• International Journal of Quality Innovation
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• 제10권2호
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• pp.29-42
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• 2009

The issue of capacity constraint resources (CCR) or bottlenecks wandering in product mix decision by applying Theory of Constraints (TOC) management philosophy has been mentioned and demonstrated in several papers. In this study, the effect for prolonging the planning period (PPP) so as to stabilize the CCR is investigated. The results show that the effect for PPP alternative will be positive or negative which is depending on the environment condition. However, a majority cases which have positive effect for PPP alternative can be recognized prior knowing the marketing demand, which is significant in the real application.

• 산업공학
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• 제16권spc호
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• pp.93-98
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• 2003

This paper addresses an AGV dispatching problem in semiconductor clean-room bays where AGVs move cassettes of wafers between machines or machines and a central buffer. Since each machine in a bay has a local buffer of limited capacity, material flow should be controlled in a careful way to maintain high system performance. It is regarded that two most important performance measures in a semiconductor bay are throughput rate and lead-time. The throughput rate is determined by a bottleneck resource and the lead-time depends on smooth material flow in the system. This paper presents an AGV dispatching procedure based on the concept of theory of constraints (TOC), by which dispatching decisions are made to utilize the bottleneck resource at the maximum level and to smooth the flow of material. The new dispatching procedure is compared with existing dispatching rules through simulation experiments.

• 산업공학
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• 제25권1호
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• pp.106-113
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• 2012

There are few factors like a due date observance of the customer's order, reducing the manufacturing lead time, and minimizing the inventory investment to successfully run the manufacturing system. It is difficult for corporation and a person concerned to be offered indicators to achieve few factors mentioned above from complex manufacturing systems having much fluctuations. Simplified-DBR based on TOC(Theory of Constraints) is a management paradigm which can offer indicators to effectively face with fluctuating market's needs when market's demand is smaller than a capacity of manufacturing system. This paper is offering a core indicator and management model which is needed to successfully run the manufacturing system for corporation and a person concerned who have short experience and knowledge and newly construct Sinplified-DBR manufacturing system. Thus, this paper provides a systemic guidance in the offered model through the simulation.

• 산업기술연구
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• 제31권B호
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• pp.51-58
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• 2011

Simulation plays a pivotal role in the analysis of complex systems. In this study, a job shop manufacturing system has been analyzed through DBR (Drum-buffer-rope) simulation. Specific attention has been put to examine the rate of due-date achievement. We first derived key factors affecting the system performance. We then developed ARENA simulation program based on DBR of TOC (Theory of Constraints) concepts. Based on the performance measure, factors, and experimental design, we obtained the results. We have drawn meaningful results through examination of the results. The results obtained from this study may provide a good base for practical applications.

• 대한안전경영과학회지
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• 제14권2호
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• pp.147-158
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• 2012

This paper aims to develop a new chain metrics for obtaining lean Overall Equipment Effectiveness(OEE) and present implementation strategy which considers the properties for Total Productive Maintenance(TPM) to reduce machine losses, Performance Analysis and Control(PAC) to reduce labor losses, Lean Production System(LPS) to reduce floor wastes, and Theory of Constraints(TOC) to minimize the problem of Capacity Constrained Resource(CCR). The study reviews the related literatures and reformulates the structure of machine losses, labor losses and field wastes. The research also develops the integrated productivity metrics according to time, units, reliability and maintainability. It is found that the study develops the actual productivity measure in terms of efficiency, effectiveness and standard productivity. In addition to that, it outlines and develops by using the integrated LPS and TPM, lean OEE measures such as Time Based Productivity(TBP), Unit Based Productivity(UBP), and Reliability & Maintainability Based Availability(RMBA). Implication examples are proposed to make it easier and available for practioners to understand the implementation strategies about TPM OEE, lean OEE and TOC OEE. Futhermore related to other studies, the research contributes to create a new chain productivity measures to clear the interrelationship concepts of productivity, efficiency and effectiveness. Moreover the paper develops the enhanced OEE measures by integration of TPM, PAC, LPS and TOC with the perspective of schedule, throughput, reliability, maintainability and availability.

• 산업공학
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• 제14권4호
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• pp.348-355
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• 2001

This paper suggests a detailed design of APS(Advanced Planning & Scheduling) system using the DBR (Drum-Buffer-Rope) which is a finite capacity scheduling logic of TOC(Theory of Constraints). Our design is composed of four modules; Network, Buffer, Drum and Subordination. The Network module defines the Product Network which is built from BOM and routings. The Buffer module inserts the Buffers into the Product Network. The Drum module describes detail procedures to create Drum Schedule on the CCR(Capacity Constraint Resource). The Subordination module synchronizes all non-constraints to the constraints by determining the length of Rope. This design documented by ARIS.

• 산업경영시스템학회지
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• 제23권59호
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• pp.21-36
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• 2000

The drum-buffer-rope(DBR) system is a finite scheduling mechanism that balances the flow of the production system. DBR controls the flow of materials through the plant in order to produce products in accordance with market demand, with a minimum of manufacturing lead time, inventory, and operating expenses. This paper integrates the best of MRP push system and JIT pull system with DBR system, efficiently adapts these logics to capacity constraint resources, and contributes to the evolution of synchronous manufacturing. The purpose of this paper is, thus, threefold. The first objective is to identify the frame of theory of constraints(TOC) and the logic of DBR scheduling. The second objective is to formulate the DBR constraint scheduling problems(DBRCSP) in a job shop environments. Finally, the paper is to suggest the solution procedure of DBRCSP for embedding TOC into MRP/JIT along with an numerical expression. In addition, illustrative numerical example is given.

• 한국철도학회:학술대회논문집
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• 한국철도학회 2006년도 추계학술대회 논문집
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• pp.990-1003
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• 2006

To cope with the change of railway safety environment and to prevent the catastrophic accident, the railway safety management system was established through the legislation of railway safety rules. And to audit and evaluate the accomplishment of railway safety rules by the railway operators, the Integrated Railway Safety Audit System(IRSAS) has been conducting. This study find out the strategy to stabilize the IRSAS by applying Theory of Constraints(TOC) Thinking Process. For meeting the IRSAS's goal of effective levelling up of railway safety, the two necessary conditions, 1)the secure of substantial safety through the IRSAS and 2)the execution of efficient IRSAS, should be fulfilled. Estimated undesirable effects(UDEs) from the IRSAS were identified, and 3 of them were selected for creating the requisite conflict clouds. Entities from these conflict clouds were synthesized into a core conflict cloud that foamed the base of Current Reality Tree. The strategic direction for change extracted from the conflict cloud is the reinforcement of IRSAS preparation system including the level up of operator's self audit, the deepening of preliminary survey, the establishment of complementing system of audit check list and the build up of auditor's specialization. These injection were logically validated via a Future Reality Tree and expected to be confirmed by further progressing of IRSAS.

• 대한조선학회논문집
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• 제45권3호
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• pp.315-321
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• 2008

A large ship usually consists of 300 to 500 blocks, for which it is extremely difficult to monitor the whole manufacturing processes from assembly to erection. In an effort to unify all the data and procedures, shipbuilding companies are installing ERP systems, which have brought great improvement throughout the company as a whole. In some departments, however, the ERP systems are not being fully utilized. This paper analyzes and solves the problems revealed especially at the production departments after an ERP system is installed. In this research, firstly a TOC(Theory of Constraints) analysis is done to find out the best solution for those problems. Secondly, based on the solution found, a Monitoring System for hull construction processes is developed with an improved user interface. The visualization of data is designed to reflect the needs of the production departments. The new system supplements the ERP system in that it selectively utilizes the unified data base and is operated under ERP environment. The system is installed in the production departments and its usefulness is verified.

• 한국전자거래학회지
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• 제10권1호
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• pp.61-80
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• 2005

업무프로세스관리(BPM) 시스템은 업무프로세스의 효율적인 실행, 통제 및 관리를 지원하는 소프트웨어 시스템으로서, 복잡한 프로세스를 자동화하고, 이를 효과적으로 관리하여 기업의 생산성 향상에 기여한다. 그러나, 상용시스템은 주로 프로세스의 자동화에 초점을 두고 있어 프로세스와 업무참여자 관점에서 효율적인 관리 방법을 제공하지 못하고 있다. 따라서, BPM 시스템은 프로세스 참여자와 전체 프로세스 효율성 향상의 관점에서 개선의 여지가 있다. 이에 본 논문에서는 업무프로세스를 보다 효율적으로 관리하는 새로운 방법을 제안한다. 제안한 방법은 업무참여자의 업무부하를 고려하여 전체 프로세스를 실행하는 방식으로서, 프로세스 참여자원 가운데 가장 큰 제약요소를 집중관리한다. 이러한 방식은 경영혁신이론으로 알려진 제약이론(Theory of Constraints)의 DBR (Drum-Buffer-Rope) 방법론을 기반으로 하고 있다. DBR 방법론을 활용하기 위해 우선, 업무프로세스와 DBR의 주적용모델의 차이점을 분석하고 업무프로세스에 적합한 드럼, 버퍼, 로프를 개발한다. 이를 토대로, 업무참여자의 업무부하와 프로세스 인스턴스 발생 패턴을 통제하는 BPM만의 DBR 방법론(BP-DBR, Business Process-DBR)을 제안한다. BP-DBR은 업무참여자의 업무환경과 전체프로세스의 효율성 개선에 기여할 것으로 기대한다. 이러한 기대효과를 증명하기 위해 기존 BPM의 프로세스 관리방법과 제안한 방법의 효과를 시뮬레이션 실험을 통해 비교한다.