ISE 402 Production Systems and Inventory Control

Catalog Description Elements of functional organization. Forecasting in production systems. Product and process design considerations. Deterministic and stochastic cases in inventory control. Production scheduling and line balancing, capacity planning, material requirement planning (MRP). Computer applications in production control. Case studies and applications.
   
Course learning objectives
  • Enable the students to have a basic understanding of the operation and control of inventory and production systems and to have a comprehensive view of such complex systems.
  • Enable the students to use quantitative methods to model, analyze, and optimize such systems and understand the limits of these quantitative methods and how they can be used in practice
   
Course learning outcomes After passing this course, students will be able to perform the following:
  1. Understand the hierarchy of production planning and control decisions from long term planning to real-time batch control Program Outcome e
  2. Appreciate the need for forecasting and be able to select appropriate forecasting model to predict future demand Program Outcome e
  3. Select appropriate deterministic/stochastic inventory model to control inventory Program Outcome e
  4. Ability to analyze performance of a production plan - cost and time Program Outcomes e and i
  5. Understand aggregate planning models including ability to formulate objective functions, resource constraints, and inventory balances Program Outcomes a, c, and e
  6. Ability to create a feasible material plan for an MPS including understanding of MRP explosion and inventory allocation Program Outcomes a and e
  7. Understand capacity requirements planning and plan revision to obtain feasibility Program Outcomes a and e
  8. Understand the basics of JIT systems, their advantages and limitations and how they compare to MRP systems Program Outcomes a and e
  9. Know the definition of supply chain management and be aware of key SCM issues Program Outcomes e, h, j, and k

Industrial and Systems Engineering Program Learning Outcomes are:

  1. Apply knowledge of mathematics, science, and engineering;
  2. design and conduct experiments, as well as analyze and interpret data;
  3. design and improve integrated systems of people, materials, information, facilities, and technology;
  4. function as a member of a multi-disciplinary team;
  5. identify, formulate, and solve industrial and systems engineering problems;
  6. understand and respect professional and ethical responsibility;
  7. communicate effectively both orally and in writing;
  8. understand the impact of engineering solutions in a global and societal context;
  9. recognize the need for life-long learning, and an ability to engage in it;
  10. have a knowledge of contemporary issues;
  11. use updated techniques, skills and tools of industrial and systems engineering throughout their professional careers.
   
Topics
  1. Introduction to production systems
  2. Demand forecasting
  3. Inventory of raw materials and finished products: deterministic models
  4. Inventory management: Stochastic models
  5. Aggregate production planning
  6. Push production control: MRP
  7. Pull production control: JIT
  8. Production scheduling
  9. Assembly line balancing
  10. Supply chain management
   
Method of assessment
Homework 20
Know-grading quiz in October 17 2
Exam 1 in December 14 at 7:15 pm 18
Exam 2 25
Teaching presentation 15
Group design project 20
Extra credit online article max of 10
   
Teaching presentation groups
  • Evaluation of forecasts, moving average, exponential smoothing, multiple step-ahead forecast, comparison of ES and MA, regression, double exponential smoothing, seasonal forecast by Ahmad Al-Jafar, Mohammad Al-Muraii, Musab Mohammad, Mansour Mubarak, Mustafa Mousa, Abdulla Al-Sagaoub, Ashraf Hashad
  • EOQ model, EPQ model, quantity discount model by Hassan Zaini, Hamzah Nowailati, Talal Bukhari
  • News boy model, lot size reorder point model by Fahad Al-Ghamdi and Nasser Al-Anazi
  • Disaggregation plans by Abdul-Rahman Al-Thunaiyan
  • Silver-Meal heuristic by Ahmad Qutubuddin
  • Sequencing: minimizing number of tardy jobs by Raad Al-Harbi
  • Assembly line balancing by Mohammed Al-Shahrani
   
Online article This extra credit work requires the student to write an article, whether based on a prior opinion of his or a new interpretation of the methods and ideas of the course, and post it on wikipedia or knol. The article will be evaluated based on the complete coverage of the idea and how much of the writer's opinion is shown in the article. Contributions can be also in a form of questions and answers posted in the industrial engineering part of wiki.answers.com, which can be accessed the sequence of clicks Wiki Answers > Categories > Technology > Engineering > Industrial Engineering
   
Design project groups
  • Mustafa Mousa, Ashraf Hashad
  • Abdulrahman Al-Thunaiyan, Hassan Zaini
  • Musab Mohammad, Hamzah Nowailati
  • Mohammad Al-Muraii, Ahmad Qutubuddin
  • Nasser Al-Anazi, Mansour Mubarak
  • Talal Bukhari, Fahad Al-Ghamdi
  • Raad Al-Harbi, Ahmad Al-Jafar
  • Abdulla Al-Sagaoub, Mohammed Al-Shahrani
   
Design project supervision Design projects will be supervised and monitored through an online wiki. Therefore, each group will have to create a wiki in pbworks.com and include in it the elements of the report as they progress in the project. I will read the wikis at least once a week and provide my suggestions if required.
   
Prerequisite ISE 205 Engineering Probability and Statistics
   
References
  1. Lecture notes
  2. Production and Operations Analysis by S. Nahmias, McGraw-Hill
  3. Factory Physics by W.J. Hopp and M.L. Spearman, McGraw Hill
  4. Inventory management and Production Planning and Scheduling by Silver, Pyke and Peterson, John Wiley
  5. Manufacturing Planning and Control for Supply Chain Management by Whybark and Jacobs, McGraw Hill
  6. Operations and Supply Management: The Core by Jacobs and Chase, McGraw Hill
  7. Inventory Management Explained: A focus on Forecasting, Lot Sizing, Safety Stock, and Ordering Systems by Piasecki, Ops Publishing
   
Instructor Dr Muhammad Al-Salamah
Office: 22/436
Phone: 1627
   
Office hours Office hours are Saturdays and Mondays and Wednesdays from 10 to 11 am.
   
Term Fall 2009