ABSTRACT

The entry addresses several complications encountered in implementing Simplified Drum‐Buffer‐Rope (S‐DBR): Multiple operations of the capacity‐constrained resource (CCR) on the same order — The entry describes how to handle this situation and notes that other methods of planning and control face similar complications.Multiple simultaneous CCRs — Sometimes there is more than one CCR. The authors recommend relieving one. If that isn’t possible, they describe ways to deal with the situation. One method is to prioritize the criticality of competing orders in terms of profit, customer relationships, and delivery times.“Wandering” bottlenecks — Managers often claim that the “bottleneck” moves around. This confirms a chaotic environment. The entry provides ways to deal with such situations.Manpower as a CCR — Sometimes the capacity of the process is not constrained by equipment but by the absence of skilled workers. The authors describe ways to deal with such situations once they are recognized. The solutions are often off the shop floor.Long manufacturing process times (including subcontracting) — The entry describes solution for instances when there is one particular long cycle time operation and when there several longer operations that have stable, predictable processing times. When an operation is outsourced, it should be treated as a long process, particularly if the supplier does not employ S‐DBR.Exceptionally large orders — These situations can be disruptive. Four situations are described; each has a solution that includes collaboration with the customer over the way the order will be filled.Sequence‐dependent setups — The entry describes ways to deal with these situations. Examples include paint lines and chemical processes where equipment has to be prepared by cleaning and/or setup between each order.