Analyzing a drum-buffer-rope scheduling system executability through simulation

This study was carried out in a plastic workshop of a refrigerator factory to solve problems of excessive work in process. In order to provide synchronous manufacturing between Capacity Constrained Resources (CCR) and non-Capacity Constraint Resources (non-CCR), an approach was developed based on the Drum-Buffer-Rope (DBR) scheduling system, which was intended for solving problems such as this. The approach was based on a heuristic that integrates Wagner-Whitin's algorithm and finite loading method to determine optimum lot sizes for non-CCR machine's material release schedule. A simulation model was used to analyze whether an improved scheduling approach was appropriate or not. An experimental study was also conducted to determine the time buffers.