRP Systems
7.2 When to order?
7.3 How much to order?
7.4 Discussion on MRP-related issues
Appendix 7.A MRP formulas

8. SYSTEMS USING ECHELON STOCKS (ESC, LRP)
8.1 General discussion of systems using global norms
8.2 When and how much to order?
8.3 Discussion on echelon stock systems

9. CHOOSING AN APPROPRIATE DPC SYSTEM
9.1 General considerations
9.2 Advantages/disadvantages of the different DPC systems
9.3 Which decoupling point control system to use?

Part 3
10. GENERAL DISCUSSION OF PRODUCTION CONTROL DECISIONS

11. PRODUCTION CONTROL FOR DETERMINISTIC, STATIC PRODUCTION SYSTEMS (SCHEDULING)
11.1 Sequencing orders without delivery date (throughput time oriented)
11.2 Sequencing orders with a delivery date (reliability oriented)
11.3 Relaxing assumptions

12. FLOW PROCESS PRODUCTION
12.1 General description
12.2 Main control attention point
12.3 Production control decisions for flow process production in MtS situations
12.4 Production control decisions for flow process production in MtO situations
12.5 Application

13. MASS ASSEMBLY PRODUCTION
13.1 General description
13.2 Main control attention points of mass assembly production
13.3 Production control decisions for mass assembly production
13.4 Application

14.SMALL SERIES PRODUCTION
14.1 General description
14.2 Main control attention points of small series production
14.3 Production control decisions for small series production
14.4 Application
Appendix 14.A Short-Term Capacity Adjustment
Appendix 14.B Flexible batching
Appendix 14.C The effect of workload control in case there is a relationship between productivity and workload

15.PROJECT BASED PRODUCTION
15.1 General description
15.2 Main control attention points of project based production
15.3 Production control decisions for project based production
15.4 Application