Focuses on the quantitative approaches necessary to computer-integrated manufacturing systems, and integrates major topics covering all phases of the production control cycle: production information processing and flow, production planning, forecasting, material requirements planning and monetary control, and scheduling. This new edition features a compendium set of 11 user-friendly computer programs for the IBM PC that enhance the teaching power of the text, allowing readers to solve real-life problems. Among programs included are growth forecasting, aggregate planning, material requirements planning, lot sizing and inventory control, and limited-resource scheduling. The chapters on scheduling give particularly thorough coverage on this difficult subject. Solutions are clearly presented, with many examples and exercises included in the text.

David D. Bedworth and James E. Bailey are the authors of Integrated Production, Control Systems: Management, Analysis, and Design, 2nd Edition, published by Wiley.

The Role of Production Control

1

(17)

Production Control as an Organizational Activity

2

(1)

Production Control as a System

3

(3)

Systems Planning and Analysis

6

(1)

Case Study

7

(6)

Text Computer Programs

13

(3)

Flow of the Text

16

(2)

Production Control Information Flow

18

(41)

Introduction

19

(1)

The Production Control Information System

20

(6)

Real-Time Computerized Production Control

26

(11)

Shop Floor Hardware for Information Processing

37

(6)

CAD/CAM and Production Control

43

(11)

Integrated Production Control Information System

54

(2)

References

56

(1)

Exercises

57

(2)

Forecasting

59

(62)

General Considerations

61

(2)

Definitions

63

(1)

Qualitative Forecasting

64

(2)

Time-Series Prediction Using Regression

66

(15)

Growth Analysis by Exponential Smoothing

81

(11)

Seasonal Forecasting

92

(5)

Cyclic Forecasting

97

(2)

Forecast Error Analysis

99

(2)

The Box-Jenkins Approach

101

(3)

Case Problem

104

(7)

References

111

(1)

Exercises

111

(10)

Aggregate Planning and Master Scheduling

121

(40)

Overview

121

(4)

Definitions

125

(2)

Graphical/Tableau Approach to Aggregate Planning

127

(5)

Empirical Approach to Aggregate Planning

132

(5)

Optimization Approaches to Aggregate Planning

137

(5)

Parametric Approach to Production Planning

142

(4)

Disaggregation to a Master Schedule

146

(10)

Conclusions

156

(1)

References

156

(1)

Exercises

157

(4)

Materials Requirement Planning

161

(32)

Overview

161

(2)

Definitions

163

(1)

How MRP Works

164

(4)

Determining Materials Requirements

168

(5)

Manufacturing Resource Planning (MRP-II)

173

(3)

Just-in-Time (JIT)

176

(3)

KANBAN

179

(1)

Case Example

180

(6)

References

186

(1)

Exercises

187

(6)

Inventory Analysis and Control

193

(52)

Introductory Comments

193

(6)

Definitions

199

(1)

ABC Inventory System

200

(3)

EOQ Models for Purchased Parts

203

(7)

Inventory Order Policies

210

(1)

EMQ Models for Manufactured Parts

211

(5)

Fallacies and Realities for EOQ and EMQ

216

(4)

Additional Lot Sizing Techniques

220

(5)

Inventory Models Under Uncertainty

225

(5)

Case Problem

230

(9)

References

239

(1)

Exercises

239

(6)

Sequencing and Scheduling

245

(49)

Overview

247

(2)

Definitions

249

(1)

The Job Shop Scheduling Process

250

(3)

Scheduling n Tasks on ONE Processor

253

(14)

Sequencing n Tasks on m Processor

267

(16)

Case Study

283

(6)

References

289

(1)

Exercises

289

(5)

Project Planning

294

(49)

Evolution of Network Planning Techniques

295

(3)

Definitions

298

(1)

Critical Path Method (CPM)

299

(10)

Project Evaluation and Review Technique (PERT)

309

(7)

Network Stochastic Considerations

316

(4)

Project Monitoring: Line-of-Balance

320

(5)

Case Problem---CPM/LOB

325

(7)

References

332

(1)

Exercises

333

(10)

Scheduling with Resource Constraints

343

(44)

Definitions

345

(1)

Allocation of Units for a Single Resource

346

(11)

Allocation of Multiple Resources

357

(2)

Resource Balancing

359

(1)

The Line-Balancing Problem

360

(4)

The Helgeson-Birnie Approach

364

(6)

Region Approach

370

(4)

Stochastic Mixed-Product Line Balancing

374

(5)

Computer Programs for Limited Resource Allocation

379

(3)

References

382

(1)

Exercises

383

(4)

Personnel Scheduling

387

(82)

Introduction

388

(1)

Definitions

389

(1)

Shift Scheduling

390

(13)

Scheduling to Variations Within Each Shift

403

(5)

Alternative Work Patterns

408

(4)

Case Study

412

(6)

References

418

(1)

Exercises

419

(2)

APPENDICES

A Areas Under the Normal Curve

421

(3)

B Documentation for Computer Programs

424

(45)

B1 FOR.BAS Growth Forecasting

424

(4)

B2 SES.BAS Seasonal Forecasting

428

(4)

B3 AGP.BAS Aggregate Planning

432

(6)

B4 DIS.BAS Disaggregation

438

(2)

B5 MRP.BAS Material Requirements Planning

440

(4)

B6 EOQ.BAS Inventory Control (EOQ and EMQ)

444

(7)

B7 SEQ.BAS Job-Shop Sequence Scheduling

451

(4)

B8 CPM.BAS Critical Path Analysis

455

(2)

B9 LOB.BAS Line-of-Balance

457

(4)

B10 RES.BAS Limited Resource Scheduling

461

(4)

B11 LNB.BAS Line Balancing

465

(4)

Index

469

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Integrated Production, Control Systems Management, Analysis, and Design

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