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References ce APICS Dictionary, 6th ed. Falls Church, VA: American Production and inventory Control Society, 1987. Bolander, S.F. and $.G. Taylor. “Process Flow Schedul- ing: Mixed Flow Scheduling Cases,” Production and Inventory Management Journal, Vol. 31, No. 4 (1990),1-6. Schedules. Toronto, Canada: Numerrix, Led., 1990. Taylor, S.G. “Are Process Industries Different?” APICS 23rd Annual Conference Proceedings (1980), 94-98 — and SF. Bolander, “Scheduling Product Families.” Production and Inventory Management, Vol. 27, No. 3 (1986,: 47-55, : 5. —, "Process Flow Scheduling: Basie Cases." Production and Inventory Management Journal, Vol. 31, No. 3 (1990), 14. —, “Process Flow Scheduling Principles,” Production and Inventory Management Journal, Vol. 32, No. 1 (1991), ori. About the Authors Darryl T. Hubbard, CPIM, is Materials Manager for Sylvania's domestic coil operations, apart of GTE’s Precision Materials Group chat supplies components to the lighting divisions and other industrial users. He has over ten years experience in planning systems development and various production and inventory management functions, the major ity of that with the Sylvania Lighting Division, U.S. His professional interests include intercompany logistics and integrating the operations and marketing functions. Hie has a BBA in management, is APICS certified, and is pursuing and MBA in marketing/operations management. Sam G. Taylor, Ph.D,, is a professor of operations man- agement in the College of Business at the University of ‘Wyoming, His research interests are in planning and sched- uling systems for process industries. Prior co his academic career, Sam worked eight years in the oil and chemical industries, He has a BS and an MS in chemical engineering anda Ph.D. in industrial engineerin. Steven F. Bolander, PhD, is a professor of management at Colorado State University where he teaches undergraduate and graduate courses in production management. Steve's research interests are in production and inventory manage- ment. Formerly he worked as manager of manufacturing systems development andasa program manager for Rockwell International. le has aBS in chemistry, an MBA, and a Ph.D. in manufacturing managemect. © PICS CPIM Systems and Technologies Reprints 95 Reprinted from the Production and Inventory Management Journal, Fourth Quarter, 1992 Process Flow Scheduling in a High-Volume Repetitive Manufacturing Environment Darryl T. Hubbard, CPIM Sam G. Taylor, Ph.D. Steven F. Bolander, Ph.D. the process structure to guide scheduling calculations for groups of products, Taylor and Bolander [2,6] recently introduced and documented process flow scheduling concepts with case studies from Scott Paper, EG&G, East- man Kodak, and Coors Brewing. These process industry cases formed the foundation for astatement of PFS principles {7} In this aricle, the use of PES principles in a repetitive manufacturing environment will be illustrated. P=: flow scheduling (PES) is a technique that uses Scheduling Environment ‘The Sylvania Lighting Division—US. is part of GTE Corporation’s Electrical Products Group. Sylvania Lighting produces a wide range of lighting products including incan- descent, fluorescent, quartz, high intensity discharge, and various other specialty lamp types, The scope ofthis article is limited to a representative group of straight fluorescent lamps that are produced on 2 high-volume line at the Dan- vers, Massachusetts, lighting plant. The basic concepts described are applicable at all the lighting plants, with some variation expected due to the characrerstis of each product line's process structure. The Product Schematic drawings of a fluorescent lamp are shown in Figure 1, which illustrate how a low-pressure mercury vapor acc is used to generate invisible ultraviolet energy. This enesgy is absorbed by the phosphor coating on the inside of the glass tube that transforms the energy into visible light. ‘The subject production linc is dedicated to a specific base configuration and produces over 100 end items of varying lengths, light output, and color. For each length lamp, rang- ing from as small as two feet to as long as eight, there are ewo light ourpur levels offered (lenoted as either option “A” or “