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Production and Supply Chain Management

Technische Universität München

Designing and Scheduling Lean Manufacturing Systems

Summer Semester 2014

Course ID: 1912

Lecture room: 0360 (Theodor-Fischer Hörsaal), Arcisstr. 21 (0505)

Martin Grunow

Paul Jana (paul.jana@tum.de)

Bryndís Stefánsdóttir (bryndis.stefansdottir@tum.de)

Sina Wochner (sina.wochner@tum.de)

Decisions related to designing and scheduling of a production system play an important role

in all manufacturing industries. Decisions like configuration of a layout, planning of material

flow and scheduling of activities on resources, are all essential for maximizing the profit of a

company. In this course, the students learn how to support these decisions by applying

various quantitative methods in application areas such as assembly systems, process

industries, automotive industry and AGVs in production centers.

The course is split up into two parts, namely a design part and a scheduling part. In the design

part, we identify different production systems and layouts like job shops, flow lines, single

flow rows and production centers for which we introduce methods which are applied to

numerous examples and practical problems. A general introduction to a collection of tools

and techniques for lean production is also provided.

In the second part of the class, we treat the scheduling of short term operations on the

different types of systems we designed in the first part. We apply different quantitative

scheduling approaches, which typically concern the allocation of limited resources to the

activities that have to be done. Approaches covered include shifting bottleneck, scheduling of

flexible assembly systems, economic lot scheduling, block planning and online vs. offline

scheduling.

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Objectives

Gain an overview of methods used in designing and scheduling production systems.

Understand the principles of lean manufacturing and their relation to planning and

scheduling.

Create designs for different types of production systems by formulating, structuring

and analyzing design problems.

Gain an overview of the scheduling objectives and requirements in manufacturing.

Evaluate and apply different planning procedures to develop production schedules for

different types of systems such as assembly lines, food processing systems and AGVs

in production centers.

Previous knowledge expected

Knowledge of quantitative approaches to production and supply chain management

The module "Produktionsmanagement und Management Science" or similar modules at other

universities is a prerequisite.

Assessment

Exam - Design part (50%)

Exam - Scheduling part (50%)

Please note that students have to pass both exams.

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Preliminary schedule

Date Room Lecture Material Lecturer

10.04.2014

13:15-16:30 0360

Introduction to course

Design: Layout types

Design: Job shops

Articles and

slides

Prof. Martin

Grunow

17.04.2014 Easter vacation – No class

24.04.2014

13:15-16:30 0360

Design: Job shops

Design: Flow lines

Articles and

slides

Prof. Martin

Grunow

01.05.2014 1st of May – No class

08.05.2014

13:15-16:30 0360 Design: Flow lines

Articles and

slides

Prof. Martin

Grunow

15.05.2014

13:15-16:30 0360

Design: Perform. of flow lines

Lean overview

Articles and

slides Paul Jana

22.05.2014

13:15-16:30 0360

Design: Center production

Design: Single flow row

Articles and

slides Paul Jana

29.05.2014 Ascension Day – No class

05.06.2014

19:00 -20:00

5510. EG.001

Exam – Design part

(in Garching)

12.06.2014

13:15-16:30 0360

Scheduling: Introduction

Scheduling: Job shops

Pinedo Intro

Pinedo Chapter 5

(not 5.5)

Bryndís

Stefánsdóttir

19.06.2014 Corpus Christi – No class

26.06.2014

13:15-16:30 0360

Scheduling: Job shops

Scheduling: Flex. assembly

systems

Articles and

Pinedo Chapter 6

Bryndís

Stefánsdóttir

03.07.2014

13:15-16:30 0360

Scheduling: Flex. assembly

systems

Scheduling: Economic lot sch.

Articles and

Pinedo Chapter 7

(not 7.4 and 7.5)

Sina

Wochner

10.07.2014

13:15-16:30 0360

Scheduling: Block planning

Scheduling: AGVs in centers

Guest lecture: Dr. Blömer –

Daimler AG: Pre-series

logistics for simultaneous ramp-

up of the Mercedes C-class on 3

continents

Articles and

slides

Sina

Wochner

18.07.2014

16.00–17.00 Audimax Exam – Scheduling part

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Literature - Design

General

Benjafaar, S., Heragu, S. S., Irani, S. A., Next generation factory layouts: research

challenges and recent progress, Interfaces, 32(6), 2002, 58-76

Singh, S. P., Sharma, R. R. K., A review of different approaches to the facility layout

problems, International Journal of Advanced Manufacturing Technology, 2006, 30 (5-6),

425-433

Drira A., Pierreval H., Hajri-Gabouj S., Facility layout problems: A survey, Annual Reviews

in Control, 31 (2), 2007, 255-267

Job shops

Heragu, S. S., Kusiak, A., Efficient models for the facility layout problem, European Journal

of Operational Research, 53 (1), 1991, 1-13

Assembly lines

Boysen, N., Fliedner, M, Scholl, A., Assembly line balancing: Which model to use when?,

International Journal of Production Economics, 111 (2), 2008, 509-528

Scholl, A., Becker, C., State of the art exact and heuristic solution procedures for simple

assembly line balancing, EJOR; 168, 2006, 666- 693. (excluding sections 3.3-3.5, 4.2, 4.3,

5.2, 5.3 )

Becker, C., Scholl, A.: A survey on problems and methods in generalized assembly line

balancing, European Journal of OperationsResearch. 168, 2006, 694-715

Gökcen, H., Erel, E., Binary integer formulation of mixed-model assembly line problem,

Computers and Industrial Engineeing, 34, 1998,451-461

Miltenburg, J., Wijngaard, J., The U-line balancing problem, Management Science, 40(10),

1994, 1378-1388

Center production

Heragu, S. S., Group technology and cellular manufacturing, IEEE Transactions on Systems,

Man, and Cybernetics, 24(2), 1994

Ho, Y.C., Moodie, C.L., Machine layout with a linear single row flow path in an automated

manufacturing system, Journal of Manufacturing Systems, 17(1), 1998, 1-22

AGVs in centers

Schrecker, A., Planung und Steuerung Fahrerloser Transportsysteme, Deutscher

Universitäts-Verlag, 2000

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Literature - Scheduling

General

Pinedo, M., Planning and Scheduling in Manufacturing and Services, Second edition,

Springer, 2009, ISBN: 978-1-4419-0909-1, e-ISBN 978-1-4419-0910-7

Paced assembly systems

Gagné, C., Gravel, M., Price, W. L., Solving real car sequencing problems with ant colony

optimization, European Journal of Operational Research, 174(3), 2006, 1427-1448

Solnon, C., Cung, V.D., Nguyen, A., Artigues, C., The car sequencing problem: Overview of

state-of-the-art methods and industrial case-study of the ROADEF’2005 challenge problem,

European Journal of Operational Research 191(3), 2008, 912-927.

Block planning

Günther, H.O., An application of MILP-based block planning in the chemical industry,

Proceedings of the Eighth International Symposium on Operations Research and Its

Applications (ISORA’09), Zhangjiajie, China, September 20–22, 2009, 103–110.

Kilic, O. A., Akkerman, R., van Donk, D. P., & Grunow, M. (2013). Intermediate product

selection and blending in the food processing industry. International Journal of Production

Research, 51(1), 26–42.

Lütke-Entrup, M., Günther, H.O., van Beek, P., Grunow, M., Seiler, T., Mixed integer linear

programming approaches to shelf life integrated planning and scheduling in yogurt

production, International Journal for Production Research, 43(23), 2005, 5071-5100.

AGVs in centers

Schrecker, A., Planung und Steuerung Fahrerloser Transportsysteme, Deutscher

Universitäts-Verlag, 2000