• Journal of Korean Institute of Industrial Engineers
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• v.5 no.1
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• pp.1-6
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• 1979

This paper discusses an application of discrete variable Servo Theory to the analysis of the effectiveness of production-inventory control system which uses exponential smoothing as a specific forecasting technique by establishing a new model which consists of such three departments as production planning, production, and inventory. The objective of the new production-inventory model is to keep the production to the optimal level of minimum production cost in production planning problem for obtaining, the stability of inventory subject to demand variation. On this basis, the dynamic characteristic of the system with the change of the parameters is clarified by the numerical analysis. The results of the numerical analysis show the effect that is obtained by the simultaneous stability of production and inventory as soon as possible.

• Journal of Korean Institute of Industrial Engineers
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• v.38 no.2
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• pp.89-97
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• 2012

This paper considers a manufacturer with a two-station make-to-stock and make-to-order serial production system. The MTS facility produces a single type of component and provides components for the MTO facility that produces customized products. In addition to the internal demand from the MTO facility, the MTS facility faces demands from the spot market with the option of to accept or reject each incoming demand. This paper addresses a joint component inventory rationing and batch production control which maximizes the manufacturer's profit. Using the Markov decision process model, we investigate the structural properties of the optimal inventory rationing and batch production policy, and present two types of heuristics. We implement a numerical experiment to compare the performance of the optimal and heuristic policies and a simulation study to examine the impact of the stochastic process variability on the inventory rationing and batch production control.

• Proceedings of the Korean Institute of Navigation and Port Research Conference
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• 2011.11a
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• pp.162-163
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• 2011

This paper presents the system dynamics methodology for modeling and control the production/inventory system. Under system dynamics point of view, we can apply some production/inventory policies as if we use the control laws for dynamics systems, then the behavior of system is analyzed and evaluated to improve the performance of production/inventory system. We also utilize the hybrid modeling method for the dynamic of production system with the combination of Matlab/Simulink and Matlab/Sateflow. Finally, the numerical simulation results are carried out in Matlab/Simulink environment and compare with the results from other works. It is shown that our approach can obtain some good performances (such as operational cost, stability of inventory, customer service level).

• IE interfaces
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• v.16 no.1
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• pp.111-116
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• 2003

Business integration has been considered as one of the most critical success factors that enable the firms to gain competitive edges. Despite this trend, it has also been found among not a few companies that the activities that should be functionally tied with are performed even independently. In this study, an integrated model of production planning and inventory has been developed. Computerization of the production planning activities is proposed and implemented. We also proposed the reasonable inventory levels of each item using historic data of the items, which are composed of safety stock from the given fill-rate, operating stock from the production patterns, and reserved stock from the production planning. This study has helped the firm to have clearer job definition of the related processes, to tightly control the inventory by setting and tracing the reasonable fill rates for every product, and to quickly respond to the market changes through the computerized production planning process.

• Journal of the Korean Operations Research and Management Science Society
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• v.37 no.2
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• pp.45-56
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• 2012

This paper considers a supply chain consisting of a component manufacturer and a product manufacturer. The component manufacturer provides components for the product manufacturer based on a vendor-managed inventory type of supply contract, and also faces demands from the market with the option of to accept or reject each incoming demand. Using the Markov decision process model, we examine the structure of the optimal production control and inventory rationing policy. Two types of heuristics are presented. One is the fixed-buffer policy and the other uses two linear functions. We implement a computational study and present managerial insights based on the observations.

• Journal of Korean Society of Industrial and Systems Engineering
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• v.43 no.3
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• pp.61-67
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• 2020

The fourth industrial revolution encourages manufacturing industry to pursue a new paradigm shift to meet customers' diverse demands by managing the production process efficiently. However, it is not easy to manage efficiently a variety of tasks of all the processes including materials management, production management, process control, sales management, and inventory management. Especially, to set up an efficient production schedule and maintain appropriate inventory is crucial for tailored response to customers' needs. This paper deals with the optimized inventory policy in a steel company that produces granule products under supply contracts of three targeted on-time delivery rates. For efficient inventory management, products are classified into three groups A, B and C, and three differentiated production cycles and safety factors are assumed for the targeted on-time delivery rates of the groups. To derive the optimized inventory policy, we experimented eight cases of combined safety stock and data analysis methods in terms of key performance metrics such as mean inventory level and sold-out rate. Through simulation experiments based on real data we find that the proposed optimized inventory policy reduces inventory level by about 9%, and increases surplus production capacity rate, which is usually used for the production of products in Group C, from 43.4% to 46.3%, compared with the existing inventory policy.

• The Journal of Information Systems
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• v.30 no.1
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• pp.151-177
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• 2021

Purpose This paper aims to improve management performance by effectively responding to production needs and reducing inventory through synchronizing production planning and procurement in the aviation industry. In this study, the differences in production planning and execution were first analyzed in terms of demand, supply, inventory, and process using the big data collected from a domestic aircraft manufacturers. This paper analyzed the problems in procurement and inventory management using legacy big data from ERP system in the company. Based on the analysis, we performed a simulation to derive an efficient procurement and inventory management plan. Through analysis and simulation of operational data, we were able to discover procurement and inventory policies to effectively respond to production needs. Design/methodology/approach This is an empirical study to analyze the cause of decrease in inventory turnover and increase in inventory cost due to dis-synchronize between production requirements and procurement. The actual operation data, a total of 21,306,611 transaction data which are 18 months data from January 2019 to June 2020, were extracted from the ERP system. All them are such as basic information on materials, material consumption and movement history, inventory/receipt/shipment status, and production orders. To perform data analysis, it went through three steps. At first, we identified the current states and problems of production process to grasp the situation of what happened, and secondly, analyzed the data to identify expected problems through cross-link analysis between transactions, and finally, defined what to do. Many analysis techniques such as correlation analysis, moving average analysis, and linear regression analysis were applied to predict the status of inventory. A simulation was performed to analyze the appropriate inventory level according to the control of fluctuations in the production planing. In the simulation, we tested four alternatives how to coordinate the synchronization between the procurement plan and the production plan. All the alternatives give us more plausible results than actual operation in the past. Findings Based on the big data extracted from the ERP system, the relationship between the level of delivery and the distribution of fluctuations was analyzed in terms of demand, supply, inventory, and process. As a result of analyzing the inventory turnover rate, the root cause of the inventory increase were identified. In addition, based on the data on delivery and receipt performance, it was possible to accurately analyze how much gap occurs between supply and demand, and to figure out how much this affects the inventory level. Moreover, we were able to obtain the more predictable and insightful results through simulation that organizational performance such as inventory cost and lead time can be improved by synchronizing the production planning and purchase procurement with supply and demand information. The results of big data analysis and simulation gave us more insights in production planning, procurement, and inventory management for smart manufacturing and performance improvement.

• Journal of Korean Institute of Industrial Engineers
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• v.40 no.1
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• pp.108-117
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• 2014

This study considers warehouse sizing decisions in an integrated single vendor-single buyer production inventory system by incorporating new decision variables and constraints associated with warehouse size into the formulations. Two typical inventory control policies proposed in the literature (i.e., Identical Delivery Quantity and Deliver What is Produced) have been investigated with consideration of warehouse investment costs. The numerical study shows that Deliver What is Produced is less flexible than Identical Delivery Quantity, resulting in the conclusion that the latter would be preferable when considering warehouse investment costs.

• Journal of the Korea Institute of Building Construction
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• v.5 no.4 s.18
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• pp.153-164
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• 2005

This study aims at establishing JIT production management system to enable manage the resources input into from procurement through construction based on correct identification of the process, an analysis on the amount of input materials and information sharing. This study has focused on the process control and working process of rebar work in domestic apartment house construction where the overall scope of Process from the planning phase to the construction phase has been analyzed in this study. Also construction phase was selected for the application of a sample case. A basic model for JIT production was generated with these processes. Furthermore A questionnaire and the on-site survey with process, checklist and control data were prepared and performed for the application of JIT production management model into rebar work. The governing scopes of JIT production management system include process management, material management, yard loading and moving management and inventory control, and the operation of each control item

• Korean Management Science Review
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• v.10 no.2
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• pp.43-59
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• 1993

A production control information system developed for multi-product, small-lot-sized production is presented. The system is composed of interrelated modules for production planning, shop floor control, and inventory/material management. The architecture of the system, functions of each module, and information processing procedures of each function are discussed.