Performance evaluation of pulled, pushed and hybrid production through simulation: a case study

Abstract

Goal: This work aims to compare performance indicators of the pulled, pushed and hybrid production schedule, with those of a specific production environment of the printing industry, using computational simulation. Design / Methodology / Approach: Through a case study, it was possible to create a conceptual model, from which a computational model that was verified and validated as representative of the real productive system was developed. There are generated fictional models of the production environments to compare cycle time, work in process and attendance to the demand, varying the quantity of orders confirmed by the final clients. Results: The CONWIP (Constant Work in Process) system presented very high cycle times and failure to meeting the demand, although it was kept in the format of the work in process. The actual real system and the pushed system obtained the worst performances regarding the work in process, besides presenting failures to meeting the demand and very high cycle times. The pulled system obtained the best performance to meet the demand, and cycle times adequate to the production requirement and moderate work in process. Limitations of the investigation: The application of the methodology was limited to the study of a single productive system of a print industry and cannot be extended to the entire sector. Practical implications: This work presents a practical application of computer simulation tools applied to Production Planning and Controls which may be replicated by other organizations or educational institutions for system performance analysis in different scenarios. Originality / Value: The original contribution of this work is the application of computational simulation for a production system in a print industry without interference in a real system.