Lateness in production systems - In a nutshell: How to determine the causes of lateness at work systems?

Abstract

Adherence to customer due dates is the yardstick for the performance of manufacturing companies. In the era of same-day delivery, consumers expect reliable delivery of ordered goods and short delivery times. Also, in the field of business-to-business supply, it is evident that adherence to delivery dates is a fundamental logistical objective for companies. Contract manufacturers, in particular, are confronted with significant challenges: strong fluctuations in customer demand, shorter requested delivery times, and high competitive pressure require appropriate organisation, planning and control of production. However, companies often miss their schedule reliability targets and fail to identify the right causes for these failures. This raises the question of what factors influence the failure to meet schedule reliability targets, how to identify such factors, and what options are available to counteract them. This contribution addresses this issue and focuses on ways to analyse the emerging lateness at work systems in production areas as a deviation of the actual form the planned throughput time. We present existing approaches to analysing the lateness behaviour at work systems and extend the current theory of logistical modelling to determine the three drivers of the so-called relative lateness – planning influences, variance of work-in-process (WIP) and sequence deviations – at work systems systematically. Through this analysis, we enable the practical applicator to initiate target-oriented countermeasures to improve the schedule reliability of their work systems with acceptable analysis expenditure.