Abstract
In this paper, a framework of rolling production plan based on bottlebeck resource is introduced. The framework consists of two parts- releasing plan and shop floor control. Semiconductor-packaging production system where a bottleneck workstation exists is used as the case study. In the bottleneck workstation, plenty of setup time is needed for changeover due to the complexity of products. Setup time in bottleneck workstation decreases the throughput per unit of time and thus has impact on the whole system. The methodologies to control the amount of work-in-process (WIP) are provided and mean flow time are used to measure their performance. To minimize total setup time and mean flow time, an adequate production plan must be adopted. The proposed framework is to discuss the multiple decisions comprising dispatching rule, releasing rule and buffer contorl must be well made to decrease total setup time and mean flow time effectively under different scenarios. Due to stochastic processing time and setup time in the bottleneck workstation, replications of simulation have to be conducted to estimate the performance of each design. In this article, an evaluative model is constructed. Moreover, optimal computing budget allocation (OCBA) is applied to efficiently allocate limited simulation budget and reduce the total simulation time. It is proved that dispatching and releasing rule have significantly impact on total setup time and mean flow time. Furthermore, the relationship of trade-off between total setup time and mean flow time are obvious and different weight will affect the choise of alternatives. Due to the characteristics of the problem, the consequence are different between the deterministic and stochastic environment, but the dispatching and releasing rules won’t make change the effect of the performance of system.