Department of Economics and Business Economics

Production planning for a ramp-up process in a multi-stage production system with worker learning and growth in demand

Research output: Contribution to journal/Conference contribution in journal/Contribution to newspaperJournal articleResearchpeer-review

  • Taebok Kim, Hanyang University
  • ,
  • Christoph H. Glock, Technische Universität Darmstadt
  • ,
  • Simon Emde

In a response to changes in customer requirements and environmental dynamics, product lifecycles have become shorter and shorter over the last decades. As a result, production ramp-ups have become more frequent in many industries, and they now often account for a significant share of the entire product lifecycle. Due to the prominent role production ramp-ups play in the lifecycle of a product, efficient production ramp-ups are now an important determinant of business success. This work proposes a mathematical model for managing production ramp-ups in a serial multi-stage production system. In the scenario considered here, both the productivity of workers and demand increase over time until a steady-state phase is reached at the end of the ramp-up. The model proposed in this paper supports the assignment of workers to the different stages of the production system and the balancing of production and demand to ensure a smooth transition from the production ramp-up to steady-state production. The model is analysed in numerical experiments to illustrate its potential for managing the production ramp-up. Our experiments show that high learning rates can have drawbacks in terms of large inventories if learning is not aligned with demand growth and across production stages.

Original languageEnglish
JournalInternational Journal of Production Research
ISSN0020-7543
DOIs
Publication statusE-pub ahead of print - Aug 2020

    Research areas

  • demand growth, learning effect, multi-stage production system, Production ramp-up

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