Study The Multi-Variety And Small Batch Production Planning And Control Based On Theory Of Constraints

Due to changes in the market of seller’s to buyer’s, as well as the continuous improvement of people’s consumption level. Increasing product variety, and their life cycles continue to shorten. multi-variety and small batch production has become a mainstream business, quickly respond to market demand and effective organization of production, preparing production plans and take reasonable and effective control turn into an issue of common concern to the current production enterprises in the implementation process, but also become the key of obtaining a favorable position in the competitively market. Therefore, it’s important that study the multi-variety and small batch production planning&controlling for those companies whose market’s environment has been rapid changed.Material Requirements Planning uses push mode of production, it’s good at improving production efficiency, but as the issues of capacity constraints has been not considered enough, and the lead time may be a question.Therefore, it can not be fit for multi-variety and small batch; just in time production uses pull model, better able to reduce the amount of WIP, increase output, but it’s pursuit the balance of ability, leading to inadequate capacity to use some of the equipment, and requiring the entire system’s environmental being higher steady, such as suppliers delivery in time and other issues in our promotion. Thus, in the face of multi-variety and small batch multi-variety and small batch production environment, how to build a scientific and effective production planning and control system has become hot and difficult which attract common concern, the problem which how to minimize inventory also be a hotspots and to shorten the production cycle, to meet customer demand.Theory of Constraints (Theory of Constraints, TOC) by the Israeli physicist Goldratt in the1980s was putted forward, the idea that a bottleneck which is decide the performance of the system is exit in each system which is insisted by TOC. TOC theory put forward their own ideas, but also introduced a series of effective methods and tools, DBR planning and control method is one of them. DBR planning and control methods both MRP’s and JIT’s advantages, using a combination of push-pull mode of production organization, by focusing on bottlenecks, set the buffer and control feeding methods can effectively reduce the amount of shop-in-progress, increasing throughput, and can better use of equipment capacity, reduce the impact of fluctuations on the system output.In this paper, On the basis of DBR and simplify Drum-Buffer-Rope, Simplify Drum Artificial-constraint Buffer Rope mode has been builded. This mode made last procedure as a system resource constraints, followed by Shipping Buffer, which could improve the on-time delivery rate, increase customer satisfaction. In front of the system resource constraints, Artificial Buffer has been setted, constructed the structure which centered by AB, before push and after pull. On one hand, AB take protection to system constraints, pass information to the final step, and accomplish activities which break up from the system constraint resources,in order to making fully utilized, on the other hand, the "door control system ", that is, when it reaches a certain limit threshold Artificial Buffer prohibited feeding, when the Artificial Buffer below a lower threshold, urging the previous process production methods to achieve effective control in the article. Papers comparative analysis of DBR, S-DBR and S-DABR three modes in the "System Type"," throughput ","constrained resource-limited" and "buffer setting type", it also shows the points which apply the mode. Meanwhile, the traditional S-DBR mode’s buffer occupation ratio could not reflect the actual production of the product shortage in the workshop, so, this paper combining the shortest working time and the remaining slack time scheduling rules to construct a new scheduling rules. The introduction of the actual production schedule variables, which could effectively avoid the "yellow blind".The last part of this paper describe the company A applied the S-DABR which provide valuable references to other enterprises to improve production of management.