A synergistic methodology and adaptive model for material management in a dynamic environment

This dissertation and the associated research compare the three main manufacturing philosophies of Manufacturing Resource Planning (MRP), Just In Time (JIT) and the Theory of Constraints (TOC) with a new manufacturing concept termed the Adaptive Model. The Adaptive model uses the synergistic effect of combining selected aspects of the JIT and TOC philosophies into a new manufacturing philosophy. Specifically, the adaptive model identified and optimized a second constraint in addition to the primary constraint. It was envisioned before conducting the research that the adaptive model would be superior to the other models.; Three different manufacturing lines of five, nine and fifteen workstations were developed and modeled. Each of these models with different buffer sizes was simulated for approximately a six month time period.; Performance factors were identified and employed for evaluating the four philosophies. These factors included Throughput levels, Work in Process (WIP) quantities, Time-in-the-system periods and idle time/utilization rates. Data for each of the performance factors were collected. The data were then analyzed and presented using a statistical software program.; The results of the data analysis are that the adaptive model produces sporadic superior results when compared with the other philosophies but with the higher costs of large WIP levels and increased time-in-the-system lengths. The research conclusion is that the TOC model for a flow shop manufacturing environment is the best overall manufacturing philosophy.