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        Integration of Bucket Brigades and Worker Collaboration on a Production Line with Discrete Workstations

        Aditya Tirta Pratama,Katsuhiko Takahashi,Katsumi Morikawa,Keisuke Nagasawa,Daisuke Hirotani 대한산업공학회 2018 Industrial Engineeering & Management Systems Vol.17 No.3

        Bucket brigades are self-balancing production lines in which each worker can move from one station to the next to continue working on a given part. Sequencing workers from slowest-to-fastest is the best policy for maximizing throughput on a continuous line. Meanwhile, throughput at discrete workstations may decrease due to blocking even though workers are properly sequenced. A method of countering the blocking condition is proposed by integrating bucket brigades and worker collaboration such that a maximum of two workers can collaborate on the same task. Prior assumptions are utilized to investigate and compare the performance of a production line in which the work content of the product at each station is deterministic and the collaboration velocity is proportional to the sum of the individual worker velocities and is influenced by the collaboration coefficient. Possible extended conditions for improvement and a procedure for achieving possibly higher throughput through worker collaboration are described. The characteristics of a self-balancing line can still be preserved, and an improvement in performance can be obtained. The results show that a bucket brigade with worker collaboration between fully cross-trained workers, slowest-to-fastest sequencing, and an additive collaboration coefficient almost always outperforms one without worker collaboration in terms of maximizing throughput.

      • KCI등재

        Cellular Bucket Brigades with Worker Collaboration on U-Lines with Discrete Workstations

        Aditya Tirta Pratama,Katsuhiko Takahashi,Katsumi Morikawa,Keisuke Nagasawa,Daisuke Hirotani 대한산업공학회 2018 Industrial Engineeering & Management Systems Vol.17 No.3

        Cellular bucket brigades (CBB) are a new design of bucket brigade that can reduce unproductive travel by workers on U-shaped production lines. With CBB, each worker works on one side of an aisle when proceeding in one direction, and on the other side when proceeding in the reverse direction; workers then exchange their work when they meet each other. The throughput of CBB may be reduced due to blocking and/or halting at discrete workstations. A method for countering these blocking/halting conditions is proposed here; it utilizes worker collaboration such that a maximum of two workers can collaborate on the same task. The collaboration velocity is proportional to the sum of individual worker velocities, and is influenced by the worker collaboration coefficient. The existing model and its assumptions are utilized here to compare the performance of CBB against worker collaboration on a three-station, twoworker U-line for which the difference collaboration coefficient and work content of the product at each station are deterministic. The results show that worker collaboration almost always outperforms CBB, except for certain cases in which each worker has a different velocity at different stations.

      • SCOPUSKCI등재

        Improving Daily Total Complete Shipment by Using System Dynamics Simulation in an Indonesian Car Spare Parts Manufacturer

        Steven Liang,Aditya Tirta Pratama,Sumarsono Sudarto 대한산업공학회 2022 Industrial Engineeering & Management Systems Vol.21 No.1

        PT. Nusahadi Citraharmonis is a leading manufacturing company in Indonesia that produces spare parts for various automotive industries. The company is an active supplier for several well-known car manufacturer in Indonesia, which are: NTC, HMMI, TMMIN, and ASKA. However, the company is currently having difficulty in fulfilling all customer demand on time. Thus, creating backlogged order in the system and decreasing the daily total complete shipment. The objective of this research is to redesign new inventory level to increase the daily total complete shipment. To solve the problem, Define-Measure-Analyze-Improve-Control (DMAIC) is used as the procedure, cause effect analysis is used as a tool to identify the key factors affecting daily total complete shipment, and system dynamics simulation is used as a tool to redesign inventory level. From the result of system dynamics simulation, the newly redesigned inventory level is able to decrease the backlogged order in the system and increase the daily total complete shipment. Besides the system dynamics simulation, standard operating procedure for operating the system is also made and given to the company for future use.

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