The SDBR Model Optimization Research To Cope With Bottleneck Shift Problem In A-plant

Manufacturing industry is seeking for new competitive advantage because the competition is more and more fierce.As backbone power of manufacturing industry,assembling industry has contributed a lot for the development of economy.However,the crisis of hollowing out of manufacturing industry requires assembling industry to make transition,which means to respond to customer faster and put time as new competitive dimension.Therefore,how to improve logistics in factory,to optimize operation and to deliver better goods to customer have attracted more attention of this kind of factories.Meanwhile,effective manufacturing method can expand competing advantage and promote the development of the entire manufacturing industry.TOC is a theory which could respond the market quickly,and it is appreciated by manufacturing enterprises.TOC is a system-based theory which concentrating on bottleneck and equity of the manufacturing system.SDBR,operation tool of TOC,regards the market order as bottleneck of system and it has proved to shorten cycle time and achieve a better delivery.However,SDBR also has some problem in the practice which reflected in the CCR shiftiness and material to be assembled are not well matched.Demand fluctuation such as product order quantity change or product order combination change always accumulates in the processes and finally cause the block in the increase of effective throughput.The objective fluctuation raises the problem of CCR shiftiness and material not matched,which causes the impact of throughput.According to the analysis,core reason of phenomenon above is SDBR's lacking of effective buffer mechanism to fluctuation.SDBR's shipping buffer is not enough to deal with all the marketing fluctuation.On this basis,this paper proposes a SDBR optimization model which improves from below points:anchored bottleneck,assembling buffer and resource sharing principle.In the A plant,assemble process is key point to transfer semi-finished goods into finished goods,and it is the reason to make assemble process as anchored bottleneck and ensure other process to keep pace with anchored bottleneck;assembling buffer could protect anchored bottleneck from fluctuation and keep processing;resource sharing principle set down a rule that let all the processes help each other to achieve a quick logistics.The rule can decrease WIP blocking in the system.In a word,SDBR optimization model can exactly find out CCR in the system and its impact,and dynamically use related rules to balance the logistics.Via Extendsim simulation,it is proved that on the three index of throughout,WIP and assembling process utility rate,SDBR optimization model is performing better than SDBR,which means on the circumstance of market order quantity change and order combination change,SDBR optimization model could solve the problems effectively.Based on the bottleneck shiftiness,SDBR optimization model is able to deal with fluctuation using buffer management and resource sharing rules.