Production Scheduling For The Process Industries
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Production Scheduling for the Process Industries
This book is aimed at manufacturing and planning managers who struggle to bring a greater degree of stability and more effective use of assets to their operations, not realizing the degree to which production scheduling affects those objectives. It has been reported that 75% of the problems on the manufacturing floor are caused by activities outside the plant floor. Poor production scheduling strategies and systems are often the biggest contributors to the 75%. The book explains in detail that no scheduling strategy, and especially no transition to a different and better scheduling strategy, will succeed without strong commitment and guidance from senior leadership. Leadership must understand their active role in the transition, that people will feel uncomfortable and even threatened by change, and that they will need to be measured by different standards. Effective scheduling requires that following the schedule and production to plan is more important than trying to maximize each day’s throughput. The book explains the advantages of a structured, regularly repeating schedule: how it can increase throughput, right-size inventory based on cycles and variabilities and therefore make it more usable, and improve customer delivery. It will explain the trade-offs between throughput, inventory, and delivery performance, how those trade-offs are actually decided in production scheduling, and how an appropriate scheduling strategy can make the trade-offs and their ramifications visible. It discusses several popular structured scheduling concepts, their similarities, and differences, to allow the readers to decide which might fit best in their environments. In addition, the authors discuss what makes an appropriate scheduling software system, and why a package designed for structured scheduling offers capabilities well beyond the Excel workbooks used by many companies, and how it offers much more design capability and ease of use than the finite scheduling modules in SAP or Oracle. Finally, the authors offer a proven roadmap for implementation, critical success factors necessary to achieve the full potential, and give examples of operations that have done this well. In addition, a guide for leaders and managers post-implementation is provided to help them fully exploit the advantages of a structured, repeating scheduling strategy.
Solving Large-Scale Production Scheduling and Planning in the Process Industries
This book presents a number of efficient techniques for solving large-scale production scheduling and planning problems in process industries. The main content is supplemented by a wealth of illustrations, while case studies on large-scale industrial applications, ranging from continuous to semicontinuous and batch processes, round out the coverage. The book examines a variety of complex, real-world problems, and demonstrates solutions that are applicable to scenarios and countries around the world. Specifically, these case studies include: • the production planning of the bottling stage of a major brewery at the Cervecería Cuauhtémoc Moctezuma (Heineken Int) in Mexico;• the production scheduling for multi-stage semicontinuous processes at an ice-cream production facility of Unilever in the Netherlands;• the resource-constrained production planning for the yogurt production line at the KRI KRI dairy production facility in Greece; and• the production scheduling for large-scale, multi-stage batch processes at a pharmaceutical batch plant in Germany. In addition, the book includes industrial-inspired case studies of: • the simultaneous planning of production and logistics operations considering multi-site facilities for semicontinuous processes; and• the integrated planning of production and utility systems in process industries under uncertainty. Solving Large-scale Production Scheduling and Planning in the Process Industries offers a valuable reference guide for researchers and decision-makers alike, as it shows readers how to evaluate and improve existing installations, and how to design new ones. It is also well suited as a textbook for advanced courses on production scheduling and planning in industry, as it addresses the optimization of production and logistics operations in real-world process industries.
Production Planning and Industrial Scheduling
In today's extremely competitive manufacturing market, effective production planning and scheduling processes are critical to streamlining production and increasing profits. Success in these areas means increased efficiency, capacity utilization, and reduced time required to complete jobs. From the initial stages of plant location and capacity dete