Research On Constraints Management-based Workload Control In Shop Floor Production

As the result of the fiercer and fiercer competition in the market, consumers'demand for individuality and diversity is increasing, which continuously push manufacturers to speed up the renovation and shrink the cycle time of production. These new features challenge the traditional production model and force it to change from the high volume, repetitive mass production to high-mix and low volume production. However, the existing technology of Lean manufacturing which is designed for high volume and repetitive production has been proven difficult to apply in new production environment. In order to adapt lean production into the new production environment, a new type of workload control manufacturing based on the Theory of Constraint will be introduced in this paper.Flow Manufacturing Production model, which is based on Constraint Management, synthesizes the theory of constrains and the theory of workload control manufacturing, makes a combination of these two theories under a new framework, and takes advantages of their strongpoint. This paper makes an elaborate expatiation on the new model's organization structure and working mechanism. The model intends to build up funnel model based on the theory of Constraints Management, which controls the material input of the whole production system by the load level of bottleneck process and adjusts the load balance of bottleneck process and non-bottleneck process by the processed volume and transport volume of bottleneck process.This paper makes an in-depth study of funnel model, workload control and buffer management in bottleneck , in order to put the workload control which is based on Constraint Management into effect. This paper has built up simulation model with the help of the system software Flexsim, based on the production practice of some textile & dyeing company. The simulation result shows the new model's superiority over other traditional models. On the basis of simulation analysis and demonstration, this paper introduces a corresponding implementary plan, and further applies this working model to the company mentioned above, in order to test the practicability and superiority of this new model by application. At the end, this paper makes a prospect on how to further perfect this model and make systematization come true, after the summarization this paper.