Rights statement: This is the author’s version of a work that was accepted for publication in Journal of Manufacturing Systems. Changes resulting from the publishing process, such as peer review, editing, corrections, structural formatting, and other quality control mechanisms may not be reflected in this document. Changes may have been made to this work since it was submitted for publication. A definitive version was subsequently published in Journal of Manufacturing Systems, 44, Part 1, 2017 DOI: 10.1016/j.jmsy.2017.05.006
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Research output: Contribution to Journal/Magazine › Journal article › peer-review
Research output: Contribution to Journal/Magazine › Journal article › peer-review
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TY - JOUR
T1 - Improving performance in POLCA controlled high variety shops
T2 - an assessment by simulation
AU - Thurer, Matthias
AU - Fernandes, Nuno Octavio
AU - Carmo-Silva, Silvio
AU - Stevenson, Mark
N1 - This is the author’s version of a work that was accepted for publication in Journal of Manufacturing Systems. Changes resulting from the publishing process, such as peer review, editing, corrections, structural formatting, and other quality control mechanisms may not be reflected in this document. Changes may have been made to this work since it was submitted for publication. A definitive version was subsequently published in Journal of Manufacturing Systems, 44, Part 1, 2017 DOI: 10.1016/j.jmsy.2017.05.006
PY - 2017/7
Y1 - 2017/7
N2 - POLCA (i.e. Paired-cell Overlapping Loops of Cards with Authorization) is a card-based production control approach developed to support the adoption of Quick Response Manufacturing. The approach has received significant research attention but has remained largely unchanged since its introduction in the late 1990s. The main improvements have occurred in the context of an electronic POLCA system, but such developments undermine the simplicity of the original card-based concept. We ask: is there any refinement possible to enhance the performance of POLCA without jeopardizing its simplicity? By analyzing POLCA, two possible refinements are identified: (i) the choice of rule to support both the card allocation and dispatching decisions; and (ii) the use of a starvation avoidance mechanism to overcome premature station idleness, as reported in the context of load limiting order release. Using simulation, we demonstrate that performance gains can be obtained by using different rules for card allocation and dispatching other than the earliest release date rule typically applied in POLCA for both decisions. Further, results demonstrate performance improvements for all combinations of card allocation and dispatching rules considered via the addition of a simple starvation avoidance mechanism. Both refinements significantly enhance POLCA performance, potentially furthering its application in practice.
AB - POLCA (i.e. Paired-cell Overlapping Loops of Cards with Authorization) is a card-based production control approach developed to support the adoption of Quick Response Manufacturing. The approach has received significant research attention but has remained largely unchanged since its introduction in the late 1990s. The main improvements have occurred in the context of an electronic POLCA system, but such developments undermine the simplicity of the original card-based concept. We ask: is there any refinement possible to enhance the performance of POLCA without jeopardizing its simplicity? By analyzing POLCA, two possible refinements are identified: (i) the choice of rule to support both the card allocation and dispatching decisions; and (ii) the use of a starvation avoidance mechanism to overcome premature station idleness, as reported in the context of load limiting order release. Using simulation, we demonstrate that performance gains can be obtained by using different rules for card allocation and dispatching other than the earliest release date rule typically applied in POLCA for both decisions. Further, results demonstrate performance improvements for all combinations of card allocation and dispatching rules considered via the addition of a simple starvation avoidance mechanism. Both refinements significantly enhance POLCA performance, potentially furthering its application in practice.
KW - Job Shop
KW - Order Release
KW - Dispatching
KW - Operations Management
KW - Discrete Event Simulation
M3 - Journal article
VL - 44
SP - 143
EP - 153
JO - Journal of Manufacturing Systems
JF - Journal of Manufacturing Systems
IS - Part 1
ER -