Optimal design of a hybrid push/pull serial manufacturing system with multiple part types

The objective of this research is to investigate the possibility of integrating Manufacturing Resource Planning (MRP)/push and Just in Time (JIT)/pull strategies in a multiproduct multistage serial manufacturing system. Each workstation is able to undertake different operations and so to produce more than one type of in-process item. A modified version of a horizontally integrated hybrid push/pull production system is developed. The system can be optimized by locating points of integration, and determining the optimal values of safety stocks for the push part and numbers of Kanbans for the pull part. A modification of genetic algorithm chromosomes and crossover procedures is developed for the optimization. The optimization involves evaluations of stochastic performance measures by a discrete event simulation model.