Workload balancing capability of pull systems in MTO production

Remco Germs · Jan Riezebos

81 citations0/0 files storedInternational Journal of Production Research

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Abstract

Pull systems focusing on throughput time control and applicable in situations with high variety and customisation are scarce. This paper compares three unit-based pull systems that can cope with such situations: POLCA, CONWIP and m-CONWIP. These systems control the shop floor throughput time of orders by limiting the number of orders on the shop floor. However, their effectiveness in terms of reducing total throughput time is questioned. Theory states that an improvement in the average total throughput time will be due to the workload balancing capability of a pull system, but that many pull systems lack this capability. This paper shows that this workload balancing capability exists for POLCA and m-CONWIP, but not for CONWIP. The magnitude of the effect differs strongly, depending on the configuration of the system, the order arrival pattern and the variability of the processing time of the orders.

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References

1961A Proof for the Queuing Formula: L = λ W 1962International Journal of Production Research 1995Factory Physics : Foundations of Manufacturing Management 1977Toyota production system and Kanban system Materialization of just-in-time and respect-for-human system 1990CONWIP: a pull alternative to kanban 2004To Pull or Not to Pull: What Is the Question?2005A review of production planning and control: the applicability of key concepts to the make-to-order industry 2018Quick Response Manufacturing

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