• Journal of the Korea Society for Simulation
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• v.21 no.4
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• pp.11-24
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• 2012

We compared a DBR(drum-buffer-rope) system with a CONWIP(constant work-in-process) system in a production line with constant processing times. Based on the observation that a WIP-controlled line production system such as DBR and CONWIP is equivalent to a m-node tandem queue with finite buffer, we applied a max-plus algebra based solution method for the tandem queue to evaluate the performance of two systems. Numerical examples with 6 workstations were also used to demonstrate the proposed analysis. The mathematical analyses support that CONWIP outperforms DBR in terms of expected waiting time and WIP. Unlike the CONWIP case, sequencing workstations in a DBR affects the performance of the system. Delaying a bottleneck station in a DBR reduces expected waiting time.

• IE interfaces
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• v.21 no.4
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• pp.418-434
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• 2008

This paper studied issues in decision making on the production control policy of a cathode plate manufacturing process in zinc refining plant. The present production system has a long lead time from raw materials (aluminum plate) to products (cathode plate) due to many WIP inventories. Because WIP inventories are stocked at each process and moved from one place to another frequently, they are the main cause of inefficiency in the process. In this paper, to solve this problem, several production control policies have been identified and studied. Several simulation models are used to compare the performances of these production control policies. The output lead time and WIP (Work In Process) of real production system are compared with those of simulation models. PUSH, CONWIP, DBR, KANBAN and CONWIP-DBR models have been used to simulate and review the optimized production control policy that achieves the target output quantities with decreased lead time and WIP. The simulation results of each production control policy show that CONWIP and CONWIP-DBR models are the good production control policy under the present production system. Especially in present production system, CONWIP with one parameter is easier control policy than CONWIP-DBR with two parameters. Therefore CONWIP has been selected as the best optimum production control policy. With CONWIP, lead time has been reduced by 97% (from 6,653 to 187 minute) and WIP has been reduced from 1,488 to 53, compared to the present system.

• Journal of the Korean Operations Research and Management Science Society
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• v.36 no.2
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• pp.51-65
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• 2011

We compared a CONWIP(constant work-in-process) system with a kanban system in a production line with constant processing times. Based on the observation that a WIP-controlled line production system such as CONWIP and kanban is equivalent to a m-node tandem queue with finite buffer, we applied a max-plus algebra based solution method for the tandem queue to evaluate the performance of two systems. Numerical examples with 6 workstations were used to demonstrate the proposed analysis. The numerical results support the previous studies that CONWIP outperforms kanban in terms of expected waiting time and WIP. Unlike the kanban case, sequencing workstations in a CONWIP does not affect the performance of the system.

• IE interfaces
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• v.11 no.3
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• pp.55-63
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• 1998

In this study we consider a CONWIP system in which the processing times at each station follow an exponential distribution and the demands for the finished products arrive according to a compound Poisson process. The demands that are not satisfied instantaneously are assumed to be lost. We assume that the lot size at each station is greater than one. For this system we develop an approximation method to obtain the performance measures such as steady state probabilities of the number of parts at each station, average number of parts at each station and the proportion of lost demands. For the analysis of the proposed CONWIP system, we model the CONWIP system as a closed queueing network with a synchronization station and analyze the closed queueing network using a product form approximation method. A recursive technique is used to solve the subnetwork in the application of the product-form approximation method. To test the accuracy of the approximation method, the results obtained from the approximation method were compared with those obtained by simulation. Comparisons with simulation have shown that the accuracy of the approximate method is acceptable.

• Journal of the Korean Operations Research and Management Science Society
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• v.23 no.3
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• pp.153-168
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• 1998

In this study we consider a CONWIP system in which the processing times at each station follow an exponential distribution and the demands for the finished Products arrive according to a compound Poisson process. The demands that are not satisfied instantaneously are assumed to be backordered. For this system we develop an approximation method to obtain the performance measures such as steady state probabilities of the number of parts at each station, the proportion of backordered demands, the average number of backordered demands and the mean waiting time of a backordered demand. For the analysis of the proposed CONWIP system, we model the CONWIP system as a closed queueing network with a synchronization station and analyze the closed queueing network using a product form approximation method. A matrix geometric method is used to solve the subnetwork in the application of the product-form approximation method. To test the accuracy of the approximation method, the results obtained from the approximation method were compared with those obtained by simulation. Comparisons with simulation have shown that the approximate method provides fairly good results.

• Proceedings of the Korean Operations and Management Science Society Conference
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• 2004.10a
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• pp.8-12
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• 2004

In this study we consider a CONWIP system in which the processing times at each station follow a Coxian distribution and the demands for the finished products arrive according to a compound Poisson process. The demands that are not satisfied are backordered according to the number of demands that exist at their arrival instants. For this system we develop an approximation method to calculate order based performance measures such as the mean time of fulfilling a customer order and the mean number o: customer orders. For the analysis of the proposed CONWIP system, we model the CONWIP system as a closed queueing network with a synchronization station and analyze the closed queueing network using a product form approximation method. Numerical tests show that the approximation method provides fairly good estimation of the performance measures of interest.

• Proceedings of the Safety Management and Science Conference
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• 1999.11a
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• pp.541-541
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• 1999

동적환경하에서의 JIT 생산 시스템의 운영에 관한 연구는 Terada, Kimura(1981), Bitran과 Chang(1985), Deleersnyder(1989), Mitra, Mitrani(1990) 그리고 Philipoom(1990)에 의한 분석적 모델의 발표로부터 시작하여 Terada와 Kimura(1981)의 다단계 연속 생산 시스템에서 간판 시스템에 대한 여러 가지 기본 공식의 제공, Bitan과 Chang(1985)에 다단계 스테이지의 조립생산 시스템에서 여러 가지 기본 공식과 해의 절차의 발표로 발전되어 왔다. 그 이후 Spearman 은 CONWIP을 이용한 간판 시스템의 변형된 형태를 연구ㆍ발표하였고(1990), Generic 간판 시스템에 대한 Chang과 YIH (1994)에 의해 연구되었다. Hybrid Push/Pull 시스템의 하나인 CONWIP 시스템은 현재까지 다른 시스템보다 정책면에서 동적인 기업환경에 적합한 것으로 평가받고 있다. 본 논문은 생산/제조 시스템의 운용에 대해 동적인 기업환경 하에서 고전적 kanban 시스템보다 우월하다고 입증된 CONWIP 시스템을 모형화하고 시스템 운영에 대한 실례를 들어 비선형 계획법의 하나인 내부점 알고리즘으로 수행, 해의 수렴과정을 고찰 기존의 시뮬레이션 결과와 비교 고찰하고자 한다.

• Journal of the Korea Safety Management & Science
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• v.5 no.4
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• pp.209-217
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• 2003

The traditional Kanban needs a lot of preconditions for fitting conditions of dynamic production processing environment. The traditional Kanban isn't suitable conditions of dynamic production processing environment. Therefore conditions of dynamic production processing environment is needed more stable system. This study is describe CONWIP system such as suitable in dynamic production processing environment. Most Pull system is a Kanban system than use Kanban cards or signal for production management and inventory control. The object of Kanban system is reducing inventory between shop-floor that can reduce inventiry cost. If the system reduce the number of Kanban cards would be reduce the working process WIP, can be reduced and can be found all potential problem of production between shop-floors. This study apply to CONWIP system model for Korean industrial companies.

• Journal of the Korean Operations Research and Management Science Society
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• v.31 no.3
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• pp.63-79
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• 2006

In this study we consider a CONWIP system in which the processing times at each station follow a Coxian distribution and the demands for the finished products arrive according to a compound Poisson process. The demands that are not satisfied immediately are either backordered or lost according to the number of demands that exist at their arrival Instants. For this system we develop an approximation method to calculate performance measures such as steady state probabilities of the number of parts at each station, proportion of lost demands and the mean number of backordered demands. For the analysis of the proposed CONWIP system, we model the CONWIP system as a closed queueing network with a synchronization station and analyze the closed queueing network using a product-form approximation method. A recursive technique is used to solve the subnetwork in the application of the product-form approximation method. To test the accuracy of the approximation method, the results obtained from the approximation method are compared with those obtained by simulation. Comparisons with simulation show that the approximation method provides fairly good results.

• Journal of the Korea Society for Simulation
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• v.23 no.4
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• pp.229-235
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• 2014

Improving the time and cost efficiency of production systems is one of the important means of building competitive advantage and staying profitable in the ever increasing competitive business environment. Among others, CONWIP (constant work-in-process) and DBR (drum-buffer-rope) methods are widely used in improving production process efficiency. In this study, we have developed simulation models for a real button factory production system. We have tried to improve the efficiency of the production process by implementing these two approaches to our model. According to our results, both CONWIP and DBR production approaches were found to have equivalently better results in reducing the waiting time of the bottleneck process. By applying either of the two production systems, efficiency of the real production process can be significantly improved as the simulated model results demonstrate.