Title: Hierarchical production planning system for a plastic container manufacturer with a combined processing-assembly and hybrid flow shop

Authors: Chihiro Hayashi

Addresses: Department of Business Administration, Faculty of Business Administration, Ryukoku University, 67 Tsukamoto-cho, Fukakusa, Fushimi-ku, Kyoto 612-8577, Japan

Abstract: This research presents a basic study on the optimisation of a hierarchical production planning system used by a plastic container manufacturer with a combined processing-assembly and hybrid flow shop. To optimise hierarchical production planning in a two-stage manufacturing process, a mathematical approach was used for decoration and assembly. First, a hierarchical production plan utilised for the two processes was formulated using the safety inventory setting and demand forecast priority parameters, which increased or decreased production capacity as controllable variables, and inventory and stockout as criteria. A mathematical analysis was then performed to minimise the inventory, which restricted the analysis to the condition in which no stockouts occurred. Production planning based on the relationship between parameters and inventory shown in the analysis provides an effective means of addressing the real process problem of minimising stockouts while preventing excess inventory.

Keywords: hierarchical production planning system; plastic container manufacturer; processing-assembly flow shop; hybrid flow shop.

DOI: 10.1504/AJMSA.2025.148899

Asian Journal of Management Science and Applications, 2025 Vol.8 No.2, pp.160 - 184

Received: 18 Apr 2024
Accepted: 04 Aug 2024
Published online: 01 Oct 2025 *