34431 - Advanced Production Systems M

Learning outcomes

The aim of the course is to provide innovative and advanced topics for the planning and the management of a production system, with particular emphasis on the stock management and distribution. The complete development of a case industry and the introduction of specific software for the analysis and the planning allow to evaluate the application of the above mentioned topics to a real context.

Course contents

INTRODUCTION TO LEAN MANUFACTURING AND LEAN SUPPLY CHAIN*

Lean Manufacturing Systems and Cell Design. The Toyota Production System (TPS). The instruments of lean production; The ten steps of lean production: 1. re-engineer the manufacturing system; 2. setup reduction; 3. integrate the quality control into the system; 4. integrate preventive maintenance; 5. level, balance, sequence, synchronize; 6. production control; 7. reduce WIP; 8. integrated suppliers; 9. autonomation; 10. CIM.

Advanced production systems project

The full development of  a production system project: from the feasibility study to the executive project. Analysis of a case industry:

• Advanced instrument for the group technology. Cellular manufacturing (CM). Clustering for the group technology and the CM. Incidence matrix. Similarity indexes: Jaccard, Simple Matching, etc. Gupta–Seiffodini similarity index. Hierarchic Algorithm for CM: Clink, Slink, UPGMA. The dendogram. Performance indexes for cell formation problem: problem density, inside cells density, etc. numerical examples and applications. Software for cellulare manufacturing;
• leveling production
• resources' project:
• Static computation of productive recourses
• Calculation of the number of operators with and without resources clustering.
• Layout project: the software LRP. Example and Application.
• Flow material analysis and design of internal transportation system planning
• Example and Application.
• Technological plants planning. Example and Application.
• Economical evaluation of production system

The evolution from PUSH to PULL

The five principles of lean manufacturing; implementation of continuos flow line . The VALUE STREAM MAPPING: the guidelines; AS IS state and TO BE state; the takt time, the flow production, the pacemaker, the FIFO lane, the load leveling box: mix and volume leveling, the pitch. Exemple and applications.

 Advanced Logistics Systems: lean supply chain

Strategy for the integrated stock management in the supply chain. The model of joint economic lot model: cost definition. The case of expeditions with constant quantity. The case of the expeditions with variable quantity. Examples. Other forms of collaboration between buyer and vendor (collaborative planning, Supplier Managed Inventory - SMI). The consignment stock model. Examples.

Advanced stock system: the flexible order picking system

Project ad control of Flexible Order Picking Systems (FOPS). The main topics of the order picking. The classification of FOP systems. Allocation strategies: the class based method and the correlation based method. The COI (Cube per Order Index) and the COI curve. Similarity frequency & COI based (SFC) index. Project paramethers; keys of performance in FOPS.

Advanced planning of distribution networks

definition and classification of distribution networks. Long period, middle period and short period decisions. Location Allocation Problem (LAP): definition of the objective and constraints. The model of direct distribution mono product-mono period with fractionated demand or no fractionated demand. The model mono product- mono period, multilevel.

 

Readings/Bibliography

A.PARESCHI, E.FERRARI, A.PERSONA, A.REGATTIERI, “Logistica Integrata e Flessibile”, Ed.Esculapio, 2002;

J.T. BLACK, S.L. HUNTER, “Lean Manufacturing Systems and Cell Design”, SME-Society of Manufacturing Engineers, 2003.

J.P.WOMACK, D.T.JONES, “Lean Thinking. Come creare valore e bandire gli sprechi”, Edizione Guerini e Associati spa, 1997.

J.P.WOMACK, D.T.JONES, D. Roos, “La macchina che ha cambiato il mondo”, Macmillan Publishing Company (USA),  1990.

 

M.ROTHER, J. SHOOK, “Learning to See-value stream mapping to add value and eliminate muda”, The lean enterprise institute, Massachusetts (USA), 1999

R.HARRIS, C.HARRIS, E.WILSON, “Making Materials Flow”, The lean enterprise institute, Massachusetts (USA), 1999

M.ROTHER,, R.HARRIS, “Creating Continuous Flow”, The lean enterprise institute, Massachusetts (USA), 1999

A.SMALLEY, “Creating Level Pull”, The lean enterprise institute, Massachusetts (USA), 1999

J.BICHENO, A. PORTIOLI STAUDACHER, “Metodologie e tecniche per la lean”, Pitagora editrice, Bologna, 2009.

 

R.MANZINI, A. PERSONA, A. REGATTIERI “Framework for designing and controlling a multi-cellular flexible manufacturing system” (2006) International Journal of Services and Operations Management (ISSN: 1744-2370), vol. 2, No. 1, pp. 1-21.

R.MANZINI, M.GAMBERI, A.PERSONA, A. REGATTIERI “Framework for designing a flexible cellular assembly system” (2004) - International Journal of Production Research (ISSN: 0020-7543), vol. 42, No.17, pp. 3505-3528.

 

R.MANZINI, D.BASSO, A.PARESCHI, A.REGATTIERI “La progettazione e il controllo di sistemi flessibili di order-picking (FOPS)”, XXX Convegno Nazionale ANIMP/OICE/UAMI. Ottobre 2003, Rapallo (ISBN: 88-88198-02-04).

R.MANZINI, M.GAMBERI, A.REGATTIERI “Design and control of a flexible order picking system (FOPS): a new integrated approach to the implementation of an expert system” (2005) (in collaborazione con) Special issue on  “Logistics and Supply Chain Management with Artificial Intelligent Techniques” – Journal of Manufacturing Technology Management (ISSN: 1741-038X), vol. 16(1): 18-35.

BINDI F., GAMBERI M., MANZINI R., REGATTIERI A., “Piattaforma software per la progettazione assistita di un impianto di stoccaggio e la scelta dell'allocazione della merce secondo i principi della correlated storage al location”, XXXIV Convegno nazionale ANIMP/OICE/UAMI. Ottobre 2007. Livorno.

BINDI F., MANZINI R., PARESCHI A., REGATTIERI A., “Similarity coefficients and clustering techniques for the correlated assignment problem in warehousing systems”, 19th International Conference on Production Research, Luglio 2007, Valparaiso-Chile.

BINDI F., FERRARI E., MANZINI R., “Progettazione e gestione di un sistema di stoccaggio”, Impiantistica italiana, Anno XX, N.2, marzo-aprile 2007.

MANZINI R., BINDI F. “Come allocare la merce negli impianti di stoccaggio”, Logistica management, Aprile 2007.

 

HILL R.M., “The single-vendor single-buyer integrated production-inventory model with a generalised policy”, European Journal of Operational Research 97 (1997) 493-499.

BRAGLIA M., ZAVANELLA L., “Modelling an industrial strategy for inventory management in supply chains: the ‘Consignment Stock' case”, International Journal of Production Research, 2003, vol. 41, no. 16, 3793–3808.

 

R.MANZINI, A. CASSARINI, A. PARESCHI, A. REGATTIERI “Progettazione e gestione di un network distributivo multilivello”, XXXI Convegno Nazionale ANIMP/OICE/UAMI. 2004, Monastier di Treviso (ISBN: 88-88198-05-9).

MANZINI R., BINDI F., PINI S., “Distribuzione. La rete della ceramica”, Logistica, Settembre 2008.

 

Altri testi di consultazione:

PARESCHI A., “Impianti industriali”, Progetto Leonardo, Soc. Editrice Esculapio, Bologna, 1994.

CHASE R.B., JACOBS F.R., AQUILANO N.J., GRANDO A., SIANESI A., “Operations Management nella Produzione e nei Servizi”, McGraw-Hill, Milano, 2004.

GARETTI M., TAISCH M., “Sistemi di produzione automatizzati”, Ed. C.U.S.L., Milano, 1997.

WARNECKE H.J., STEINHILPER R., “Sistemi flessibili di produzione”, Edizioni Tecniche Nuove, Milano, 1987.

HURRION R.D., “Simulation: applications in manufacturing”, Springer-Verlag, Berlin, 1986.

HARTLEY J., “FMS at work”, IFS (Publications) Ltd., Bedford (UK), 1984.

LAMBERT D., STOCK J., “Strategic Logistics Management”, McGraw-Hill, 2001

BOARIO M., DE MARTINI M., DI MEO E., GROS-PIETRO G.M., “Manuale di Logistica”, UTET, Torino, 1992, Voll. 1-2-3.

GRANDO A., “Logistica e produzione”, UTET, Milano, 1996.

DEL MAR D., “Operations and industrial management”, McGraw-Hill, 1985.

TERSINE R.J., “Production/operations management”, North Holland, New York, 1985.

MORTIMER J., “Logistics in manufacturing”, Ed. IFS Ltd, UK/Springer Verlag, 1988.

FERROZZI C., SHAPIRO R.D., HESKETT J.L., “Logistica e strategia”, 1-2, ISEDI, 1993, Torino.

BOWERSOX D.J., “Logistica, strategia e integrazione in azienda”, Tecniche Nuove,1989, Milano.

TOMPKINS J.A., WHITE J.A., BOZER Y.A., TANCHOCO J.M.A., “Facilities Planning”, John Wiley & Sons, Inc., 2003.

CAVALIERI S., PINTO R., “Orientare al successo la supply chain. Strategie, processi e tecniche per gestire la complessità della rete logistica”, ISEDI, 2007.

 

Teaching methods

theoretical lessons and exercises. Case studies.

Assessment methods

Written exam with four sections: two concern a numerical project, the other two concern theoretical themes.

group project for numerical application

Teaching tools

theoretical lessons and exercises. Software of support to theoretical lessons.

Office hours

See the website of Cristina Mora