Integrated Machine-Scheduling and Inventory Planning of Door Manufacturing Operations at Bursa Oyak RENAULT
M.S. Thesis Presentation by Nurcan Bozkaya Department of Industrial Engineering Bilkent University
A car passes through press, body-shell, painting and assembly stages during its manufacturing process. Due to the increased competition among car manufacturers, they aim to continuously advance and improve their processes. In this study, we analyze planning operations for the production of front/back and left/right doors in body-shell department of Bursa Oyak-Renault factory and propose a decision support system to improve their planning processes. In this study, we propose developed four different mathematical models and two heuristics approaches which decrease the current costs of the company particularly with respect to inventory carrying and setup perspectives.In the body shell department of the company, there are two parallel manufacturing cells which produces doors to be assembled on the consumption line. The effective planning and scheduling of the jobs on these lines requires solving the problem of integrated machine-scheduling and inventory planning subject to inclusive eligibility constraints and sequence independent setup times with job availability in flexible manufacturing cells of the body shell department. The novelty in the models lie in the integration of inventory planning and production scheduling decisions with the aim of streamlining operations of the door manufacturing cells with the consumption line. One of the proposed heuristic approaches is Rolling Horizon Algorithm (RHA) which divides the planning horizon into sub-intervals and solves the problem by rolling the solutions for sub-intervals. The other proposed algorithm is Two-Pass Algorithm which divides the planning horizon into sub-intervals but unlike RHA, it updates job list by adding new jobs or deleting existing ones.These approaches are implemented with Gurobi optimization software and Java programming language and applied within a decision support system that supports daily planning activities.
This thesis is supervised by Asst. Prof. Alper Şen Assoc. Prof. Osman Alp Assoc. Prof. Mehmet Taner
