Use of workload control in production planning and control: modeling on a simulation software

Barreto, Bruno da Silva; Sagawa, Juliana Keiko; Silva, Mateus Scalet

doi:10.1590/1806-9649-2021v28e5744

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ORIGINAL ARTICLE • Gest. Prod. 28 (2) • 2021 • https://doi.org/10.1590/1806-9649-2021v28e5744 copy https://doi.org/10.1590/1806-9649-2021v28e5744 copy

Use of workload control in production planning and control: modeling on a simulation software

Disseminando o uso do controle de carga no planejamento e controle da produção: modelagem utilizando software de simulação

Authorship SCIMAGO INSTITUTIONS RANKINGS

Abstract:

This paper aims at presenting a structure of implementation of the Workload Control (WLC) approach on a commercial discrete event simulation software by comprehensively demonstrating how to construct and simulate this approach. This research was developed considering the lack of studies fully describing this implementation on this kind of software, which hinders the dissemination and use of the WLC approach by managers. Initially, the logic was developed on a dedicated and structured language and then converted to the simulation software. A detailed description of the WLC implementation contributes to the business domain by facilitating its replication and application in other manufacturing environments, reducing the project time needed to develop the base model and allowing managers and/or researchers to focus directly on the adjustments of the model to the environment being modeled. In the academic domain, this paper addresses a gap in the WLC literature concerning the lack of tutorials for simulation and the lack of information, in the existing papers, regarding the development of the computational model.

Keywords:
Workload control; Simulation; Software; Tutorial; Job shop; Make-to-order

Modules/ submodules	Objects	Attributes/ tabs of the objects	Implemented routines/commands	Line of the algorithm of periodic release of the WLC classified as Method B (Land, 2006Land, M. (2006). Parameters and sensitivity in workload control. International Journal of Production Economics, 104(2), 625-638. http://dx.doi.org/10.1016/j.ijpe.2005.03.001. http://dx.doi.org/10.1016/j.ijpe.2005.03... )
Order creation	Generator of entities (Source “Chegada”)	Tab Source	Definition of the arrival date	$A_{j}$
		Tab Triggers, On Creation, Set label + customized code	Creation of labels, definition of the number of operations, production routing, processing time, and due dates	$S_{j}$
				$p_{j s}$
				$δ_{j}$
		Tab Triggers, On Creation, customized code	Calculation of the planned lead time, calculation of the planned release date	$T_{s}^{* D} = \sum_{s \in S_{j}}^{} p_{j s}$
		Tab Triggers, On Creation, customized code		$t_{j}^{* R} = A_{j} + T_{s}^{* D}$
Periodic opening of the pool	Source TIC	Tab Trigger, Event: OnExit	Counter of time of 5 units (seconds)	$T$
	Source TIC	Tab Trigger, Event: OnExit	Verification the pool exit (open or closed)	$T$
	Item Cylinder		Transitory item from Source TIC to Sink TAC
Order release	Job pool/queue of orders (Queue)	Tab Triggers – On entry – Sort by Expression	Ascending ordination (Ascending, available on the software)	1. Ordination of the tasks based on the planned release date: $t_{j}^{* R} = δ_{j} - \sum_{s \in S j}^{} T_{s}^{* D}$
		Tab Flow, Send to Port, customized code	Verification of the workloads in the Table of Workloads (table “Cargas”).	Reading of $L_{s t}^{A}$ ; Assess the projected workload in relation to the norm: $L_{s t}^{A} + p_{j s} \leq Λ_{s}^{A} \forall s \in S_{j}$
		Tab Flow, Send to Port, customized code	Assessing whether the processing time of the order to be released, added to the machine workload, exceeds the norm. In case it does not exceed the norm, it adds to the existing workload and directs to the shop floor. In case it exceeds the norm, it directs to the queue reentry.
	Reentry of non-released orders, Processor1	Tab Processor, Process time	Generating a waiting period to guarantee that the release/pool exit is closed, allowing that the non-released orders return later to the pool.
Order execution	Queue before each machine “Fila Est i” (Queue)	Tab Trigger, On Entry	Reading of processing time and updating the workload of the shop floor in function of the released orders	$L_{s t}^{A} = L_{s t}^{A} + p_{j s} \forall s \in S_{j}$
	Machines (Processor)	Tab Process, on Process time	Execution of the corresponding operation	Operation with processing time $p_{j s}$
		Tab Trigger, Event On Entry	Counter of processed objects per machine
		Tab Trigger, Event On Exit	Update of the existing workload (in each machine), subtracting the processing time of the order already processed.	$L_{s t}^{A} = L_{s t}^{A} - p_{j s}^{+} \forall s \in S_{j}$
	Sink Exit	Tab Triggers, Event On Entry	Registration of the moment at which the order exists the system	$T'_{j} = D_{j} - A_{j}$
	Sink Exit	Tab Triggers, Event On Entry	Calculation of the total throughput time and shop floor throughput time.	$T'_{j} = D_{j} - A_{j}$
Collection of indicators	Sink Exit	Tab Triggers, Event On Entry	Readings of total throughput time and of the processing/waiting time on each entity, on the Source and on the pool.	$\hat{w} (n) = \sum_{}^{} W_{j}$

Universidade Federal de São Carlos Departamento de Engenharia de Produção , Caixa Postal 676 , 13.565-905 São Carlos SP Brazil, Tel.: +55 16 3351 8471 - São Carlos - SP - Brazil
E-mail: gp@dep.ufscar.br

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[1] Source: adapted from Land (2006)Land, M. (2006). Parameters and sensitivity in workload control. International Journal of Production Economics, 104(2), 625-638. http://dx.doi.org/10.1016/j.ijpe.2005.03.001.
http://dx.doi.org/10.1016/j.ijpe.2005.03... .

Shop	Six stations, each with unique capacity
Routing length	Uniform discrete distribution of [1.6]
Sequence of stations in the routing	Randomly chosen, no re-entrant loops
Inter-arrival times	Exponential distribution (average: 0.648 time unit)
Due dates	Uniform distribution with values between 35 and 60 units of time
Operation processing times	2-Erlang distribution (average: 1 time unit)
Priority dispatching rule	First come, first served - FCFS