Systems and methods for manufacturing a product in a pull and push manufacturing system and associated methods and computer program products for modeling the same

A method of manufacturing a product in a pull and push manufacturing system, where the product comprises at least one model and each model includes at least one component, said method comprising:

• receiving at least one order for at least one model of the product, wherein each model has an associated assembly time, and wherein the orders are in a predefined sequence and each order includes a defined release time;
• generating a component firing order schedule (CFOS) for a number of components corresponding to the models ordered based upon the defined release times of the respective orders and manufacturing times associated with the components, wherein the components are in a predetermined sequence and each component has a defined release time;
• releasing each order at a respective release time and releasing each component in the CFOS at a respective release time;
• producing the components released at a number of production centers and thereafter assembling the orders released from the produced components at a number of assembly lines, wherein at least one of the assembly times of the models ordered, the manufacturing times of the components of the models ordered, the number of production centers and the number of assembly lines are determined based modeling the manufacturing system.

A system of manufacturing a product in a pull and push manufacturing system, where the product comprises at least one model and each model includes at least one component, said system comprising:

• an order scheduler capable of receiving at least one order for at least one model of the product, wherein each model has an associated assembly time, and wherein the orders are in a predefined sequence and each order includes a defined release time;
• a component scheduler capable of generating a component firing order schedule (CFOS) for a number of components corresponding to the models ordered based upon the defined release times of the respective orders and manufacturing times associated with the components, wherein the components are in a predetermined sequence and each component has a defined release time;
• a make-to-order (MTO) portion capable of releasing each component in the CFOS at a respective release time and thereafter producing the components released at a number of production centers;
• and
• an assemble-to-order (ATO) portion capable of releasing each order at a respective release time and thereafter assembling the orders released from the produced components at a number of assembly lines,
• wherein at least one of the assembly times of the models ordered, the manufacturing times of the components of the models ordered, the number of production centers and the number of assembly lines are determined based modeling the manufacturing system.

A computer program product for modeling the manufacturing of a product in a pull and push manufacturing system, where the product comprises at least one model and each model includes at least one component, said computer program product comprising a computer-readable storage medium having computer-readable program code portions stored therein, the computer-readable program portions comprising:

• a first executable portion for simulating operation of the manufacturing system, wherein said first executable portion simulates the operation by:
• generating a master firing order schedule (MFOS) for a number of orders for models of the product over a defined time period, wherein the orders are in a predefined sequence and each order includes a defined release time;
• generating a component firing order schedule (CFOS) for a number of components corresponding to the models ordered in the MFOS based upon the defined release times of the respective orders and manufacturing times associated with the components, wherein the components are in a predetermined sequence and each component has a defined release time;
• releasing each order in the MFOS at a respective release time and releasing each component in the CFOS at a respective release time;
• producing the components at a set number of production centers for the respective set manufacturing times, wherein when a subsequent component is released before all preceding components in the CFOS are produced the subsequent component is buffered until the preceding components are produced;
• and
• assembling the orders from the produced components at a set number of assembly lines for set assembly times associated with the models ordered, wherein when a subsequent order is released before the models in all preceding orders in the MFOS are assembled the subsequent order is buffered until the models in all preceding components are assembled;
• and
• a second executable portion for adjusting at least one of the set assembly time for at least one of the models of the product, the set manufacturing time for at least one of the components of the models, the set number of production centers and the set number of assembly lines based upon at least one of a subsequent component and a subsequent order being buffered.