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On the backlog-sequencing decision for extending the applicability of ConWIP to high-variety contexts: an assessment by simulation

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  • Matthias Thürer
  • Nuno O. Fernandes
  • Mark Stevenson
  • Ting Qu

Abstract

Constant Work-in-Process (ConWIP) is a card-based control system that was developed for simple flow shops – a lack of load-balancing capabilities hinders its application to more complex shops. In contrast, load balancing is an integral part of Workload Control, a production planning and control concept developed for high-variety environments. One means of load balancing evident in the Workload Control literature is through the use of a capacity slack-based backlog-sequencing rule. This study therefore investigates the potential of the backlog-sequencing decision to improve load balancing in the context of ConWIP, thereby making it suitable for more complex, high-variety environments. Using simulation, we demonstrate that: (i) the choice of backlog-sequencing rule significantly impacts throughput times and tardiness-related performance measures; and (ii) capacity slack-based sequencing rules achieve significant performance improvements over ‘classical’ ConWIP backlog-sequencing rules. These results significantly extend the applicability of ConWIP. Results from the Workload Control literature however do not directly translate across to ConWIP. The simplified release procedure of ConWIP makes backlog-sequencing based on planned release dates dysfunctional. This negatively impacts the performance of modified capacity slack-based sequencing rules that were recently shown to be the best choice for Workload Control.

Suggested Citation

  • Matthias Thürer & Nuno O. Fernandes & Mark Stevenson & Ting Qu, 2017. "On the backlog-sequencing decision for extending the applicability of ConWIP to high-variety contexts: an assessment by simulation," International Journal of Production Research, Taylor & Francis Journals, vol. 55(16), pages 4695-4711, August.
    • Handle: RePEc:taf:tprsxx:v:55:y:2017:i:16:p:4695-4711
    DOI: 10.1080/00207543.2017.1281462
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    References listed on IDEAS

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    1. Land, Martin J. & Stevenson, Mark & Thürer, Matthias & Gaalman, Gerard J.C., 2015. "Job shop control: In search of the key to delivery improvements," International Journal of Production Economics, Elsevier, vol. 168(C), pages 257-266.
    2. Cao, Dong & Chen, Mingyuan, 2005. "A mixed integer programming model for a two line CONWIP-based production and assembly system," International Journal of Production Economics, Elsevier, vol. 95(3), pages 317-326, March.
    3. Oosterman, Bas & Land, Martin & Gaalman, Gerard, 2000. "The influence of shop characteristics on workload control," International Journal of Production Economics, Elsevier, vol. 68(1), pages 107-119, October.
    4. Fredendall, Lawrence D. & Ojha, Divesh & Wayne Patterson, J., 2010. "Concerning the theory of workload control," European Journal of Operational Research, Elsevier, vol. 201(1), pages 99-111, February.
    5. Land, Martin J., 2009. "Cobacabana (control of balance by card-based navigation): A card-based system for job shop control," International Journal of Production Economics, Elsevier, vol. 117(1), pages 97-103, January.
    6. Thürer, Matthias & Land, Martin J. & Stevenson, Mark, 2014. "Card-based workload control for job shops: Improving COBACABANA," International Journal of Production Economics, Elsevier, vol. 147(PA), pages 180-188.
    7. Wallace J. Hopp & Mark L. Spearman, 2004. "To Pull or Not to Pull: What Is the Question?," Manufacturing & Service Operations Management, INFORMS, vol. 6(2), pages 133-148, August.
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    Cited by:

    1. Guodong Huang & Jie Chen & Yacob Khojasteh, 2021. "A cyber-physical system deployment based on pull strategies for one-of-a-kind production with limited resources," Journal of Intelligent Manufacturing, Springer, vol. 32(2), pages 579-596, February.
    2. Fernando José Gómez Paredes & Moacir Godinho Filho & Matthias Thürer & Nuno O. Fernandes & Charbel José Chiappeta Jabbour, 2022. "Factors for choosing production control systems in make-to-order shops: a systematic literature review," Journal of Intelligent Manufacturing, Springer, vol. 33(3), pages 639-674, March.

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