Up-to-date manufacturing companies have faced a market-driven environment of pull production order. There should be a difference in operating manufacturing resources according to the type, quantity, and delivery time of manufactured products, because the process situation in pull production is changed by customer orders. And it should be taken into account from the stage of preparing for production such as process design and the placement and utilization of manufacturing resources. However, the feasibility of production plans is limited because most of small manufacturing businesses make production/supply plan of the parts and products assuming that equipment abilities in scheduling is sufficient without managing process standard information systemically. In this study, a discrete event simulation system based on BOM (bill of material), that is F-OPIS (online productivity innovation system), is introduced and a case study on application of the system leading to improving productivities is presented. F-OPIS deals with a decision-problem on production management and it is specialized for small-and- medium sized manufacturing companies. The target company of this case study is a typical small-and-medium sized manufacturing company in Korea, that produces various machined parts. The target company adopts make-to-stock production management to prevent tardy delivery because of fluctuations in demand. Therefore, it is required to apply an efficient inventory control solution for improving productivities. In this paper, based on the constraints of working capacity of manufacturing resources, the bottleneck process is analyzed as production conditions are changed. Consequently, an improvement plan is proposed, that eventually enhances overall utilization rates of resources in the bottleneck process and reduces overall production lead-time and inventory level.

This study develops a dynamic scheduling model for parallel machine scheduling problem based on genetic algorithm (GA). GA combined with discrete event simulation to minimize the makespan and verifies the effectiveness of the developed model. This research consists of two stages. In the first stage, work sequence will be generated using GA, and the second stage developed work schedule applied to a real work area to verify that it could be executed in real work environment and remove the overlapping work, which causes bottleneck and long lead time. If not, go back to the first stage and develop another schedule until satisfied. Small size problem was experimented and suggested a reasonable schedule within limited resources. As a result of this research, work efficiency is increased, cycle time is decreased, and due date is satisfied within existed resources.