SIE 462 - Production Systems Analysis

SIE 462 - Production Systems Analysis (3) Production systems, quantitative methods for forecasting, aggregate planning, inventory control, materials requirements planning, production scheduling, manpower planning and facility design. 3ES. P, 340.

Askin, Ronald G., Production Systems Analysis, text in progress, 1997.

Goldratt, Eliyahu and Jeff Cox, The Goal, 1994.

Nahmias, Steven, Production and Operations Analysis, 1989.

Harmon and Peterson, Reinventing the Factory, The Free Press, New York, 1990.

Monden, Toyota Production System, Ind. Engr. & Mgmt. Press, 1983.

Elsayed & Boucher, Analysis and Control of Production Systems, Prentice-Hall, 1985.

Schonberger, Operations Management, Business Publications, 1985.

Silver and Peterson, Decision Systems for Inventory Management and Production Planning, John Wiley & Sons, 1985.

Vollmann, Berry, Whybark, Manufacturing Planning and Control Systems, Irwin, 1988.

Ronald G. Askin, Professor of Systems & Industrial Engineering

1. Probability distributions (normal, poisson, binomial, exponential)
2. Statistics for estimating population parameters and building linear models
3. Formulation of linear programming models
4. Structure of solutions of linear programming models
5. Economic interpretation of duality

Announcing prerequisites in first class. Review of material with statement of expected level of background understanding and verbal quizzing of students during review. Checking of student transcripts.

To convey the essential decisions, systems, and models of production planning and control.

1. Understand the hierarchy of production planning and control decisions from long term planning to real-time batch control.
2. Ability to select an appropriate production control scheme for a specific manufacturing environment.
3. Understand the interaction between marketing, purchasing, engineering design, manufacturing, and production control.
4. Ability to analyze performance of a production plan - cost and time.
5. Ability to specify optimal parameter values for various production control systems.
6. Understanding of aggregate planning models including ability to formulate objective functions, resource constraints, and inventory balances.
7. Ability to create a Master Production Schedule.
8. Ability to create a feasible material plan for an MPS including understanding of MRP explosion and inventory allocation.
9. Understanding of capacity requirements planning and plan revision to obtain feasibility, including planned order firming.
10. Understanding of impact of setup time and reduction strategies.
11. Ability to plan production and orders in a stochastic environment.
12. Knowledge of basic scheduling rules and their properties.

1. Basics of Production Systems and Relation to the firm (2 hours)
2. Basic Laws of Production Systems (2)
3. Forecasting (6)
4. Aggregate Planning and Dissagregation (6)
5. EOQ/Reorder Point Inventory Models - Extensions: Constraints, Lead Time Minimization, Price Breaks, Stochastic and Dynamic Demand (8)
6. Kanban Control and Just-in-Time Systems (5)
7. CONWIP (1)
8. Material Requirements Planning (MRP) (4)
9. Manufacturing Resources Planning (MRP II) (4)
10. Scheduling - Single Machine, Flow Shop, Job Shop (6)
11. Theory of Constraints (1)

Class Requirements:

1. Two 75 minute lectures per week.
2. Homework set every other week (approximately).
3. Two in-class exams and a final exam.

1. Students are expected to use spread sheets for some homework problems.
2. Students also may use LP package of their choice to solve an aggregate planning problem.

One optional class project in lieu of an examination. Requires design of an inventory control system for a local charitable organization.

1. Two exams
2. Biweekly homework
3. Final exam

Contribution to program objectives: Goals 1, 2, 4

Prepared by: Ronald G. Askin   Date: November 18, 1997