Use of the manufacturing system design decomposition for comparative analysis and effective design of production systems

The focus of this paper is on the use of the Manufacturing System Design Decomposition (MSDD) to make effective cost and production system design decisions. A comparative study is conducted to illustrate how and why the total cost is reduced when the functional requirements defined by the MSDD are achieved. The ultimate goal of this research was to advance manufacturing and production system development to being guided by engineering science and design rather than the common practice of duplicating another person’s or entity’s notion of the best physical implementation.     

Synchronization in manufacturing systems: quantification and relation to logistics performance

The term ‘synchronization’ in manufacturing refers to the provision of the right components to the subsequent production steps at the right moment in time. It is widely assumed that synchronization is beneficial to the logistics performance of manufacturing systems. However, it has been shown that synchronization phenomena can be detrimental to systems in which they emerge. To study if synchronization phenomena also occur in and affect manufacturing systems’ performance, a formal quantification and holistic understanding of the types of synchronization phenomena emerging in manufacturing are needed. This article aims to fill this research gap by developing synchronization measures for manufacturing systems, applying these measures to real-world production feedback data and utilising them to test the assumption about synchronization’s beneficial effect on logistics performance. We identify two distinct synchronization types occurring in manufacturing systems, logistics and physics synchronization, and show that they are negatively correlated. Further, we show that logistics synchronization and due date performance exhibit anti-correlation and thus question the assumption that synchronization leads to higher efficiency in manufacturing systems. This article aids production managers in designing and optimising production systems, and supports further empirical research in production planning and control and production system design.     

Lot-splitting approach of a hybrid manufacturing system under CONWIP production control: a mathematical model

This paper discusses the advantages of lot splitting in hybrid manufacturing environments where cellular and functional layouts are combined under Constant Work in Process (CONWIP) production control. The proposed model fills a research gap in the related literature by applying lot splitting and pull production simultaneously. A linear CONWIP control mathematical model that minimises the average flow time is developed in case of lot splitting. The developed model has sequence-dependent set-up times. The demand level, coefficient of variation (CV) impact and set-up time reduction effect on CONWIP production control are also investigated. The model is solved using GAMS21.6 optimisation software; the optimal backlog list, the number and size of sublots are reported. The proposed model is compared with lot production under push control in different settings as well as with two different heuristics from the literature. Experimental results indicate that in all settings, the lot splitting is more advantageous than lot production in terms of average flow time. CV has a greater effect than set-up time reduction on average flow time.     

A systematic approach to determine the optimal maintenance policy for an automated manufacturing system

We propose a systematic approach to determine the optimal maintenance policy for an automated manufacturing system which includes a flexible manufacturing cell (FMC) and several automated machine shops. The systematic approach combines simulation, fractional factorial design, noise or outer array of Taguchi design, regression metamodelling, and classical queueing analysis. A useful expression of the fractional utilization of the manufacturing system is derived and incorporated into formulating and solving the corresponding decision problem. The systematic approach provides an effective implementation procedure to handle practical maintenance problems found in a complex manufacturing environment. © 1997 John Wiley & Sons, Ltd.     

Application of Axiomatic Design principles to control complexity dynamics in a mixed-model assembly system: a case analysis

The purpose of this paper is to test the validity of Axiomatic Design (AD)-based complexity theory as an explanatory construct and as a methodological guidance for the early detection of need for change in flexible manufacturing systems in order to maintain competitiveness even in turbulent environmental conditions. The AD approach postulates that there are general design principles that govern the behaviour of a system. This proposition is empirically investigated for a flexible mixed-model assembly system by the examination of a long-term study conducted in a medium-sized industrial company. The findings of the long-term study suggest the introduction of a company specific cycle of functional periodicity in combination with a set of functional requirements working together as a regular trigger to detect whether the system range is moving away from the once defined manufacturing system's design range. The paper extends the research work made in the field of AD by focusing on mechanisms that help to control the effects of time-dependent complexity in manufacturing (re)design. Examples of methods and lead measures are given that can be used by organisations in early detecting and controlling complexity driven efficiency losses in manufacturing systems.     

Congruence of manufacturing decision areas in a production system: a research framework

A well designed production system secures environmental and internal fit. Environmental fit in a production system refers to alignment of manufacturing decisions to the external settings such as product and market. Internal fit implies that manufacturing decisions are mutually supportive. This paper develops a framework to analyse congruence of manufacturing decision areas in a production system. The framework considers six broad manufacturing decision areas. Based on the literature review, 54 decision types and alternative decision choices for each decision type are identified. The subjective and/or objective constructs to measure decision type are presented which should be useful in designing construct and in data gathering to conduct empirical research. Using the proposed framework, many research questions concerning the settings of several decision types for a specific type of production system can be generated and empirically tested.     

Analysis of the steady state probability distribution of a manufacturing system under the prioritised hedging point control policy

In order to evaluate the average production cost of a multi-product-type, multi-stage and multi-parallel-machine manufacturing system (denoted as mP/mS/mM), one of the effective ways is to obtain its steady-state probability distribution. Because the two-product-type and multi-parallel-machine system that demand backlog is not allowed can be considered as a basic building block of the mP/mS/mM system, we begin by investigating the method of obtaining its steady-state probability distribution under the prioritised hedging point control policy. Although the shape of the distribution domains of the work-in-process (WIP) levels influences the steady-state probability balance equations, we develop a unified form of the marginal probability balance equations for all the possible shapes of distribution domains, which can be used to calculate the marginal probability distribution for each product type for the two-product-type and multi-parallel-machine system. Furthermore, we extend this analysis method to both the multiple-product-type, multi-parallel-machine, and single-stage system and the more complex mP/mS/mM system, and propose a method to obtain their approximate marginal probability distributions of the WIP levels. Finally, numerical experiments are conducted to verify the accuracy of the proposed method of analysing the steady-state probability distribution of an mP/mS/mM system.     

The impact of maintainability on the manufacturing system architecture

The rapid development of big data technologies can improve the maintainability of machines and equipment in manufacturing systems, which could impact the selection of the optimal system architecture. In this paper, two typical architectures for large manufacturing systems ? serial lines in parallel and reconfigurable manufacturing systems ? are considered, and their productivities are compared. A decision locus is calculated that divides the configuration space into two areas; in each area, one of the architectures is the preferred one. It is also investigated how the locus is affected by different parameters, such as system size, buffer capacity and machine or gantry maintainability. The analysis provides valuable managerial insights for designing the architecture of large manufacturing systems.     

Antecedents of effective performance measurement system implementation: an empirical study of UK manufacturing firms

This paper examines the antecedents to effective performance measurement system (PMS) implementation. There have been only a few studies which have investigated this topic, and to-date there is no consensus about what factors are significant. Using empirical data collected from 349 UK manufacturing firms, we identify six potential factors from an item pool derived from an extensive literature review. Subsequent regression analysis reveals that all six factors have a significant influence on PMS implementation effectiveness. We characterise these factors into two sub-sets, with the technical sub-set accounting for most of the variance in the dependent variable. We also demonstrate that ‘softer’ social factors additionally have a significant, albeit comparatively small, effect. These, we argue, are essential in order to bind an organisation’s approach to performance measurement into one cohesive whole. Our findings provide managers with a clearer view of the factors which may influence the effectiveness of their PMS implementation. Moreover, we anticipate that the findings should provide empirical stimulation of an important debate about how to ensure that organisations can implement PMSs that are adequate for their purposes. As such, while the findings have current utility, their additional value is in providing a platform for subsequent research.     

Data envelopment analysis with multiple modes of functioning. Application to reconfigurable manufacturing systems

In principle, data envelopment analysis (DEA) does not consider the possibility, which can occur in practice, of a production system being able to operate in different modes of functioning. In this paper, a new DEA modelling approach is proposed in which the different modes of functioning are taken into account and included in the analysis. The observed input consumption and output production in each mode of functioning is used to derive a mode-specific technology. The overall DEA technology aggregates these mode-specific technologies according to their respective time allocations. The proposed model computes a target operating point for each mode of functioning so that the operation of the overall system is efficient. The proposed approach is applied to assess the technical, cost and allocative efficiency of a reconfigurable manufacturing system. The inputs considered are modules/tools usage, labour and energy consumption. The outputs are the number of units produced of each part type. The production possibility set is determined by previous observations of the system functioning, from which the best practices can be identified. Technical, cost and allocative efficiency scores can be computed. The proposed approach not only generates input cost savings but also lead time reductions.     

On the stability and bullwhip effect of a production and inventory control system

This paper focuses on the discrete-time automatic pipeline, inventory and order-based production control system (APIOBPCS), a well-established production and inventory control model. The feedback mechanism within the replenishment rule enables the model to mitigate the bullwhip effect, but introduces a stability problem. In this research, a comprehensive stability analysis is conducted for arbitrary lead times using difference equation theory. On the basis of stability, a state space approach is advocated to analyse the impact of replenishment parameters, demand processes, and lead times on the robustness of the bullwhip effect. The stability results demonstrate that the production control system can easily be destabilised without incorporating the work-in-progress (WIP) feedback loop. Furthermore, it reveals that the stability problem for long lead times can be simplified with the stability condition independent of the lead time. The results obtained in this study provide useful guidelines for the selection of replenishment parameters to guarantee stability and mitigate the bullwhip effect.     

An ISM approach for modelling the enablers of flexible manufacturing system: the case for India

The volatile condition of today's market is forcing the manufacturing managers to adapt the flexible manufacturing systems (FMS) to meet the challenges imposed by international competition, ever changing customer demands, rapid delivery to market and advancement in technology. There are certain enablers, which help in the implementation of FMS or in the transition process from traditional manufacturing systems to FMS. The utmost need is to analyse the behaviour of these enablers for their effective utilization in the implementation of FMS. The main objective of this paper is to understand the mutual interaction of these enablers and identify the ‘driving enablers’ (i.e. which influence the other enablers) and the ‘dependent enablers’ (i.e. which are influenced by others). In the present work, these enablers have been identified through the literature, their ranking is done by a questionnaire-based survey and interpretive structural modelling (ISM) approach has been utilized in analysing their mutual interaction. An ISM model has been prepared to identify some key enablers and their managerial implications in the implementation of FMS.     

Performance measurement and management: a system of systems perspective

Despite changes in tools and practices, the conceptual foundations of performance measurement and management (PMM) are still predominantly rooted in control systems research. While PMM approaches have delivered significant organisational benefits, including creating alignment, supporting monitoring and control, and enabling prediction and optimisation of resource allocation, this paper argues that this paradigm is not capable of responding to increasingly complex and highly uncertain organisational environments. Drawing on ideas emerging in the literature on systems engineering and complex systems, we propose a novel perspective that considers PMM from a ‘system of systems’ (SoS) point of view, whose essential characteristics are autonomy, belonging, connectivity, diversity and emergence. After identifying the assumptions underpinning existing PMM approaches, we outline a SoS-based paradigm to PMM and conclude by articulating the main implications for the practice of PMM and setting out a research agenda.     

Relative impact of different ERP forms on manufacturing organisations: an exploratory analysis of a global manufacturing survey

There are many types of enterprise resource planning (ERP) systems, ranging from very large and very functional vendor products such as those provided by SAP and Oracle, through in-house systems, and smaller vendor products. Thus, there is a substantial range of enterprise computing support available for manufacturing organisations and their manufacturing planning and control. The Global Manufacturing Research Group (GMRG) has collected a systematic survey of manufacturing organisations around the world, providing a picture of manufacturing operations. We have taken GMRG data and organised it around seven levels of ERP functionality, and analysed these data to determine effectiveness in terms of how ERP systems are used in global manufacturing firms, their role in accomplishing manufacturing planning and control, the relationship between ERP forms and data-management practices, the satisfaction firms have across ERP forms, and finally, relative perceived benefits and costs across ERP forms.     

The link between Industry 4.0 and lean manufacturing: mapping current research and establishing a research agenda

In recent years, Industry 4.0 has emerged as one of the most discussed concepts and has gained significant popularity in both academia and the industrial sector. Both Industry 4.0 and lean manufacturing utilise decentralised control and aim to increase productivity and flexibility. However, there have been few studies investigating the link between these two domains. This article explores this novel area and maps the current literature. This is achieved through a systematic literature review methodology, investigating literature published up to and including August 2017. This article identifies four main research streams concerning the link between Industry 4.0 and lean manufacturing, and a research agenda for future studies is proposed.     

Reviewing the intellectual structure and evolution of the innovation systems approach: A social network analysis

The increased attention of policymakers and researchers to the concept of innovation systems in recent decades has led to an increase in studies in this field and, consequently, its dynamics. This increase in the number of studies indicates the necessity of conducting studies to delineate the intellectual structure and process of development and evolution of this field. The present study aims to present a picture of the structure, evolution, and dynamics of innovation systems through the analysis of academic social networks based on bibliometric criteria and identify emerging issues for research. Accordingly, using citation, word co-occurrence, co-citation, and bibliographic coupling analyses, we analyzed 3250 documents which had been published between 1988 and 2018 and extracted from the Web of Science database. Through a systematic review, theoretical roots and frameworks affecting this field were identified and the existing research streams were introduced. According to the analyses, historical and contemporary views were categorized into four clusters. In addition, the most important and emerging issues in this field were identified and the most influential documents, journals, and authors were introduced.     

Alternative production strategies based on the comparison of additive and traditional manufacturing technologies

Additive manufacturing technology has been evolving for several years. New material options, better processing speeds and greater autonomy are some of the characteristics of this technology that are still under research. However, in its current state, many commercially available 3D printers are competing with traditional manufacturing techniques in the fabrication of end-use products. In this paper, different additive manufacturing technologies are compared with injection moulding in a real-world case study. The comparison is conducted in terms of lead time and total production cost. From the case under study, it becomes obvious that none of the additive manufacturing technologies examined is yet able to practically replace injection moulding for medium- and high production volumes. However, when considering low-volume production, both rapid tooling and additive manufacturing may offer an alternative that could result into shorter lead times and decreased total production costs. In addition, the introduction of Additive Manufacturing in a producer’s production portfolio can increase flexibility, reduce warehousing costs and assist the company towards the adoption of a mass customisation business strategy.     

A mathematical model and a heuristic approach for design of the hybrid manufacturing systems to facilitate one-piece flow

One-piece flow is a design rule that entails production in manufacturing cells on a ‘make one, check one, and move-on one’ basis (Black, J.T., 2007. Design rules for implementing Toyota Production System. International Journal of Production Research, 45 (16), 3639–3664), which reduces manufacturing lead time significantly. This paper proposes a sequential methodology comprised of a mathematical model and a heuristic approach (HA) for the design of a hybrid cellular manufacturing system (HMS), to facilitate one-piece flow practice. The mathematical model is employed in the cases of small- and medium-sized problems, and it attempts to minimise the total number of exceptional operations, while considering machine capacities and alternative machines. The machine-part matrix achieved by the mathematical model is input into the flow line design stage of the HA, where backflow within the cells is eliminated. However, for industrial problems, the proposed HA is utilised. After the formation of the cells by clustering, the HA attempts to eliminate exceptional operations of a given cellular configuration together with a functional structure by employing alternative machines, based on the decision rules developed. Later, unidirectional flow within the cells is achieved and the capacity and budget constraints are satisfied. A medium-sized problem is solved by using both of the approaches, namely, the model integrated with the flow-line design stage of the HA and the complete HA. The results are discussed and the limitations are explained.     

IT investments and business performance improvement: the mediating role of lean manufacturing implementation

The main purpose of this study is to examine whether the application of current information technology (IT) and different principles of lean manufacturing (LM) are interdependent and complimentary or they are mutually exclusive. This study draws on the so-called IT-enabled organisational capabilities perspective to study the relationships between IT, LM and business performance improvement. Using a questionnaire-based survey, the data come from 231 leading Iranian and Malaysian auto-part manufacturers. The findings suggest that LM and IT are mutually interdependent and value of IT investments can be effectively transformed into business performance improvement for auto-part manufacturers through the higher levels of lean manufacturing system (LMS) implementation. Advanced manufacturing technology (AMT) competency is a valuable intermediate capability which links IT investments into LMS implementation. It was found that IT investment is one of the minimum requirements of LMS implementation for surveyed business, and the value of IT investment is truly transformed to LMS implementation when IT investments offer competent administrative AMTs to effectively manage all production processes. Findings also recommend that managers should avoid isolating the performance metrics only on areas such as net financial measures, while assessing the business value of IT and LM.     

Design of manufacturing systems by a hybrid approach with neural network metamodelling and stochastic local search

Metamodels are models of simulation models. Metamodels are able to estimate the simulation responses corresponding to a given combination of input variables. A simulation metamodel is easier to manage and provides more insights than simulation alone. Traditionally, the multiple regression analysis is utilized to develop the metamodel from a set of simulation experiments. Simulation can consequentially benefit from the metamodelling in post-simulation analysis. A backpropagation (BP) neural network is a proven tool in providing excellent response predictions in many application areas and it outperforms regression analysis for a wide array of applications. In this paper, a BP neural network is used to generate metamodels for simulated manufacturing systems. For the purpose of optimal manufacturing systems design, mathematical models can be formulated by using the mapping functions generated from the neural network metamodels. The optimization model is then solved by a stochastic local search approach, simulated annealing (SA), to obtain an optimal configuration with respect to the objective of the systems design. Instead of triggering the detailed simulation programs, the SA-based optimization procedure evaluates the simulation outputs by the neural network metamodels. By using the SA-based optimization algorithm, the solution space of the studied problem is extensively exploited to escape the entrapment of local optima while the number of time consuming simulation runs is reduced. The proposed methodology is illustrated to be both effective and efficient in solving a manufacturing systems design problem through an example.