Configuration and multistep switching of machines in dynamic hybrid MTS/MTO production systems

This study proposes the configuration of MTS-/MTO-dedicated and hybrid (switchable) machines under a multistep switching policy where each hybrid machine can be switched stepwise and compares it to the existing model with MTS-dedicated and hybrid machines under a group switching policy that makes all hybrid machines switch together. Since companies have been required to satisfy wide varieties of customers' needs in recent years, the dynamic hybrid make-to-stock (MTS) / make-to-order (MTO) production system–one of the flexible production strategies with superior efficiency and productivity–is widely adopted in the garment industry. This system contains MTS and MTO streams in a shared facility and holds dedicated and hybrid machines that can be switched between MTS and MTO production. The machine configuration and switching policy are essential factors to increase the effectiveness of this system; hence, the features of such components must be investigated. Numerical experiments demonstrate that the cost and the number of MTO customers waiting can be reduced by appropriately setting the multistep switching policy and the machine configuration. Effective operating rules can also be achieved using our proposed search heuristics. These results contribute to the improvement of the existing dynamic hybrid system and the expansion of its possible applications.