Evaluation of Pull Control Strategies and Production Authorisation Card Policies Recovery Period in a Multi-product System

  • Chukwunonyelum Emmanuel OnyeochaEmail author
  • Joseph Khoury
  • John Geraghty
Part of the Lecture Notes in Management and Industrial Engineering book series (LNMIE)


Pull production control strategies have demonstrated poor responses to large variations in demand volume. A recently developed pull production control strategy referred to as Base Stock-Kanban-CONWIP control strategy is capable of minimising WIP while maintaining high volume flexibility. This paper investigates the recovery period of pull production control strategies and production authorisation card policies after lumpy demands in a multi-product manufacturing system. Discrete event simulation and multi-objective optimisation approach were adopted to develop sets of non-dominated optimal solutions for configuring suitable decision set to the pull control strategies. It was shown that the shared Kanban allocation policy outperforms the dedicated Kanban allocation policy. Additionally the Basestock-Kanban CONWIP control strategy outperforms the alternatives.


Pull control strategies Production authorisation card policies Multi-product system Lumpy demand 


  1. Bamber L, Dale BG (2000) Lean production: a study of application in a traditional manufacturing environment. Prod Plan Control 11(3):291–298CrossRefGoogle Scholar
  2. Baynat B, Buzacott JA, Dallery Y (2002) Multi-product kanban-like control systems. Int J Prod Res 40:4225–4255CrossRefzbMATHGoogle Scholar
  3. Deleersnyder JL, Hodgson TJ, King RE, O’Grady PJ, Savva A (1992) Integrating kanban type pull systems and MRP type push systems: insights from a Markovian model. IIE Trans 24:43–56CrossRefGoogle Scholar
  4. Kernan B, Geraghty J (2004) A multi-objective genetic algorithm for extend. In: Proceedings of the first irish workshop on simulation in manufacturing, services and logistics, Limerick, Ireland, pp 83–92 Kimball GE (1988) General principles of inventory control. Journal of manufacturing and operations management 1:119-130Google Scholar
  5. Kimball GE (1988) General principles of inventory control. J manufact oper manag 1:119–130Google Scholar
  6. Krishnamurthy A, Suri R, Vernon M (2004) Re-examining the performance of MRP and Kanban material control strategies for multi-product flexible manufacturing systems. J Flex Manuf Syst 16:123–150CrossRefzbMATHGoogle Scholar
  7. Marek RP, Elkins DA, Smith DR (2001) Understanding the fundamentals of kanban and CONWIP pull systems using simulation. In: Peters BA, Smith JS, Medeiros DJ, Rohrer MW (eds) Proceedings of the 33rd conference on winter simulation, Arlington, Virginia, vol 1. IEEE Computing Society, Washington, DC, USA, pp 921–929Google Scholar
  8. Nelson BL, Swann J, Goldsman D, Song W (2001) Simple procedures for selecting the best simulated system when the number of alternatives is large. Oper Res 49:950–963CrossRefGoogle Scholar
  9. Olaitan OA, Geraghty J (2013) Evaluation of production control strategies for negligible-setup, multi-product, serial lines with consideration for robustness. J Manuf Technol Manage 24(3):331–357CrossRefGoogle Scholar
  10. Onyeocha CE, Geraghty J (2012) A modification of the hybrid kanban-CONWIP production control strategy for multi-product manufacturing systems. In: IMC29: international manufacturing conference proceedings, University of Ulster, Belfast, UKGoogle Scholar
  11. Onyeocha CE, Khoury J, Geraghty J (2013). A comparison of kanban-like control strategies in a multi-product manufacturing system under erratic demand. In: Pasupathy, R, Kim S-H, Tolk A, Hill R, Kuhl ME (eds) Proceedings of the 2013 conference on winter simulation, vol 1. IEEE, Washington DC, USA, pp 2730–2741Google Scholar
  12. Spearman ML, Woodruff D, Hopp W (1990) CONWIP: a pull alternative to Kanban. Int J Prod Res 28:879–894CrossRefGoogle Scholar
  13. Sugimori Y, Kusunoki K, Cho F, Uchikawa S (1977) Toyota production system and Kanban system: materialization of just-in-time and respect-for-human system. Int J Prod Res 15(6):553–564CrossRefGoogle Scholar
  14. Womack JP, Jones DT, Roos D (1990) The machine that changed the world: the story of lean production. Harper Collins Publishers, New YorkGoogle Scholar

Copyright information

© Springer International Publishing Switzerland 2015

Authors and Affiliations

  • Chukwunonyelum Emmanuel Onyeocha
    • 1
    Email author
  • Joseph Khoury
    • 2
  • John Geraghty
    • 1
  1. 1.Enterprise Process Research Centre, School of Mechanical and Manufacturing EngineeringDublin City UniversityDublinIreland
  2. 2.Methode Electronics Malta LimitedIndustrial Estate MriehelQormiMalta

Personalised recommendations