A review of production planning and control: the applicability of key concepts to the make-to-order industry

• Published in: International journal of production research Vol. 43; no. 5; pp. 869 - 898
• Main Authors: Stevenson, M., Hendry, L. C., Kingsman †, B. G.
• Format: Journal Article
• Language: English
• Published: London Taylor & Francis Group 01.03.2005; Washington, DC Taylor & Francis; Taylor & Francis LLC
• Subjects: Applied sciences; Comparative analysis; Control systems; Customization; Exact sciences and technology; Job shop; Job shops; Make-to-order (MTO); Operational research and scientific management; Operational research. Management science; Production planning; Production planning and control (PPC); Scheduling, sequencing; Small and medium sized enterprises (SME); Small business; Studies; Workload control (WLC); Manufacturing resource planning; Decision support system; Decision making; Customization; Job shop; Production planning and control (PPC); In-process inventory; Small and medium sized enterprises (SME); Production management; Workload control (WLC); Kanban; Make-to-order (MTO); Production planning; World wide web; Resource management; Small medium sized firm
• ISSN: 0020-7543; 1366-588X
• DOI: 10.1080/0020754042000298520

The paper reviews 'classic approaches' to Production Planning and Control (PPC) such as Kanban, Manufacturing Resource Planning (MRP II) and Theory of Constrains (TOC), and elaborates upon the emergence of techniques such as Workload Control (WLC), Constant Work In Process (CONWIP), Paired cell Overlapping Loops of Cards with Authorization (POLCA) and web- or e-based Supply Chain Management (SCM) solutions. A critical assessment of the approaches from the point of view of various sectors of the Make-To-Order (MTO) Industry is presented. The paper considers factors such as the importance of the customer enquiry stage, company size, degree of customization and shop floor configuration and shows them to play a large role in the applicability of planning and control concepts. The paper heightens the awareness of researchers and practitioners to the PPC options, aids managerial system selection decision-making, and highlights the importance of a clear implementation strategy. WLC emerges as the most effective Job Shop solution; whilst for other configurations there are several alternatives depending on individual company characteristics and objectives. The paper outlines key areas for future research, including the need for empirical research into the use of Workload Control in small and medium sized MTO companies.