This paper investigates the specific planning environment of an automotive part manufacturer and characterizes this environment based on variables regarding the product, its demand and the manufacturing process.The fit of different planning methods, namely material requirements planning, reorder point, cyclic planning, kanban, and heijunka to this specific planning environment is analyzed and evaluated by exploratory research. The results show that different product characteristics make it hard to apply a single planning method. None of the investigated methods show the ability to cover the complex
requirements of a combined planning environment of two partly divergent product types with a deep value chain.
Philipp Spenhoff ? Marco Semini ? Erlend Alfnes ? Jan Ola Strandhagen
. The fit of planning methods for the part manufacturing industry,a case study[J]. Advances in Manufacturing, 2014
, 2(2)
: 165
-172
.
DOI: 10.1007/s40436-014-0075-0
1. Newman WR, Sridharan V (1995) Linking manufacturing planning and control to the manufacturing environment. Integr Manuf Syst 6:36–42
2. Krajewski LJ, King BE, Ritzman LP et al (1987) Kanban, MRP,and shaping the manufacturing environment. Manag Sci 33:39–57
3. Jonsson P, Mattsson SA (2003) The implications of fit between planning environments and manufacturing planning and control methods. Int J Oper Prod Manag 23:872–900
4. Berry WL, Hill T (1992) Linking systems to strategy. Int J Oper Prod Manag 12:3–15
5. Olhager J, Rudberg M (2002) Linking manufacturing strategy decisions on process choice with manufacturing planning and control systems. Int J Prod Res 40:2335–2351
6. Olhager J, Wikner J (2000) Production planning and control tools. Prod Plan Control 11:210–222
7. Jonsson P, Mattsson SA (2002) The selection and application of material planning methods. Prod Plan Control 13:438–450
8. Wiendahl HP, Glaessner J, Petermann D (1992) Application of load-oriented manufacturing control in industry. Prod Plan Control 3:118–129
9. Wiendahl HP (1987) Load oriented production control. Hanser,Munich
10. Riezebos J (1997) On the determination of the period length in a period batch control system. Proc Int Matador Conf, MacMillan Press Ltd. 1997:131–136
11. Raymond L (2005) Integrating kanban with MRPII. Productivity,Portland
12. Porter K, Little D, Peck M, Rollins R (1999) Manufacturing classifications: relationships with production control systems.Integr Manuf Syst 10:189–199
13. Schonsleben P (2000) Varying concepts of planning and control in enterprise logistics. Prod Plan Control 11(1):2–6
14. Yin RK (2009) Case study research: design and methods. SAGE,London
15. Eisenhardt KM (1989) Building theories from case study research. Acad Manag Rev 14(4):532–550
16. Giauque WC, Sawaya WJ (1992) Strategies for production control. Prod Invent Manag J 33(3):36–41
17. Jonsson P (2008) Logistics and supply chain management.McGraw-Hill, Maidenhead
18. Hopp WJ, Spearman ML (2008) Factory physics, 3rd edn.Waveland, Chicago
19. Slack N, Chambers S, Johnston R (2010) Operations management,6th edn. Pearson Education, Harlow
20. Groenevelt H, Johansen J, Lederer PJ (1996) Cyclic planning.University of Rochester, New York
21. Fauske H, Alfnes E, Semini M (2008) Lean supply chain control in hydro automotive structures. In: APMS 2008 conference proceedings
22. Bicheno J, Holweg M (2009) The lean toolbox: the essential guide to lean transformation. PICSIE, Buckingham
23. Cohen MA, Agrawal N, Agrawal V (2006) Winning in the aftermarket. Harv Bus Rev 84(5):129–138
24. Vollmann TE, Berry WL, Whybark DC et al (2011) Manufacturing planning and control for supply chain management, 6th edn. McGrawHill/Irwin, New York
25. Olhager J (2013) Evolution of operations planning and control: from production to supply chains. Int J Prod Res 51(23–24):6836–6843
26. Greasley A (2007) Operations management. SAGE Publications Limited, London
27. Felberbauer T, Altendorfer K, Hubl A (2012) Using a scalable simulation model to evaluate the performance of production system segmentation in a combined MRP and kanban system. In:IEEE simulation conference (WSC), Proceedings of the 2012 Winter, pp 1–12
28. Benton W, Shin H (1998) Manufacturing planning and control: the evolution of MRP and JIT integration. Eur J Oper Res 110:411–440
29. Taal M, Wortmann JC (1997) Integrating MRP and finite capacity planning. Prod Plan Control 8:245–254
30. Tempelmeier H (2013) A multi-level inventory system with a make-to-order supplier. Int J Prod Res 51(23–24):6880–6890
31. Wang CH (2010) Some remarks on an optimal order quantity and reorder point when supply and demand are uncertain. Comput Ind Eng 58:809–813
32. Stevenson WJ (2008) Operations management, 10th edn.McGraw-Hill/Irwin, London
33. Levner E, Kats V, Alcaide Lo´pez de Pablo D et al (2010) Complexity of cyclic scheduli ng problems: a state-of-the-art survey. Comput Ind Eng 59:352–361
34. Powell D, Alfnes E, Semini M (2010) The application of lean production control methods within a process-type industry: the case of hydro automotive structures. Advances in production management systems, new challenges, new approaches. Springer, Berlin, Heidelberg, pp 243–250
35. Karmarkar US, Schrage L (1985) The deterministic dynamic product cycling problem. Oper Res 33:326–345
36. Spenhoff P, Alfnes E, Powell D et al (2012) The application of lean production control methods within a process-type industry:the case of Benteler aluminium systems Norway. In: the 14th international conference on modern information technology in the innovation processes of the industrial enterprises
37. Chee SL, Chong MY, Chin JF (2012) Milk-run kanban system for raw printed circuit board withdrawal to surface-mounted equipment.J Ind Eng Manag 5:382–405
38. Bohnen F, Buhl M, Deuse J (2013) Systematic procedure for leveling of low volume and high mix production. CIRP J Manuf Sci Technol 6(1):53–58
39. Pool A, Wijngaard J, van der Zee DJ (2011) Lean planning in the semi-process industry, a case study. Int J Prod Econ 131:194–203
40. Coleman BJ, Vaghefi MR (1994) Heijunka: a key to the Toyota production system. Prod Invent Manag J 35:31–35
41. Alfnes E, Strandhagen JO (2000) Enterprise design for mass customisation: the control model methodology. Int J Logist 3(2):111–125