Controlling shop floor operations in a multi-family, multi-cell manufacturing environment through constant work-in-process

This paper discusses pertinent issues in applying CONstant Work-In-Process (CONWIP) principles to control shop floor operations in a manufacturing environment characterized by several product families processed along different routes in several production cells. The approach we take is to simultaneously answer two major questions: (1) what is the best WIP level? and (2) how to arrange the backlog list for a given system? The problem is posed as a mathematical programming model and solved via a simulated annealing heuristic. We design an experiment that captures essential elements of the systems under investigation. We then execute an extensive simulation to evaluate the effectiveness of various control schemes in a multi-cell, multi-family production environment. Specifically, we compare two variants of CONWIP control, one where containers are restricted to stay within given cells all the time and the other where containers are allowed to move through the entire system. We demonstrate the superiority of the latter in all the simulated scenarios.