• Journal of Korean Institute of Industrial Engineers
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• v.22 no.2
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• pp.231-245
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• 1996

Semiconductor manufacturing line includes several batch processes which are to be controlled effectively to enhance the productivity of the line. The key problem in batch processes is a dynamic batch sizing problem which determines number of lots processed simultaneously in a single botch. The batch sizing problem in semiconductor manufacturing has to consider delay of lots, setup cost of the process, machine utilization and so on. However, an optimal solution cannot be attainable due to dynamic arrival pattern of lots, and difficulties in forecasting future arrival times of lots of the process. This paper proposes an efficient batch sizing heuristic, which considers delay cost, setup cost, and effect of the forecast errors in determining the botch size dynamically. Extensive numerical experiments through simulation are carried out to investigate the effectiveness of the proposed heuristic in four key performance criteria: average delay, variance of delay, overage lot size and total cost. The results show that the proposed heuristic works effectively and efficiently.

• Journal of Korean Institute of Industrial Engineers
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• v.33 no.2
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• pp.246-253
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• 2007

All of the machines in a production line can be classified into bottleneck and non-bottleneck machines. A bottleneck is a resource whose capacity limits the throughput of the whole production facility. This paper addresses a batch sizing problem at the bottleneck machine. Traditionally, most batch sizing decisions have been made based on the EOQ (economic order quantity) model where setup and inventory costs are considered while throughput rate is assumed to be given. However, since batch size affects the capacity of the bottleneck machine, the throughput rate may not be constant. As the batch size increases, the frequency of the setup decreases. The saved setup time can be transferred to processing time, which results in higher throughput. But, the larger batch size may also result in longer lead time and larger WIP inventory level. This paper presents an alternative method to determine batch size at the bottleneck machine in a manufacturing line. A linear search algorithm is introduced to find optimal throughput rate and batch size at the same time. Numerical examples are provided to see how the proposed method works and to investigate the effects of some parameters.

• Journal of Korean Institute of Industrial Engineers
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• v.40 no.4
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• pp.424-427
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• 2014

In this paper, we consider a production system in which the items are produced by batch. For a production planning of the system, we formulate a lot-sizing problem in which each production should be a multiple of a given unit batch and backlogging is allowed. We propose an optimal dynamic programming algorithm for the plan whose complexity is $O(T^2)$ where T is the maximum number of periods in a plan.

• Journal of Korean Institute of Industrial Engineers
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• v.17 no.1
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• pp.29-35
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• 1991

This paper deals with a production-inventory model for two-stage batch production system. We propose a lot-sizing scheme which combines the integer multiple lot requirements (IMLR) policy and the integer split lot requirements (ISLR) policy. An iterative search procedure for optimal decision variables is presented and numerical examples are solved to illustrate the validity of the model. The results show that the proposed scheme outperforms the existing policies.

• Proceedings of the Korean Operations and Management Science Society Conference
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• 2006.11a
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• pp.506-512
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• 2006

In this paper, we propose a lot-sizing and scheduling problem that seeks to minimize the sum of production cost and inventory cost over a given planning horizon while considering idle state of a machine in a batch production system. For this problem, we develop an integer programming model. And, we develop an efficient 2-phase heuristic algorithm to find a high quality feasible solution within reasonable time bounds. In the first phase, we seek to minimize the production cost by assigning batches to machines. Then, in the second phase, we find a production sequence of batches that reduces the inventory cost, while considering adding or deleting idle states between batches. Computational results show that the developed heuristic algorithm finds excellent feasible solutions within reasonable time bounds. Also, we could significantly reduce the total cost consisting of production cost and inventory cost by using the developed heuristic algorithm at a real manufacturing system that produces zinc alloys.

• Industrial Engineering and Management Systems
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• v.14 no.3
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• pp.289-298
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• 2015

This paper analyses the best batch formations for order picking throughput in narrow-aisle order picking systems. Our analytical comparison finds that a high pick density variation leads to a heavy picker blocking. Simulation experiments show that a distance-based batching algorithm reduces picker blocking by decreasing the number of aisles visited and stabilizing the variation in number of picks per aisle by packing orders tightly, and that the solution quality and mechanism for determining the batch size dictated by the sorting strategy causes varying amounts of blocking. We conclude that combining a distance-based batching method with an appropriate batch sizing strategy will reduce picker blocking and shorten travel in narrow-aisle picking systems.

• Journal of Korean Society of Industrial and Systems Engineering
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• v.17 no.32
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• pp.177-186
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• 1994

Economic Lot size decision is studied on this thesis foe the muti-product small batch production system. Even though economic lot size decision has been studied for the MRP system. this could be applied at the industry under the multi-product small batch production system because of very complicate and manager's lack of understand. Therefore, this technique is applied at the industry in order to minimize ordering cosy based on optimal quantity and period, and holding cost according to optimize inventory level under the muti-product small batch production system. After that, lot size decision technique is compared with lot size decision technique which has been used for analyzing and emphasizing productivity

• Fashion & Textile Research Journal
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• v.16 no.5
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• pp.776-784
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• 2014

KS K 0051(2009) was established in 1990 and revised in 1994, 1999, 2004 and 2009. Recently the structure of apparel production and distribution are changing like as small quantity batch production, increase of importing abroad apparel and increase of on-line shopping mall. Based on Social and economic conditions, examine the potential for use of KS K 0051(2009) standard sizing system for female adult's garments are needed. Through which, it was intended to suggestion for the revision of standard sizing system for female adult's garments which can facilitate communication among consumer, producer and sellers. The improvement point was discussed through review of the current KS K 0051 (2009) and abroad standard sizing system for female adult's garments, ISO 3637(1977), ISO 4416(1981), BS EN 13402-2(2002), BS EN 13402-3(2004), JIS L 4005(2001) and GB/T 1335.2(2008). Also, the revision of standard sizing system for female adult's garments was suggested using data of 6th Size Korea. As a result of this study, in the revision, formal wear, casual wear, training wear and under wear were separated to simplify the classification and the classification of body type were excluded. Also, it is possible that size designation was simplified through optional notation and letter code based on bust girth could be marked together in casual wear.

• Journal of Institute of Control, Robotics and Systems
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• v.7 no.10
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• pp.867-873
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• 2001

The purpose of this study is to find analytic solution of determining the optimal capacity (lot-size) of multiproduct acyclic multistage production and inventory system to meet the finished product demand under the constraint of finite intermediate storage. Intermediate storage is a practical way to mitigate the material flow imbalance through the line of supply and demand chain. However, the cost of constructing and operating storage facilities is becoming substantial because of increasing land value, environmental and safety concern. Therefore, reasonable decision-making about the capacity of processes and storage units is an important subject for industries. The industrial solution for this subject is to use the classical economic lot sizing method, EOQ/EPQ(Economic Order Quantity/Economic Production Quantity) model, incorporated with practical experience. But EOQ/EPQ model is not suitable for the chemical plant design with highly interlinked processes and storage units because it is developed based on single product and single stage. This study overcomes the limitation of the classical lot sizing method. The superstructure of the plant consists of the network of serially and/or parallelly interlinked non-continuous processes and storage units. The processes transform a set of feedstock materials into another set of products with constant conversion factors. A novel production and inventory analysis method, PSW(Periodic Square Wave) model, is applied to describe the detail material flows among equipments. The objective function of this study is minimizing the total cost composed of setup and inventory holding cost. The advantage of PSW model comes from the fact that the model provides a set of simple analytic solutions in spite of realistic description of the material flows between processes and storage units. the resulting simple analytic solution can greatly enhance the proper and quick investment decision for the preliminary plant design problem confronted with economic situation.

• Journal of Institute of Control, Robotics and Systems
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• v.4 no.6
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• pp.802-810
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• 1998

The purpose of this study is to find the analytic solution of determining the optimal capacity of processes and storages to meet the product demand. Recent trend to reduce product delivery time and to provide high quality product to customer requires the increasing capacity of storage facilities. However, the cost of constructing and operating storage facilities is becoming substantial because of increasing land value, environmental and safety concern. Therefore, reasonable decision making about the capacity of processes and storages is important subject for industries. The industrial solution for this subject is to use the classical economic lot sizing method, EOQ(Economic Order Quantity) model, trimmed with practical experience but the unrealistic assumption of EOQ model is not suitable for the chemical plant design with highly interlinked processes and storages. This study, a first systematic attempt for this subject, clearly overcomes the limitation of classical lot sizing method. The superstructure of the plant consists of the network of serially and/or parallelly interlinked processes and storages. A novel production and inventory analysis method, PSW(Periodic Square Wave) model, is applied. The objective function of optimization is minimizing the total cost composed of setup and inventory holding cost. The advantage of PSW model comes from the fact that the model provide a set of simple analytic solution in spite of realistic description of material flow between process and storage. The resulting simple analytic solution can greatly enhance the proper and quick investment decision for the preliminary plant design confronting diverse economic situation.