Bottleneck based CONWIP production flow control system in make-to-order manufacturing

In this thesis, production flow control systems which have make-to-order and include bottleneck manufacturing environments are analyzed. First of all, MRP, JIT, kanban, POLCA and CONWIP, which are production control systems, are studied and their differences are stated. Because of easy applicable and has advantages over the others, CONWIP is shown as appropriate system for small and medium-sized enterprises which has make-to-order and include bottleneck manufacturing environments. Secondly, a mathematical model is developed for B-CONWIP system which is determined production scheduling and lot sizes using bottleneck machine's data and its objective function has earliness, lateness and overwork as manufacturing cost and unbalanced workload cost as the requirements of CONWIP. Thirdly, the mathematical model is solved with hypothetical data by CPLEX which is module of GAMS and analyzed. Fourthly, B-CONWIP system's implementation steps for small and medium-sized enterprise is described. Finally, the mathematical model is solved with small and medium-sized enterprise's data and results are compared with actual production scheduling which is applied.