Návrh konceptu plánování a řízení materiálových toků a zásob v hutnicko-strojírenském logistickém řetězci

Abstract

Presented thesis is focused on increase of performance in production processes with complex multidirectional material flows, technologically intensive production with multiple levels of final products processing, and with floating bottlenecks occurrence in the environment with logistic chains of metallurgical and coherent engineering production.

The main objective is to design a new conception of production, material flows and stock planning and control, based on implementation of theory of constraints principles and bottlenecks management, which will increase the performance of production processes in metallurgical and engineering industry and its logistic chains. The stated aim was fulfilled with the help of the following partial objectives:

- by applying the well-known principles of theory of constraints and bottleneck management to increase performance of production processes and logistic chains to the area of user-specific and low-volume production in metallurgical and consecutive engineering industry, - limiting impact of specific conditions in these areas to the possibility of implementing the principles resulting from theory of constraints and bottlenecks management, and maximizing the effects from the point of differences in production processes, combined into logistic chains, - generalizing outputs of the new conception of production planning and control material and stock flow, so that they can be implemented into production processes and logistic chains of similar nature,

The aims are fulfilled via case study from the area of a specific metallurgical and engineering logistic chain. This study was performed in the environment with variable demands, where the logistic chain, operating under the conditions of current method of production planning and control, is not able to meet requirements of all customers. That is why it is necessary to increase available capacity of its sources (its performance).

Conception of production, material flows and stock planning and control designed in this work, is based on the principle of so-called “production lines”. Author defined the production line as a time or space determined production capacity for accumulated realization of production segments with high potential of accumulation. Mentioned principle enables us to divide complex production into fast and slow production lines. Majority of the assortment is processed in the fast production line, which can be controlled in accordance with the conception of large-scale productions and thus use its advantages. Remaining part of assortment is managed in accordance with the principles of small-lot and single-parts productions.

The fast line can lower the fluctuation of floating bottlenecks, increase regularity, steadiness and fluency of material flows, increase performance of production devices and simplify system of production planning and control. The slow line needs to respond to more complex situation in material flows, dynamic shift of bottlenecks and management of protection stacks, placed before these limitations. However, it happens in significantly lesser scope, with lower state of work-in-process products and possibility to concentrate on selected nodes, which can cause risks of performance loss.