A Study on the Selection between Push and Pull Production Systems When Delivery Date Is Postponed Due to Customer Request
The manufacturer of construction materials, which is the subject of this study, plans production and produces the materials based on the required delivery date after it receives an order from a construction company (customer). However, the progress of a construction project may be delayed due to bad...
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| Published in | Journal of Japan Industrial Management Association Vol. 73; no. 2; pp. 43 - 53 |
|---|---|
| Main Author | |
| Format | Journal Article |
| Language | Japanese |
| Published |
Japan Industrial Management Association
15.07.2022
公益社団法人 日本経営工学会 |
| Subjects | |
| Online Access | Get full text |
| ISSN | 1342-2618 2187-9079 |
| DOI | 10.11221/jima.73.43 |
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| Abstract | The manufacturer of construction materials, which is the subject of this study, plans production and produces the materials based on the required delivery date after it receives an order from a construction company (customer). However, the progress of a construction project may be delayed due to bad weather, shortage of personnel, etc., and the construction company may request the manufacturer to postpone the delivery date of the order. The manufacturer of construction materials has no choice but to accept this request, which causes the material manufacturers to store the inventory of finished products from the day production finished to the postponed delivery date, resulting in an increase in storage costs. In order to solve this problem, this study examines the introduction of a Pull production system that is different from the current production system (Push production system). In this study, the author analytically calculated a mathematical formula (decision formula) to determine which type of production system is capable of reducing inventory more easily and numerically verified it. In addition, the relationship between the factors that affect the choice of production system (postponed delivery term, demand distribution, production lead time, production cycle time, and safety coefficient) was clarified using the proposed formula in this study. Furthermore, the author compared his formula with the results of numerical simulations conducted in existing studies. Using the formula proposed in this study, it is possible to easily calculate which production system is capable of reducing the expected value of inventory simply applying a spreadsheet software commonly used in business practice. |
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| AbstractList | The manufacturer of construction materials, which is the subject of this study, plans production and produces the materials based on the required delivery date after it receives an order from a construction company (customer). However, the progress of a construction project may be delayed due to bad weather, shortage of personnel, etc., and the construction company may request the manufacturer to postpone the delivery date of the order. The manufacturer of construction materials has no choice but to accept this request, which causes the material manufacturers to store the inventory of finished products from the day production finished to the postponed delivery date, resulting in an increase in storage costs. In order to solve this problem, this study examines the introduction of a Pull production system that is different from the current production system (Push production system). In this study, the author analytically calculated a mathematical formula (decision formula) to determine which type of production system is capable of reducing inventory more easily and numerically verified it. In addition, the relationship between the factors that affect the choice of production system (postponed delivery term, demand distribution, production lead time, production cycle time, and safety coefficient) was clarified using the proposed formula in this study. Furthermore, the author compared his formula with the results of numerical simulations conducted in existing studies. Using the formula proposed in this study, it is possible to easily calculate which production system is capable of reducing the expected value of inventory simply applying a spreadsheet software commonly used in business practice.
本研究が対象とする建設資材の製造業者は，顧客である建設業者から受注した時点で要求される納期に基づき生産を計画し，実行している．ただし，建設作業の進捗は，当初の計画に対して，悪天候や人員の不足等の影響によって，遅れてしまうことがあり，建設業者は，建設資材の製造業者に対して，発注した時点の納期を延期して欲しいと要求することがある．建設資材の製造業者は，この要求を受け入れざるを得ないのが現状であることから，生産を完了してから延期後の納期迄の間，製造業者は完成品の在庫を保管することとなり，保管費用が増加するという問題が発生している．本研究では，この問題の解決のために，現状の生産方式（Push生産方式）とは異なる生産方式（Pull生産方式）の導入を検討する．検討にあたり，Push生産方式とPull生産方式とでは，どちらの方が在庫数の期待値を低減できるのかを判定するための数式（判定式）を解析的に導出し，数値検証を行った．また，本研究で示した判定式によって，生産方式の選択に影響を与える各要因（納期延期期間，需要分布，生産リードタイム，生産サイクルタイム，安全係数）間の関係性を明確にした．更に，本研究の判定式と既存研究で行われた数値シミュレーションによって示されている結果とを比較し，考察を行った．判定式によって，実務で一般的に使用されている表計算ソフトを用いるだけで，どちらの生産方式の方が在庫数の期待値を低減できるのか容易に算出できるようになった点は，事例研究として貢献できた点である． The manufacturer of construction materials, which is the subject of this study, plans production and produces the materials based on the required delivery date after it receives an order from a construction company (customer). However, the progress of a construction project may be delayed due to bad weather, shortage of personnel, etc., and the construction company may request the manufacturer to postpone the delivery date of the order. The manufacturer of construction materials has no choice but to accept this request, which causes the material manufacturers to store the inventory of finished products from the day production finished to the postponed delivery date, resulting in an increase in storage costs. In order to solve this problem, this study examines the introduction of a Pull production system that is different from the current production system (Push production system). In this study, the author analytically calculated a mathematical formula (decision formula) to determine which type of production system is capable of reducing inventory more easily and numerically verified it. In addition, the relationship between the factors that affect the choice of production system (postponed delivery term, demand distribution, production lead time, production cycle time, and safety coefficient) was clarified using the proposed formula in this study. Furthermore, the author compared his formula with the results of numerical simulations conducted in existing studies. Using the formula proposed in this study, it is possible to easily calculate which production system is capable of reducing the expected value of inventory simply applying a spreadsheet software commonly used in business practice. |
| Author | NAKATSUKA, Akihiro |
| Author_FL | 中塚 昭宏 |
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| References | [20] 圓川隆夫, 伊藤謙治:「生産マネジメントの手法」, 朝倉書店 (1996) (ISBN-13：978-4254126136) [9] Wang, D. and Xu, C.-G.: “Hybrid push/pull production control strategy simulation and its applications”, Production Planning & Control, Vol. 8, No. 2, pp. 142-151 (1997) https://doi.org/10.1080/095372897235406 [21] Little, J. D. C.: “A proof for the queuing formula: L = λW ”, Operations Research, Vol. 9, No. 3, pp. 383-387 (1961) https://doi.org/10.1287/opre.9.3.383 [5] 村松林太郎:「新版 生産管理の基礎」, 国元書房 (1979) (ISBN-13：978-4765815031) [4] 和田雅宏:「インダストリアルエンジニアリングの最前線 最新テクノロジーを活用した生産効率の向上」，日科技連出版社 (2020) (ISBN-13：978-4817196965) [18] Geraghty, J. and Heavey, C.: “A comparison of hybrid push/pull and CONWIP/pull production inventory control policies”, International Journal of Production Economics, Vol. 91, No. 1, pp. 75-90 (2004) https://doi.org/10.1016/S0925-5273(03)00210-X [15] Spearman, M. L. and Zazanis, M. A.: “Push and pull production systems: Issues and comparisons”, Operations Research, Vol. 40, No. 3, pp. 521-532 (1992) https://doi.org/10.1287/opre.40.3.521 [14] Spearman, M. L. and Woodruff, D. L. and Hopp, W. J: “CONWIP: A pull alternative to kanban”, International Journal of Production Research, Vol. 28, No. 5, pp. 879-894 (1990) https://doi.org/10.1080/00207549008942761 [2] 和田雅宏, 曹 徳弼, 圓川隆夫: “発注納期より確定納期が遅れる取引のpush/pull型生産在庫”, 日本経営工学会論文誌, Vol. 50, No. 3, pp. 184-190 (1999) https://doi.org/10.11221/jima.50.184 [6] Hodgson, T. J. and Wang, D.: “Optimal hybrid push/pull control strategies for a parallel multistage system: part I”, International Journal of Production Economics, Vol. 29, No. 6, pp. 1279-1287 (1991) https://doi.org/10.1080/00207549108930133 [8] Pandey, P. C. and Khokhajaikiat, P.: “Performance modeling of multistage production systems operating under hybrid push/pull control”, International Journal of Production Economics, Vol. 43, No. 2-3, pp. 115-126 (1996) https://doi.org/10.1016/0925-5273(96)00037-0 [7] Hodgson, T. J. and Wang, D.: “Optimal hybrid push/pull control strategies for a parallel multistage system: part II”, International Journal of Production Economics , Vol. 29, No. 7, pp. 1453-1460 (1991) https://doi.org/10.1080/00207549108948022 [22] Silver, E. A., Pyke, D. F. and Peterson, R.: Inventory Management and Production Planning and Scheduling, 3rd edition, Wiley (1998) (ISBN-13 : 978-0471119470) [24] 宮川雅巳:「統計技法」, 共立出版 (1998) (ISBN-13：978-4320016132) [19] 徳山博于, 曹 徳弼, 熊本和浩:「生産マネジメント」, 朝倉書店 (2002) (ISBN-13：978-4254275377) [11] 加藤宏幸, 後藤正幸, 俵 信彦: “発注サイクル期間の異なるPush型生産システムとPull型生産システムの発注量・在庫量変動に基づく特性解析”, 日本経営工学会論文誌, Vol. 49, No. 3, pp. 127-134 (1998) https://doi.org/10.11221/jima.49.127 [25] 国沢清典:「確率統計演習1確率」, 培風館 (1966) (ISBN-13：978-4563008093) [10] 和田雅宏: “生産組み合わせ制約のある多品種変量受注生産方式の設計”, 経営システム, Vol. 3, No. 4, pp. 233-242 (1994) [23] 篠崎信雄:「統計解析入門」, サイエンス社 (1994) (ISBN-13：978-4781907413) [3] Cao, D.-B., Yin, Y. and Kaku, I.: “A criterion of production model selection for building material with delivery delay”, International Journal of Production Research, Vol. 48, No. 12, pp. 3429-3443 (2010) https://doi.org/10.1080/00207540802651931 [13] Hopp, W. J. and Spearman, M. L.: Factory Physics, 3rd edition, McGraw-Hill Higher Education (2007) (ISBN-13 : 978-1577667391) [16] Hopp, W. J. and Spearman, M. L.: “To pull or not to pull: What is the question?”, Manufacturing & Service Operations Management, Vol. 6, No. 2, pp. 133-148 (2004) https://doi.org/10.1287/msom.1030.0028 [12] Cochran, J. K. and Kaylani, H. A.:“Optimal design of a hybrid push/pull serial manufacturing system with multiple part types”, International Journal of Production Research., Vol. 46, No. 4, pp. 949-965 (2008) https://doi.org/10.1080/00207540600905547 [1] 曹 徳弼, 和田雅宏, 圓川隆夫: “納期延期を伴う需要の生産方式の選択問題”, 日本経営工学会論文誌, Vol. 50, No. 1, pp. 41-48 (1999) https://doi.org/10.11221/jima.50.41 [17] Bonvik, A. M., Couch, C. E. and Gershwin, S. B.: “A comparison of production-line control mechanisms”, International Journal of Production Research, Vol. 35, No. 3, pp. 789-804 (1997) https://doi.org/10.1080/002075497195713 |
| References_xml | – reference: [8] Pandey, P. C. and Khokhajaikiat, P.: “Performance modeling of multistage production systems operating under hybrid push/pull control”, International Journal of Production Economics, Vol. 43, No. 2-3, pp. 115-126 (1996) https://doi.org/10.1016/0925-5273(96)00037-0 – reference: [21] Little, J. D. C.: “A proof for the queuing formula: L = λW ”, Operations Research, Vol. 9, No. 3, pp. 383-387 (1961) https://doi.org/10.1287/opre.9.3.383 – reference: [12] Cochran, J. K. and Kaylani, H. A.:“Optimal design of a hybrid push/pull serial manufacturing system with multiple part types”, International Journal of Production Research., Vol. 46, No. 4, pp. 949-965 (2008) https://doi.org/10.1080/00207540600905547 – reference: [5] 村松林太郎:「新版 生産管理の基礎」, 国元書房 (1979) (ISBN-13：978-4765815031) – reference: [13] Hopp, W. J. and Spearman, M. L.: Factory Physics, 3rd edition, McGraw-Hill Higher Education (2007) (ISBN-13 : 978-1577667391) – reference: [16] Hopp, W. J. and Spearman, M. L.: “To pull or not to pull: What is the question?”, Manufacturing & Service Operations Management, Vol. 6, No. 2, pp. 133-148 (2004) https://doi.org/10.1287/msom.1030.0028 – reference: [2] 和田雅宏, 曹 徳弼, 圓川隆夫: “発注納期より確定納期が遅れる取引のpush/pull型生産在庫”, 日本経営工学会論文誌, Vol. 50, No. 3, pp. 184-190 (1999) https://doi.org/10.11221/jima.50.184 – reference: [20] 圓川隆夫, 伊藤謙治:「生産マネジメントの手法」, 朝倉書店 (1996) (ISBN-13：978-4254126136) – reference: [7] Hodgson, T. J. and Wang, D.: “Optimal hybrid push/pull control strategies for a parallel multistage system: part II”, International Journal of Production Economics , Vol. 29, No. 7, pp. 1453-1460 (1991) https://doi.org/10.1080/00207549108948022 – reference: [23] 篠崎信雄:「統計解析入門」, サイエンス社 (1994) (ISBN-13：978-4781907413) – reference: [25] 国沢清典:「確率統計演習1確率」, 培風館 (1966) (ISBN-13：978-4563008093) – reference: [1] 曹 徳弼, 和田雅宏, 圓川隆夫: “納期延期を伴う需要の生産方式の選択問題”, 日本経営工学会論文誌, Vol. 50, No. 1, pp. 41-48 (1999) https://doi.org/10.11221/jima.50.41 – reference: [24] 宮川雅巳:「統計技法」, 共立出版 (1998) (ISBN-13：978-4320016132) – reference: [17] Bonvik, A. M., Couch, C. E. and Gershwin, S. B.: “A comparison of production-line control mechanisms”, International Journal of Production Research, Vol. 35, No. 3, pp. 789-804 (1997) https://doi.org/10.1080/002075497195713 – reference: [14] Spearman, M. L. and Woodruff, D. L. and Hopp, W. J: “CONWIP: A pull alternative to kanban”, International Journal of Production Research, Vol. 28, No. 5, pp. 879-894 (1990) https://doi.org/10.1080/00207549008942761 – reference: [19] 徳山博于, 曹 徳弼, 熊本和浩:「生産マネジメント」, 朝倉書店 (2002) (ISBN-13：978-4254275377) – reference: [3] Cao, D.-B., Yin, Y. and Kaku, I.: “A criterion of production model selection for building material with delivery delay”, International Journal of Production Research, Vol. 48, No. 12, pp. 3429-3443 (2010) https://doi.org/10.1080/00207540802651931 – reference: [18] Geraghty, J. and Heavey, C.: “A comparison of hybrid push/pull and CONWIP/pull production inventory control policies”, International Journal of Production Economics, Vol. 91, No. 1, pp. 75-90 (2004) https://doi.org/10.1016/S0925-5273(03)00210-X – reference: [9] Wang, D. and Xu, C.-G.: “Hybrid push/pull production control strategy simulation and its applications”, Production Planning & Control, Vol. 8, No. 2, pp. 142-151 (1997) https://doi.org/10.1080/095372897235406 – reference: [10] 和田雅宏: “生産組み合わせ制約のある多品種変量受注生産方式の設計”, 経営システム, Vol. 3, No. 4, pp. 233-242 (1994) – reference: [22] Silver, E. A., Pyke, D. F. and Peterson, R.: Inventory Management and Production Planning and Scheduling, 3rd edition, Wiley (1998) (ISBN-13 : 978-0471119470) – reference: [11] 加藤宏幸, 後藤正幸, 俵 信彦: “発注サイクル期間の異なるPush型生産システムとPull型生産システムの発注量・在庫量変動に基づく特性解析”, 日本経営工学会論文誌, Vol. 49, No. 3, pp. 127-134 (1998) https://doi.org/10.11221/jima.49.127 – reference: [15] Spearman, M. L. and Zazanis, M. A.: “Push and pull production systems: Issues and comparisons”, Operations Research, Vol. 40, No. 3, pp. 521-532 (1992) https://doi.org/10.1287/opre.40.3.521 – reference: [4] 和田雅宏:「インダストリアルエンジニアリングの最前線 最新テクノロジーを活用した生産効率の向上」，日科技連出版社 (2020) (ISBN-13：978-4817196965) – reference: [6] Hodgson, T. J. and Wang, D.: “Optimal hybrid push/pull control strategies for a parallel multistage system: part I”, International Journal of Production Economics, Vol. 29, No. 6, pp. 1279-1287 (1991) https://doi.org/10.1080/00207549108930133 |
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| SubjectTerms | delivery delay based on requests from customers inventory little's formula production management pull production system Pull生産方式 push production system Push生産方式 selection of production system リトルの公式 在庫 生産方式の選択 生産管理 顧客要求による納期延期 |
| Title | A Study on the Selection between Push and Pull Production Systems When Delivery Date Is Postponed Due to Customer Request |
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