Workload control in unbalanced job shops

Workload control (WLC) has been developed as a production planning and control approach for job shop manufacturing. By balancing loads across work centres, WLC anticipates the fact that multiple work centres may become potential bottlenecks in the short term. This approach is generally tested in job shop models that assume equal utilisation levels for all work centres, which will create maximum bottleneck shiftiness. However, job shop practice clearly shows differences in utilisation levels, which means that some work centres can be seen as non-bottlenecks, having protective capacity. This study investigates the effect of different levels of protective capacity on the performance of state-of-the-art WLC release methods. More in detail, it shows how the level of protective capacity interacts with the influence of workload norms at work centres. Despite the fact that WLC has been developed for highly balanced utilisations, results indicate that WLC could also be effective in unbalanced situations. However, norm setting requires careful attention. Disregarding the norms of non-bottleneck work centres, a common sense approach, might strongly deteriorate performance when the level of protective capacity is not sufficiently high. Contrarily, tighter norms for non-bottleneck work centres are shown to perform better in this situation. © 2013 Taylor and Francis.