IEOR e-Seminar by Dr. Sivasundari
Title of the talk: Production Planning for the Manufacturing Industry by Application of Mathematical Modeling
Speaker: Dr. Sivasundari.
Day, Date and Time: Thursday, April 15, 2021 11:30 am to 12:30 pm.
Thursday, Apr 15, 2021 11:30 am | 1 hour | (UTC+05:30) Chennai, Kolkata, Mumbai, New Delhi
Abstract of the talk:
Integrated production, workforce, and capacity planning are the key factors for the success of any manufacturing industries, achieving the targeted daily production quantity and workforce deployments are also challenging tasks. Production planning is the most effective tool for integrating the above key factors and to overcome the challenges faced in a volatile market, especially in a single-piece flow-based cellular manufacturing large scale engineering industry.
Optimization and Operational research techniques are extensively used to derive better solutions and decisions making techniques to any industrial problems. Based on the research gap and historical data from the case study industry (which is in south-India and it is one of the leading auto-electrical part manufacturers in India), where we have identified several significant problems in production flow.
At this point, we have suggested relevant production planning objectives which were developed and solved using mathematical model; to achieve our major research objectives of developing the production plan for a product flow line with different product families and with multi-periods. And also, we have extended to a generic multi-objective optimization model for multi-stages product flow line. Finally, we have incorporated the above flow values to control any dynamic shop floor situations by using the Decision Support System (DSS).
As a result, to achieve the objectives, three major phases for measurement of production planning performances are discussed as follows. In the first phase, a production plan for product flow line (final product are the alternators) is formulated with the help of Linear Programming (LP) to analyse the production planning at multi-products and multi-periods level; it is known as macro-analysis. For the same, we have collected the data from the case study organization and its policies, which are relevant to macro-analysis. From the analysis, we have arrived at a production plan based on minimum production cost within the available capacities, which are equally distributed throughout the planning horizons.
In the second phase, we have extended the mathematical model with multi-stage (i.e., modules) levels for the entire product flow line; it is known as micro-analysis. The production plan of macro-analysis solutions is considered as the demand for micro-analysis for each product family within the planning period. Thereafter we have incorporated the organization policies as an operating condition for calculating the input variables of machine-hours, labour hours, capacity details and so on. Later we have adopted the Lexicographic approach for sequentially solving the four objective functions, i.e., Setup cost minimization, Production gap minimization, Workforce minimization and Production cost minimization for individual product family.
In addition, Goal programming approach is used, to minimize the four objective functions deviation variables which are considered as a single objective, for individual product family and multi-period wise. In this micro-analysis, we have identified the major decision variables for the detailed production and workforce plan for the entire product flow line based on minimizing the deviational variables.
Finally, in the third phase, we have developed the Decision Support System (DSS) for generically incorporating both macro and micro-analysis solutions to address the dynamic situation; it is called a composite methodology.
Dr. Sivasundari obtained her PhD from Faculty of Mechanical Engineering from College of Engineering Guindy, Anna University Chennai, and her Masters in Industrial Engineering from College Of Engineering Guindy, Anna University, Chennai. She has eight years of work experience in various industries including TVS. She is a recipient of Best Employee Award for Innoviative Change in Production Line and in the area of Time Study and Standard Measurement and a recipient of various Young Manager Awards. She has also published here works in several international journals and conferences.