A multicriteria model for supporting setup reduction investment decisions

One critical manufacturing challenge of the 1990s is for firms to effectively apply new operations management techniques while embracing wider philosophies such as total quality management (TQM) and computer integrated manufacturing (CIM), etc. Setup cost and/or time reduction is one such technique capable of producing many benefits for manufacturing firms, including reduced inventory, better equipment utilization, and improved quality. It is thereby viewed as an important component of just-in-time (JIT) manufacturing practice. Existing problems with the setup reduction decision include the many factors that must be considered, as well of an absence of validated and usable models for estimating potential benefits from setup reduction investment made in different contexts. This paper discusses the attainment of gains from setup reduction mainly by improving existing equipment and work practices rather than purchasing new equipment or technology. The model proposed in this paper is based on the application of the analytic hierarchical process (AHP) on seven weighted factors to obtain a preliminary indication as to whether investment in setup reduction is desirable in a given manufacturing context, and the expected benefits of such investment. A flexible scaling system, thus obtained, allows the model to handle a wide range of managerial predispositions to setup reduction.