Search results for: aggregate production planning

Authors: B. Fahimnia, L.H.S. Luong, R. M. Marian

Abstract:

The Aggregate Production Plan (APP) is a schedule of the organization-s overall operations over a planning horizon to satisfy demand while minimizing costs. It is the baseline for any further planning and formulating the master production scheduling, resources, capacity and raw material planning. This paper presents a methodology to model the Aggregate Production Planning problem, which is combinatorial in nature, when optimized with Genetic Algorithms. This is done considering a multitude of constraints of contradictory nature and the optimization criterion – overall cost, made up of costs with production, work force, inventory, and subcontracting. A case study of substantial size, used to develop the model, is presented, along with the genetic operators.

Keywords: Aggregate Production Planning, Costs, and Optimization.

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Authors: Ömer Faruk Baykoç, Ümit Sami Sakalli

Abstract:

In this paper, we propose a fuzzy aggregate production planning (APP) model for blending problem in a brass factory which is the problem of computing optimal amounts of raw materials for the total production of several types of brass in a period. The model has deterministic and imprecise parameters which follows triangular possibility distributions. The brass casting APP model can not always be solved by using common approaches used in the literature. Therefore a mathematical model is presented for solving this problem. In the proposed model, the Lai and Hwang-s fuzzy ranking concept is relaxed by using one constraint instead of three constraints. An application of the brass casting APP model in a brass factory shows that the proposed model successfully solves the multi-blend problem in casting process and determines the optimal raw material purchasing policies.

Keywords: Aggregate production planning, Blending, brasscasting, possibilistic programming.

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Authors: Wen-Lung Huang, Shih-Pin Chen

Abstract:

This paper investigates the optimization problem of multi-product aggregate production planning (APP) with fuzzy data. From a comprehensive viewpoint of conserving the fuzziness of input information, this paper proposes a method that can completely describe the membership function of the performance measure. The idea is based on the well-known Zadeh-s extension principle which plays an important role in fuzzy theory. In the proposed solution procedure, a pair of mathematical programs parameterized by possibility level a is formulated to calculate the bounds of the optimal performance measure at a . Then the membership function of the optimal performance measure is constructed by enumerating different values of a . Solutions obtained from the proposed method contain more information, and can offer more chance to achieve the feasible disaggregate plan. This is helpful to the decision-maker in practical applications.

Keywords: fuzzy data, aggregate production planning, membership function, parametric programming

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Authors: Phruksaphanrat B.

Abstract:

This research proposes a Preemptive Possibilistic Linear Programming (PPLP) approach for solving multiobjective Aggregate Production Planning (APP) problem with interval demand and imprecise unit price and related operating costs. The proposed approach attempts to maximize profit and minimize changes of workforce. It transforms the total profit objective that has imprecise information to three crisp objective functions, which are maximizing the most possible value of profit, minimizing the risk of obtaining the lower profit and maximizing the opportunity of obtaining the higher profit. The change of workforce level objective is also converted. Then, the problem is solved according to objective priorities. It is easier than simultaneously solve the multiobjective problem as performed in existing approach. Possible range of interval demand is also used to increase flexibility of obtaining the better production plan. A practical application of an electronic company is illustrated to show the effectiveness of the proposed model.

Keywords: Aggregate production planning, Fuzzy sets theory, Possibilistic linear programming, Preemptive priority

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Authors: P. Luangpaiboon, P. Aungkulanon

Abstract:

This work presents a multiple objective linear programming (MOLP) model based on the desirability function approach for solving the aggregate production planning (APP) decision problem upon Masud and Hwang-s model. The proposed model minimises total production costs, carrying or backordering costs and rates of change in labor levels. An industrial case demonstrates the feasibility of applying the proposed model to the APP problems with three scenarios of inventory levels. The proposed model yields an efficient compromise solution and the overall levels of DM satisfaction with the multiple combined response levels. There has been a trend to solve complex planning problems using various metaheuristics. Therefore, in this paper, the multi-objective APP problem is solved by hybrid metaheuristics of the hunting search (HuSIHSA) and firefly (FAIHSA) mechanisms on the improved harmony search algorithm. Results obtained from the solution of are then compared. It is observed that the FAIHSA can be used as a successful alternative solution mechanism for solving APP problems over three scenarios. Furthermore, the FAIHSA provides a systematic framework for facilitating the decision-making process, enabling a decision maker interactively to modify the desirability function approach and related model parameters until a good optimal solution is obtained with proper selection of control parameters when compared.

Keywords: Aggregate Production Planning, Desirability Function Approach, Improved Harmony Search Algorithm, Hunting Search Algorithm and Firefly Algorithm.

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Authors: S. Homrossukon, D. Aromstain

Abstract:

The simple methods used to plan and measure non patterned production system are developed from the basic definition of working efficiency. Processing time is assigned as the variable and used to write the equation of production efficiency. Consequently, such equation is extensively used to develop the planning method for production of interest using one-dimensional stock cutting problem. The application of the developed method shows that production efficiency and production planning can be determined effectively.

Keywords: Production Planning, Parallel Machine, Production Measurement, Cutting and Packing.

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Authors: S. Ismail, Z. Yaacob

Abstract:

The main aim of this research is to study the possible use of recycled fine aggregate made from waste rubble wall to substitute partially for the natural sand used in the production of cement and sand bricks. The bricks specimens were prepared by using 100% natural sand; they were then replaced by recycled fine aggregate at 25, 50, 75, and 100% by weight of natural sand. A series of tests was carried out to study the effect of using recycled aggregate on the physical and mechanical properties of bricks, such as density, drying shrinkage, water absorption characteristic, compressive and flexural strength. Test results indicate that it is possible to manufacture bricks containing recycled fine aggregate with good characteristics that are similar in physical and mechanical properties to those of bricks with natural aggregate, provided that the percentage of recycled fine aggregates is limited up to 50-75%.

Keywords: Bricks, cement, recycled aggregate, sand

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Authors: F. Keller, G. Reinhart

Abstract:

The efficient and economic allocation of resources is one main goal in the field of production planning and control. Nowadays, a new variable gains in importance throughout the planning process: Energy. Energy-efficiency has already been widely discussed in literature, but with a strong focus on reducing the overall amount of energy used in production. This paper provides a brief systematic approach, how energy-supply-orientation can be used for an energy-cost-efficient production planning and thus combining the idea of energy-efficiency and energy-flexibility.

Keywords: Production planning and control, energy, efficiency, flexibility.

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Authors: Magdi M. E. Zumrawi, Faiza O. A. Khalill

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Steel slag is a by-product of the steel industry and can be used potentially as aggregate in the asphalt mixture. This study evaluates the use of Steel Slag Aggregates (SSA) as a substitute for natural aggregates in the production of hot mix asphalt (HMA) for road construction. Based on intensive laboratory testing program, the characteristic properties of SSA were assessed to determine its suitability to be used in HMA. Four different percentages (0, 50, 75, and 100%) of SSA were used, and the proposed mix designs for HMA were conducted in accordance with Marshall mix design. The experiment results revealed that the addition of SSA has a significant improvement on the properties of HMA. An increase in density and stability and a reduction in flow and air voids values were clearly observed in specimens prepared with 100% SSA. It is concluded that the steel slag can be considered reasonable alternative source of aggregate for concrete asphalt mixture production.

Keywords: Aggregate, asphalt mixture, stability, steel slag.

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Authors: Pirom Thangchitpianpol, Suttipong Jumroonrut

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This research investigates the distribution of food demand for animal food and the optimum amount of that food production at minimum cost. The data consist of customer purchase orders for the food of laying hens, price of food for laying hens, cost per unit for the food inventory, cost related to food of laying hens in which the food is out of stock, such as fine, overtime, urgent purchase for material. They were collected from January, 1990 to December, 2013 from a factory in Nakhonratchasima province. The collected data are analyzed in order to explore the distribution of the monthly food demand for the laying hens and to see the rate of inventory per unit. The results are used in a stochastic linear programming model for aggregate planning in which the optimum production or minimum cost could be obtained. Programming algorithms in MATLAB and tools in Linprog software are used to get the solution. The distribution of the food demand for laying hens and the random numbers are used in the model. The study shows that the distribution of monthly food demand for laying has a normal distribution, the monthly average amount (unit: 30 kg) of production from January to December. The minimum total cost average for 12 months is Baht 62,329,181.77. Therefore, the production planning can reduce the cost by 14.64% from real cost.

Keywords: Animal food, Stochastic linear programming, Production planning, Demand Uncertainty.

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Authors: Yin-Yann Chen

Abstract:

As the gradual increase of the enterprise scale, the firms may possess many manufacturing plants located in different places geographically. This change will result in the multi-site production planning problems under the environment of multiple plants or production resources. Our research proposes the structural framework to analyze the multi-site planning problems. The analytical framework is composed of six elements: multi-site conceptual model, product structure (bill of manufacturing), production strategy, manufacturing capability and characteristics, production planning constraints, and key performance indicators. As well as the discussion of these six ingredients, we also review related literatures in this paper to match our analytical framework. Finally we take a real-world practical example of a TFT-LCD manufacturer in Taiwan to explain our proposed analytical framework for the multi-site production planning problems.

Keywords: Multi-Site, Production Planning, Supply Chain, TFT-LCD.

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Authors: Tomas Duranik, Juraj Ruzbarsky, Markus Stopper

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CONWIP (constant work-in-process) as a pull production system have been widely studied by researchers to date. The CONWIP pull production system is an alternative to pure push and pure pull production systems. It lowers and controls inventory levels which make the throughput better, reduces production lead time, delivery reliability and utilization of work. In this article a CONWIP pull production system was simulated. It was simulated push and pull planning system. To compare these systems via a production planning system (PPS) game were adjusted parameters of each production planning system. The main target was to reduce the total WIP and achieve throughput and delivery reliability to minimum values. Data was recorded and evaluated. A future state was made for real production of plastic components and the setup of the two indicators with CONWIP pull production system which can greatly help the company to be more competitive on the market.

Keywords: CONWIP, constant work in process, delivery reliability, hybrid production planning, PPS.

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Authors: A. Kampker, P. Burggräf, Y. Bäumers

Abstract:

In order to be competitive, companies have to reduce their production costs while meeting increasing quality requirements. Therefore, companies try to plan their assembly processes as detailed as possible. However, increasing product individualization leading to a higher number of variants, smaller batch sizes and shorter product life cycles raise the question to what extent the effort of detailed planning is still justified. An important approach in this field of research is the concept of determining the economic planning depth for assembly process planning based on production specific influencing factors. In this paper first solution hypotheses as well as a first draft of the resulting method will be presented.

Keywords: Assembly process planning, economic planning depth, planning benefit, planning effort.

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Authors: Daxing Wang, Jikai Teng

Abstract:

An aggregate signature scheme can aggregate n signatures on n distinct messages from n distinct signers into a single signature. Thus, n verification equations can be reduced to one. So the aggregate signature adapts to Mobile Ad hoc Network (MANET). In this paper, we propose an efficient ID-based aggregate signature scheme with constant pairing computations. Compared with the existing ID-based aggregate signature scheme, this scheme greatly improves the efficiency of signature communication and verification. In addition, in this work, we apply our ID-based aggregate sig- nature to authenticated routing protocol to present a secure routing scheme. Our scheme not only provides sound authentication and a secure routing protocol in ad hoc networks, but also meets the nature of MANET.

Keywords: Identity-based cryptography, Aggregate signature, Bilinear pairings, Authenticated routing scheme.

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Authors: Guoliang Fan, Aiping Li, Nan Xie, Liyun Xu, Xuemei Liu

Abstract:

Mass customization production increases the difficulty of the production line layout planning. The material distribution process for variety of parts is very complex, which greatly increases the cost of material handling and logistics. In response to this problem, this paper presents an approach of production line layout planning based on complexity measurement. Firstly, by analyzing the influencing factors of equipment layout, the complexity model of production line is established by using information entropy theory. Then, the cost of the part logistics is derived considering different variety of parts. Furthermore, the function of optimization including two objectives of the lowest cost, and the least configuration complexity is built. Finally, the validity of the function is verified in a case study. The results show that the proposed approach may find the layout scheme with the lowest logistics cost and the least complexity. Optimized production line layout planning can effectively improve production efficiency and equipment utilization with lowest cost and complexity.

Keywords: Production line, layout planning, complexity measurement, optimization, mass customization.

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Authors: Dong Wook Lee, Seung Hyun Kim, Jeongho Oh

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With the strengthened regulation on the mandatory use of recycled aggregate, development of construction materials using recycled aggregate has recently increased. This study aimed to secure the performance of asphalt concrete mixture by developing recycled-modified asphalt using recycled basalt aggregate from the Jeju area. The strength of the basalt aggregate from the Jeju area used in this study was similar to that of general aggregate, while the specific surface area was larger due to the development of pores. Modified asphalt was developed using a general aggregate-recycled aggregate ratio of 7:3, and the results indicated that the Marshall stability increased by 27% compared to that of asphalt concrete mixture using only general aggregate, and the flow values showed similar levels. Also, the indirect tensile strength increased by 79%, and the toughness increased by more than 100%. In addition, the TSR for examining moisture resistance was 0.95 indicating that the reduction in the indirect tensile strength due to moisture was very low (5% level), and the developed recycled-modified asphalt could satisfy all the quality standards of asphalt concrete mixture.

Keywords: Asphalt Concrete Mixture, Performance Grade, Recycled Basalt Aggregate, Recycled-Modified Asphalt.

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Authors: Vladimira Vytlacilova

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The article presents findings from the study and analysis of the results of an experimental programme focused on the production of concrete and fibre reinforced concrete in which natural aggregate has been substituted with brick or concrete recyclate. The research results are analyzed to monitor the effect of mechanicalphysical characteristics on the durability properties of tested cementitious composites. The key parts of the fibre reinforced concrete mix are the basic components: aggregates – recyclate, cement, fly ash, water and fibres. Their specific ratios and the properties of individual components principally affect the resulting behaviour of fresh fibre reinforced concrete and the characteristics of the final product. The article builds on the sources dealing with the use of recycled aggregates from construction and demolition waste in the production of fibre reinforced concrete. The implemented procedure of testing the composite contributes to the building sustainability in environmental engineering.

Keywords: Recycled aggregate, Polypropylene fibres, Fibre Reinforced Concrete, Fly ash.

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Authors: Hasan Şahan Arel

Abstract:

In this study, literature related to the replacement of cement with waste marble and the use of waste marble as an aggregate in concrete production was examined. Workability of the concrete decreased when marble powder was used as a substitute for fine aggregate. Marble powder contributed to the compressive strength of concrete because of the CaCO₃ and SiO₂ present in the chemical structure of the marble. Additionally, the use of marble pieces in place of coarse aggregate revealed that this contributed to the workability and mechanical properties of the concrete. When natural standard sand was replaced with marble dust at a ratio of 15% and 75%, the compressive strength and splitting tensile strength of the concrete increased by 20%-26% and 10%-15%, respectively. However, coarse marble aggregates exhibited the best performance at a 100% replacement ratio. Additionally, there was a greater improvement in the mechanical properties of concrete when waste marble was used in a coarse aggregate form when compared to that of when marble was used in a dust form. If the cement was replaced with marble powder in proportions of 20% or more, then adverse effects were observed on the compressive strength and workability of the concrete. This study indicated that marble dust at a cement-replacement ratio of 5%-10% affected the mechanical properties of concrete by decreasing the global annual CO₂ emissions by 12% and also lowering the costs from US$40/m³ to US$33/m³.

Keywords: Cement production, concrete, CO2 emission, marble, mechanical properties.

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Authors: Ji Wenzhan, Zhang Tao, Li Guoyou

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Concrete is the most widely used building material in the world. At the same time, the world produces a large amount of construction waste each year. Waste concrete is processed and treated, and the recycled aggregate is used to make pervious concrete, which enables the construction waste to be recycled. Pervious concrete has many advantages such as permeability to water, protection of water resources, and so on. This paper tests the recycled aggregate obtained by crushing high-strength waste concrete (TOU) and low-strength waste concrete (PU), and analyzes the effect of porosity, amount of cement, mineral admixture and recycled aggregate on the strength of permeable concrete. The porosity is inversely proportional to the strength, and the amount of cement used is proportional to the strength. The mineral admixture can effectively improve the workability of the mixture. The quality of recycled aggregates had a significant effect on strength. Compared with concrete using "PU" aggregates, the strength of 7d and 28d concrete using "TOU" aggregates increased by 69.0% and 73.3%, respectively. Therefore, the quality of recycled aggregates should be strictly controlled during production, and the mix ratio should be designed according to different use environments and usage requirements. This test prepared a recycled aggregate permeable concrete with a compressive strength of 35.8 MPa, which can be used for light load roads and provides a reference for engineering applications.

Keywords: Recycled aggregate, pervious concrete, compressive strength, permeability.

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Authors: Fahad K. Alqahtani

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Nowadays construction industry is developing means to incorporate waste products in concrete to ensure sustainability. To meet the need of construction industry, a synthetic aggregate was developed using optimized technique called compression moulding press technique. The manufactured aggregate comprises mixture of plastic, waste which acts as binder, together with by-product waste which acts as fillers. The physical properties and microstructures of the inert materials and the manufactured aggregate were examined and compared with the conventional available aggregates. The outcomes suggest that the developed aggregate has potential to be used as substitution of conventional aggregate due to its less weight and water absorption. The microstructure analysis confirmed the efficiency of the manufacturing process where the final product has the same mixture of binder and filler.

Keywords: Fly ash, plastic waste, quarry fine, red sand, synthetic aggregate.

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Authors: Chaimongkol Limpianchob

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This work addresses the problem of production planning that arises in the production of aromatic coconuts from Samudsakhorn province in Thailand. The planning involves the forwarding of aromatic coconuts from the harvest areas to the factory, which is classified into two groups; self-owned areas and contracted areas, the decisions of aromatic coconuts flow in the plant, and addressing a question of which warehouse will be in use. The problem is formulated as a mixed-integer linear programming model within supply chain management framework. The objective function seeks to minimize the total cost including the harvesting, labor and inventory costs. Constraints on the system include the production activities in the company and demand requirements. Numerical results are presented to demonstrate the feasibility of coconuts supply chain model compared with base case.

Keywords: Aromatic coconut, supply chain management, production planning, mixed-integer linear programming.

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Authors: R. Pernicova, D. Dobias

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The present article describes the limits of using recycled concrete aggregate (denoted as RCA) in the top layer of concrete roads. The main aim of this work is to investigate the possibility of reuse of recycled aggregates obtained by crushing the old concrete roads as a building material in the new top layers of concrete pavements. The paper is based on gathering the current knowledge about how to use recycled concrete aggregate, suitability, and modification of the properties and its standards. Regulations are detailed and described especially for European Union and for Czech Republic.

Keywords: Concrete, Czech Republic, pavements, recycled concrete aggregate, RCA, standards.

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Authors: Partha P. Gopmandal, S. Bhattacharyya

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We have studied the migration of a charged permeable aggregate in electrolyte under the influence of an axial electric field and pressure gradient. The migration of the positively charged aggregate leads to a deformation of the anionic cloud around it. The hydrodynamics of the aggregate is governed by the interaction of electroosmotic flow in and around the particle, hydrodynamic friction and electric force experienced by the aggregate. We have computed the non-linear Nernest-Planck equations coupled with the Dracy- Brinkman extended Navier-Stokes equations and Poisson equation for electric field through a finite volume method. The permeability of the aggregate enable the counterion penetration. The penetration of counterions depends on the volume charge density of the aggregate and ionic concentration of electrolytes at a fixed field strength. The retardation effect due to the double layer polarization increases the drag force compared to an uncharged aggregate. Increase in migration sped from the electrophretic velocity of the aggregate produces further asymmetry in charge cloud and reduces the electric body force exerted on the particle. The permeability of the particle have relatively little influence on the electric body force when Double layer is relatively thin. The impact of the key parameters of electrokinetics on the hydrodynamics of the aggregate is analyzed.

Keywords: Electrophoresis, Advective flow, Polarization effect, Numerical solution.

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Authors: D. Sarkar, M. Pal, A. K. Sarkar

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Asphaltic concrete for pavement construction in India are produced by using crushed stone, gravels etc. as aggregate. In north-Eastern region of India, there is a scarcity of stone aggregate. Therefore the road engineers are always in search of an optional material as aggregate which can replace the regularly used material. The purpose of this work was to evaluate the utilization of substandard or marginal aggregates in flexible pavement construction. The investigation was undertaken to evaluate the effects of using lower quality aggregates such as over burnt brick aggregate on the preparation of asphalt concrete for flexible pavements. The scope of this work included a review of available literature and existing data, a laboratory evaluation organized to determine the effects of marginal aggregates and potential techniques to upgrade these substandard materials, and a laboratory evaluation of these upgraded marginal aggregate asphalt mixtures. Over burnt brick aggregates are water susceptible and can leads to moisture damage. Moisture damage is the progressive loss of functionality of the material owing to loss of the adhesion bond between the asphalt binder and the aggregate surface. Hence zycosoil as an anti striping additive were evaluated in this study. This study summarizes the results of the laboratory evaluation carried out to investigate the properties of asphalt concrete prepared with zycosoil modified over burnt brick aggregate. Marshall specimen were prepared with stone aggregate, zycosoil modified stone aggregate, over burnt brick aggregate and zycosoil modified over burnt brick aggregate. Results show that addition of zycosoil with stone aggregate increased stability by 6% and addition of zycosoil with over burnt brick aggregate increased stability by 30%.

Keywords: Asphalt Concrete, Over Burnt Brick Aggregate, Marshall Stability, Zycosoil.

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Authors: A. H. Yehia, M. M. Rashwan, K. A. Assaf, K. Abd el Samee

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The aim of this work is to use an environmental, cheap; organic non-traditional admixture to improve the structural behavior of sustainable reinforced concrete beams contains different ratios of recycled concrete aggregate. The used admixture prepared by using wastes from vegetable oil industry. Under and over reinforced concrete beams made from natural aggregate and different ratios of recycled concrete aggregate were tested under static load until failure. Eight beams were tested to investigate the performance and mechanism effect of admixture on improving deformation characteristics, modulus of elasticity and toughness of tested beams. Test results show efficiency of organic admixture on improving flexural behavior of beams contains 20% recycled concrete aggregate more over the other ratios.

Keywords: Deflection, modulus of elasticity, non-traditional admixture, recycled concrete aggregate, strain, toughness, under and over reinforcement.

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Authors: Yeşim Tosun, Remzi Şahin

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This paper presents results of compressive strength, capillary water absorption, and density tests conducted on concrete containing recycled aggregate (RCA) which is obtained from structural waste generated by the construction industry in Turkey. In the experiments, 0%, 15%, 30%, 45% and 60% of the normal (natural) coarse aggregate was replaced by the recycled aggregate. Maximum aggregate particle sizes were selected as 16 mm, 22,4 mm and 31,5 mm; and 0,06%, 0,13% and 0,20% of air-entraining agent (AEA) were used in mixtures. Fly ash and superplasticizer were used as a mineral and chemical admixture, respectively. The same type (CEM I 42.5) and constant dosage of cement were used in the study. Water/cement ratio was kept constant as 0.53 for all mixture. It was concluded that capillary water absorption, compressive strength, and density of concrete decreased with increasing RCA ratio. Increasing in maximum aggregate particle size and amount of AEA also affect the properties of concrete significantly.

Keywords: Capillary water absorption, compressive strength, density, recycled concrete aggregates.

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Authors: Yousef Abu Nahleh, Arun Kumar, Fugen Daver, Reham Al-Hindawi

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Despite the availability of natural disaster related time series data for last 110 years, there is no forecasting tool available to humanitarian relief organizations to determine forecasts for emergency logistics planning. This study develops a forecasting tool based on identifying probability of disaster for each country in the world by using decision tree modeling. Further, the determination of aggregate forecasts leads to efficient pre-disaster planning. Based on the research findings, the relief agencies can optimize the various resources allocation in emergency logistics planning.

Keywords: Decision tree modeling, Forecasting, Humanitarian relief, emergency supply chain.

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Authors: Erika Yamaguchi, Sirawadee Arunyanrt, Shunichi Ohmori, Kazuho Yoshimoto

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In this paper, we suggest a simulation tool to make a decision of monthly production planning for maximizing a profit of Specialty store retailer of Private label Apparel (SPA) firms. Most of SPA firms are fabless and make outsourcing deals for productions with factories of their subcontractors. Every month, SPA firms make a booking for production lines and manpower in the factories. The booking is conducted a few months in advance based on a demand prediction and a monthly production planning at that time. However, the demand prediction is updated month by month, and the monthly production planning would change to meet the latest demand prediction. Then, SPA firms have to change the capacities initially booked within a certain range to suit to the monthly production planning. The booking system is called “capacity-booking”. These days, though it is an issue for SPA firms to make precise monthly production planning, many firms are still conducting the production planning by empirical rules. In addition, it is also a challenge for SPA firms to match their products and factories with considering their demand predictabilities and regulation abilities. In this paper, we suggest a model for considering these two issues. An objective is to maximize a total profit of certain periods, which is sales minus costs of production, inventory, and capacity-booking penalty. To make a better monthly production planning at SPA firms, these points should be considered: demand predictabilities by random trends, previous and next month’s production planning of the target month, and regulation abilities of the capacity-booking. To decide matching products and factories for outsourcing, it is important to consider seasonality, volume, and predictability of each product, production possibility, size, and regulation ability of each factory. SPA firms have to consider these constructions and decide orders with several factories per one product. We modeled these issues as a linear programming. To validate the model, an example of several computational experiments with a SPA firm is presented. We suppose four typical product groups: basic, seasonal (Spring / Summer), seasonal (Fall / Winter), and spot product. As a result of the experiments, a monthly production planning was provided. In the planning, demand predictabilities from random trend are reduced by producing products which are different product types. Moreover, priorities to produce are given to high-margin products. In conclusion, we developed a simulation tool to make a decision of monthly production planning which is useful when the production planning is set every month. We considered the features of capacity-booking, and matching of products and factories which have different features and conditions.

Keywords: Capacity-booking, SPA, monthly production planning, linear programming.

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Authors: Shiva Abdoli, Daniel T. Semere

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Several researches have been conducted to study consumption of energy in cutting process. Most of these researches are focusing to measure the consumption and propose consumption reduction methods. In this work, the relation between the cutting parameters and the consumption is investigated in order to establish a generalized energy consumption model that can be used for process and production planning in real production lines. Using the generalized model, the process planning will be carried out by taking into account the energy as a function of the selected process parameters. Similarly, the generalized model can be used in production planning to select the right operational parameters like batch sizes, routing, buffer size, etc. in a production line. The description and derivation of the model as well as a case study are given in this paper to illustrate the applicability and validity of the model.

Keywords: Process parameters, cutting process, energy efficiency, Material Removal Rate (MRR).

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Authors: Jamshaid ur Rehman, Shahida Wizarat

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The principal focus of this study is on the measurement and analysis of labor learnings in Pakistan. The study at the aggregate economy level focus on the labor productivity movements and at large-scale manufacturing level focus on the cost structure, with isolating the contribution of the learning curve. The analysis of S-shaped curve suggests that learnings are only below one half of aggregate learning curve and other half shows the retardation in learning, hence retardation in productivity movements. The study implies the existence of learning economies in term of cost reduction that is input cost per unit produced decreases by 0.51 percent every time the cumulative production output doubles.

Keywords: Cost, Inflection Point, Learning Curve, Minima, Maxima, and Productivity

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