Design and operational enhancements for a batch process driven supply chain

Abstract

Film manufacturing at Eastman Kodak involves large-scale batch steps dictated by both technical and economic factors. Large-scale batch processes can lead to an unresponsive and wasteful supply chain. This thesis explores supply chain design and operational improvements that can mitigate the effects large-scale batch steps have on the overall performance of the supply chain. Specifically, the thesis investigates: 1. The applicability of using customer demand signals to drive upstream production processes. 2. Methods for mitigating effects of long component lead times. 3. Reducing the disparity between scheduling and manufacturing lead times The thesis also describes various simulations created to explore the above issues. These simulations were key discovery tools in finding creative ways to reduce the large-scale batch process effects. The results, respectively, are: 1. The decision to use customer demand signals to drive upstream production processes depends on the operational characteristics of the production process. 2. Provided certain conditions exist, a method, the Second Look Process, can improve supply chain responsiveness in the face of long lead-times. 3. An organization must realize its processes can impose inefficiencies in its supply chain operations; it must take a look at these inefficiencies and balance them with the organizational costs of eliminating them. In light of the constraints large-scale batch processes place on supply chain design and operations, this thesis provides methods and conceptual frameworks within which real bottom-line cost savings can be realized.