Process Simulation And Optimization In Sustainable Logistics And Manufacturing (ecoproduction)

The aim of this book is to present qualitative aspects of logistics operations and supply chain management which help to implement the sustainable policy principles in the companies and public sector’s institutions. Authors in individual chapters address the issues related to reverse network configuration, forward and reverse supply chain integration, CO2 reduction in transportation, improvement of the production operations and management of the recovery activities. Some best practices from different countries and industries are presented. This book will be valuable to both academics and practitioners wishing to deepen their knowledge in the field of logistics operations and management with regard to sustainability issues. Preface 6 Contents 8 Part I Manufacturing Operations 10 Simulation Method for the Benefits of a Small Business in Sustainable World 11 Abstract 11 1 Introduction 11 2 The Basic Requirements of an Environmental Protection and Work Safety in the Manufacturing Company 12 3 The Background of a Simulation Project, Objectives and Measures 13 3.1 Description of the Modeled System and the Problems of Environmental Protection and Work Safety 15 3.2 The Logic of the Production System Operation 16 3.3 Main Issues 18 4 The Design of the Production System 19 4.1 The Results of the Simulation and Analysis of Experiments 24 4.2 Reducing Costs and Waste 25 5 Final Conclusions 26 References 29 Operational Measurements for Evaluating the Transformation of Production-Logistics System and Their Reflecting in Simulation Software 30 Abstract 30 1 Introduction 30 2 Ratio Analysis 33 3 Basic Operational Metrics and Indicators of a Production-Logistics System: Selection Method 34 3.1 Stage One: Questionnaire Survey 35 3.2 Stage Two: In-depth Study 37 3.3 Stage Three: The Use of Logistics and Production System Performance Measures and Indicators for Analyzing Logistics States 43 4 Project of Reflecting Measures and Indicators of Efficiency of Production-Logistics Process in a Simulation Model 44 5 Summary 44 References 48 Methodology of Assortment Analysis in Companies with a Wide Range of Products for Building the Flexibility of Customer Service 50 Abstract 50 1 Introduction: Production Environment Characteristics 50 2 Statistical Indicators and Measures 51 3 The Logic of Validation Experiments in the Methodology of Selecting a Product Range 54 4 The Analysis of Results: Correlation Analysis 57 4.1 Framework Methodology for Validating Product Range Analysis 57 4.2 Results of Descriptive Statistical Analysis of Input Data 59 4.3 Results of Descriptive Statistical Analysis 59 4.3.1 Correlation Analysis Results 60 5 Product Range Segmentation Model in the Enterprises with Wide Range of Products 61 6 Conclusion 63 References 63 Global Sensitivity Analysis of Heijunka Controlled Assembly Line 65 Abstract 65 1 Introduction 65 2 Variance-Based Global Sensitivity Analysis 67 3 Microelectronic Assembly Line 69 4 Sensitivity Analysis of a Heijunka Controlled Assembly Line 71 5 Conclusions 73 References 73 Stability Analysis of the Production System Using Simulation Models 75 Abstract 75 1 Introduction 75 2 The Role of Production Systems Modelling in Ensuring the Stability 77 3 Simulation Modelling of Production Systems 79 4 Reorganization and Optimization of a Production System with the Use of Simulation Models 82 4.1 Characteristics of the Production System 82 4.2 Assessment and Minimization of the Risk Level in the Production Line 85 5 Assessment of the Stability of the Production System 86 References 88 Simulation Modeling of Acrylic Bathtubs Production Using Task-Oriented Approaches as a Tool to Improve Energy Efficiency of Thermoforming Process 90 Abstract 90 1 Introduction 90 2 Aim of the Simulation Model 91 3 Methodology 91 4 Course of Research 92 5 Conclusions 100 References 101 Part II Production Operations 102 Simulation Analysis of Traffic Congestion in Mineral Mining Transport 103 Abstract 103 1 Introduction 103 2 Modelling Framework 104 3 Building FlexSim Model 105 4 Kostrza Village Case Study 107 5 Results of Analysis 108 6 Conclusion 112 References 113 An Optimization Model in Support of Biomass Co-firing Decisions in Coal Fired Power Plants 114 Abstract 114 1 Introduction 114 2 Problem Description 116 2.1 Biomass Co-firing: Estimating Biomass Usage 116 2.2 Biomass Co-firing: Estimating Costs and Savings 117 2.3 Mathematical Problem Formulation 119 3 Numerical Analysis 120 3.1 Data Collection 120 3.2 Experimental Results 121 4 Conclusions 124 References 126 Part III Supply Chain Management 127 Using Simulation Modeling and Analysis to Assess the Effect of Variability and Flexibility on Supply Chain Lead Time 128 Abstract 128 1 Introduction 128 2 Conceptual Model and Model Validation 131 3 Application Example and Simulation Results 132 4 Simulation Results 135 4.1 Effect of SFL on Lead Time 135 4.2 Effect of PPTT on Lead Time 136 4.3 Effect of Operations Time Variation on Lead Time 137 4.4 Effect of Factors on Mean Lead Time and Variability in Lead Time 138 5 Conclusions 139 References 139 Models of Organizing Transport Tasks Including Possible Disturbances and Impact of Them on the Sustainability of the Supply Chain 141 Abstract 141 1 Introduction 141 2 Disturbances in Supply Chain 145 3 Measures of Supply Chain 147 4 Effect of Selected Disturbances on the Efficiency of the Supply Chain 148 5 Conclusions and Further Investigations 150 References 151 Part IV Cross-Disciplinary Methodologies 152 IDEF0 as a Project Management Tool in the Simulation Modeling and Analysis Process in Emergency Evacuation from Hospital Facility: A Case Study 153 Abstract 153 1 Introduction 153 2 The SMA Process 154 3 Project Management Methodologies 156 4 IDEF0 158 5 PMBOK, PRINCE2, and SCRUM Comparison in View of ICOM Logical Set 160 6 IDEF0 as a PM Tool in SMA Process in Babinski Hospital 161 7 Conclusions 163 References 164 Transforming a Student Project into a Business Project: Case Study in Use of Simulation Tools 165 Abstract 165 1 Introduction 166 2 Concept of Course: Logistics Processes Design 168 3 Syllabus Outline of Simulation Laboratory Classes 171 4 Student Projects Descriptions 173 5 Student Projects Transformation: Case Study 174 6 Conclusions 180 References 182 Front Matter....Pages i-viii Front Matter....Pages 1-1 Simulation Method for the Benefits of a Small Business in Sustainable World....Pages 3-21 Operational Measurements for Evaluating the Transformation of Production-Logistics System and Their Reflecting in Simulation Software....Pages 23-42 Methodology of Assortment Analysis in Companies with a Wide Range of Products for Building the Flexibility of Customer Service....Pages 43-57 Global Sensitivity Analysis of Heijunka Controlled Assembly Line....Pages 59-68 Stability Analysis of the Production System Using Simulation Models....Pages 69-83 Simulation Modeling of Acrylic Bathtubs Production Using Task-Oriented Approaches as a Tool to Improve Energy Efficiency of Thermoforming Process....Pages 85-96 Front Matter....Pages 97-97 Simulation Analysis of Traffic Congestion in Mineral Mining Transport....Pages 99-109 An Optimization Model in Support of Biomass Co-firing Decisions in Coal Fired Power Plants....Pages 111-123 Front Matter....Pages 125-125 Using Simulation Modeling and Analysis to Assess the Effect of Variability and Flexibility on Supply Chain Lead Time....Pages 127-139 Models of Organizing Transport Tasks Including Possible Disturbances and Impact of Them on the Sustainability of the Supply Chain....Pages 141-151 Front Matter....Pages 153-153 IDEF0 as a Project Management Tool in the Simulation Modeling and Analysis Process in Emergency Evacuation from Hospital Facility: A Case Study....Pages 155-166 Transforming a Student Project into a Business Project: Case Study in Use of Simulation Tools....Pages 167-184