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Job shop control: In search of the key to delivery improvements

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  • Land, Martin J.
  • Stevenson, Mark
  • Thürer, Matthias
  • Gaalman, Gerard J.C.

Abstract

The last major performance breakthroughs in job shop control stem from the 1980s and 1990s. We generate a new search direction for designing job shop control policies, providing a key to delivery improvements. Based on a common characteristic shared by the most effective job shop control policies, we posit that control should have a specific focus during high load periods. A probability analysis reveals that substantial periods of high load are common, and even occur under assumptions of stationarity and moderate utilization. Subsequent simulations show nearly all tardy deliveries can be attributed to high load periods; and that the success of the best control policies can be explained by their ability to switch focus specifically during these periods, from reducing the dispersion of lateness to speeding up the average throughput time. Building on this, we demonstrate that for example small capacity adjustments targeted at handling high load periods can improve the percentage tardy and other delivery-related performance measures to a much greater extent than the best existing policies. Sensitivity analysis confirms the robustness of this approach and identifies a performance frontier reflecting the trade-off between capacity resources used and delivery performance realized. We conclude that a paradigm shift in job shop research is required: instead of developing single policies for application under all conditions, new policies are needed that respond differently to temporary high load periods. The new paradigm can be used as a design principle for realizing improvements across a range of planning and control decisions relevant to job shops.

Suggested Citation

  • Land, Martin J. & Stevenson, Mark & Thürer, Matthias & Gaalman, Gerard J.C., 2015. "Job shop control: In search of the key to delivery improvements," International Journal of Production Economics, Elsevier, vol. 168(C), pages 257-266.
  • Handle: RePEc:eee:proeco:v:168:y:2015:i:c:p:257-266
    DOI: 10.1016/j.ijpe.2015.07.007
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    References listed on IDEAS

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    1. C. H. Jones, 1973. "An Economic Evaluation of Job Shop Dispatching Rules," Management Science, INFORMS, vol. 20(3), pages 293-307, November.
    2. Land, Martin J. & Gaalman, Gerard J. C., 1998. "The performance of workload control concepts in job shops: Improving the release method," International Journal of Production Economics, Elsevier, vol. 56(1), pages 347-364, September.
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    4. Fernandes, Nuno O. & Carmo-Silva, S., 2011. "Workload control under continuous order release," International Journal of Production Economics, Elsevier, vol. 131(1), pages 257-262, May.
    5. Matthias Thürer & Mark Stevenson & Cristovao Silva & Martin J. Land & Lawrence D. Fredendall & Steven A. Melnyk, 2014. "Lean Control for Make-to-Order Companies: Integrating Customer Enquiry Management and Order Release," Production and Operations Management, Production and Operations Management Society, vol. 23(3), pages 463-476, March.
    6. Land, Martin, 2006. "Parameters and sensitivity in workload control," International Journal of Production Economics, Elsevier, vol. 104(2), pages 625-638, December.
    7. Oosterman, Bas & Land, Martin & Gaalman, Gerard, 2000. "The influence of shop characteristics on workload control," International Journal of Production Economics, Elsevier, vol. 68(1), pages 107-119, October.
    8. Matthias Thürer & Martin J. Land & Mark Stevenson & Lawrence D. Fredendall & Moacir Godinho Filho, 2015. "Concerning Workload Control and Order Release: The Pre-Shop Pool Sequencing Decision," Production and Operations Management, Production and Operations Management Society, vol. 24(7), pages 1179-1192, July.
    9. Kenneth R. Baker, 1984. "Sequencing Rules and Due-Date Assignments in a Job Shop," Management Science, INFORMS, vol. 30(9), pages 1093-1104, September.
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    Citations

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    Cited by:

    1. Kasper, T.A. Arno & Land, Martin J. & Teunter, Ruud H., 2023. "Non-hierarchical work-in-progress control in manufacturing," International Journal of Production Economics, Elsevier, vol. 257(C).
    2. Matthias Thürer & Mark Stevenson, 2016. "Card-based delivery date promising in pure flow shops with order release control," International Journal of Production Research, Taylor & Francis Journals, vol. 54(22), pages 6798-6811, November.
    3. Fernandes, Nuno O. & Thürer, Matthias & Silva, Cristóvão & Carmo-Silva, Sílvio, 2017. "Improving workload control order release: Incorporating a starvation avoidance trigger into continuous release," International Journal of Production Economics, Elsevier, vol. 194(C), pages 181-189.
    4. Matthias Thürer & Nuno O. Fernandes & Mark Stevenson & Cristovao Silva & Silvio Carmo-Silva, 2019. "POLC-A: an assessment of POLCA’s authorization element," Journal of Intelligent Manufacturing, Springer, vol. 30(6), pages 2435-2447, August.
    5. Thürer, Matthias & Stevenson, Mark & Land, Martin J., 2016. "On the integration of input and output control: Workload Control order release," International Journal of Production Economics, Elsevier, vol. 174(C), pages 43-53.
    6. Nuno O. Fernandes & Matthias Thürer & Federica Costa, 2024. "Work Faster, Work in Parallel, or Work Overtime? An Assessment of Short-Term Capacity Adjustments by Simulation," Mathematics, MDPI, vol. 12(16), pages 1-8, August.
    7. Federica Costa & Alberto Portioli-Staudacher, 2021. "Labor flexibility integration in workload control in Industry 4.0 era," Operations Management Research, Springer, vol. 14(3), pages 420-433, December.
    8. Matthias Thürer & Mark Stevenson, 2016. "Workload control in job shops with re-entrant flows: an assessment by simulation," International Journal of Production Research, Taylor & Francis Journals, vol. 54(17), pages 5136-5150, September.
    9. Sagawa, Juliana Keiko & Oliveira, Allan Freitas & Mušič, Gašper & Land, Martin J. & Maluf, Arthur Sarro, 2023. "Smart workload input-output control of production systems: A proof of concept," European Journal of Operational Research, Elsevier, vol. 309(1), pages 286-305.
    10. Kasper, T.A. Arno & Land, Martin J. & Teunter, Ruud H., 2023. "Towards System State Dispatching in High‐Variety Manufacturing," Omega, Elsevier, vol. 114(C).
    11. Thürer, Matthias & Stevenson, Mark, 2018. "Bottleneck-oriented order release with shifting bottlenecks: An assessment by simulation," International Journal of Production Economics, Elsevier, vol. 197(C), pages 275-282.
    12. Stefan Haeussler & Philipp Neuner & Matthias Thürer, 2023. "Balancing earliness and tardiness within workload control order release: an assessment by simulation," Flexible Services and Manufacturing Journal, Springer, vol. 35(2), pages 487-508, June.
    13. Matthias Thürer & Nuno O. Fernandes & Mark Stevenson & Ting Qu, 2017. "On the backlog-sequencing decision for extending the applicability of ConWIP to high-variety contexts: an assessment by simulation," International Journal of Production Research, Taylor & Francis Journals, vol. 55(16), pages 4695-4711, August.
    14. Matthias Thürer & Mark Stevenson, 2021. "Material handling and order release control in high-variety make-to-order shops: an assessment by simulation," Operations Management Research, Springer, vol. 14(3), pages 494-506, December.
    15. Matthias Thürer & Mark Stevenson & James Aitken & Cristovao Silva, 2020. "State-dependent service rates in make-to-order shops: an assessment by simulation," Operations Management Research, Springer, vol. 13(1), pages 70-84, June.
    16. Thürer, Matthias & Stevenson, Mark & Silva, Cristovao & Qu, Ting, 2017. "Drum-buffer-rope and workload control in High-variety flow and job shops with bottlenecks: An assessment by simulation," International Journal of Production Economics, Elsevier, vol. 188(C), pages 116-127.

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