Flexible manufacturing systems performance in U.S. automotive manufacturing plants: a case study

Flexible manufacturing systems (FMS) philosophy is a key weapon in achieving global manufacturing competitiveness. It encompasses a wide range of dimensions to improve all aspects of operational performance metrics. The aim of the study is to examine the current state of flexibility adoption in U.S. automotive manufacturing facilities and its impact on operational performance metrics. It utilizes survey questionnaire developed based on previous work in U.S. manufacturing industry. The survey was originally distributed to 420 facility managers in the U.S. domestic automotive industry. It was revealed that 70% of the respondents had implemented all 15 flexibility dimensions listed in the questionnaire. The data analysis conducted shows that implementation of certain flexibility dimensions will lead to significant improvement in specific operational performance metrics. This considerable finding can be used as a guide for manufacturing managers to achieve certain objectives in operational performance improvement in a rapidly changing environment.     

An Empirical Investigation of the Contribution of Strategic Sourcing to Manufacturing Flexibilities and Performance*

Empirical studies for achieving manufacturing flexibility goals have centered around the uses and advantages of advanced technology. Few studies have examined alternative ways of attaining flexibility objectives. Strategic sourcing finds mention in the literature as a potential route to manufacturing flexibility. However, little empirical evidence exists to validate this view. Literature also describes manufacturing flexibility as a multidimensional concept but fails to adequately examine the synergies among the different dimensions. This research investigates the influence of strategic sourcing and advanced manufacturing technologies on specific manufacturing flexibilities, and examines relationships among different flexibilities. The results are tied to manufacturing cost reduction. The findings suggest that strategic sourcing can assist in the achievement of modification flexibilities. Volume and modification flexibility are found to influence new product flexibility. Modification flexibility is found to influence manufacturing cost reduction. The results show that strategic sourcing can be used to target specific manufacturing flexibilities and that interflexibility synergies need to be considered while formulating flexibility-based manufacturing strategies.     

Fit,Flexibility and Performance in Manufacturing: Coping with Dynamic Environments

This research develops the notion of environmental fit and flexibility and illustrates the importance of such fit empirically using survey data from 101 manufacturing firms. Two dimensions of environmental dynamism are identified and the fit between them and different approaches to flexibility are assessed. Hierarchical regressions provide evidence that flexibility is a stronger predictor of performance in more dynamic environments. Specifically, presence of the unpredictability or the volatility aspects of environmental dynamism each warrant the use of different types of manufacturing flexibility strategies. Statistical results are interpreted with the caveat that while implemented capability must be used to study performance effects, this study uses perceived importance scales for flexibility.     

An aggregate production planning framework for the evaluation of volume flexibility

Flexibility in manufacturing has been identified as one of the key factors to success in the marketplace. Many types of flexibility have been identified in the literature among which volume flexibility is one of the most important. Volume flexibility of a manufacturing system is defined as its ability to be operated profitably at different overall output levels. Volume flexibility permits a manufacturing system to adjust production upwards or downwards within wide limits. In this paper, we develop an aggregate production planning model for volumeflexible production systems. The model can be used with a Monte Carlo simulation to evaluate the optimal level of investment in volume flexibility for a firm operating under a given set of market conditions. In addition, the model can be used to develop some conclusions about the relationship between the value of volume flexibility and the cost of holding inventory, the cost of shortage, forecast accuracy, and the length of the planning horizon.     

Flexibility configurations: Empirical analysis of volume and product mix flexibility

In this paper we address flexibility and investigate the relationship between volume and product mix flexibility. One view of flexibility is that of being a capability in itself; another view is that of flexibility as an enabler, providing the manufacturing system with properties on which other competitive capabilities are built. In this research, the latter view of flexibility is used, where flexibility acts as a second order competitive criterion. The aim is to differentiate between two dimensions of flexibility important to the manufacturing value chain, i.e., volume and product mix flexibility, and to investigate how different flexibility configurations are related to various manufacturing practices. A clustering research approach is used to identify groups of companies based on flexibility configurations. The groups are then analyzed with respect to characteristics and impact on operational performance. For the empirical investigation, we use empirical data from the high performance manufacturing (HPM) study, including three industries and seven countries—a total of 211 plants. We find that flexibility configurations based on high or low levels of volume and mix flexibility combinations show significant differences both in terms of operational performance, and in terms of emphasis put into different flexibility source factors.     

Implementation of holonic scheduling and control in flow-line manufacturing systems: die-casting case study

The success of a flow-line manufacturing system depends on effective production scheduling and control. However, it has been found that current flow-line manufacturing scheduling and control algorithms lack the flexibility to handle interruptions or resource breakdowns; hence, system performance drops automatically and rapidly when interruptions occur. The objective of this research is to investigate if the performance of a flow-line manufacturing system can be improved by integrating agent-based, holonic scheduling and production control. A holonic manufacturing scheduling model has been developed and implemented into a die-casting manufacturing flow line throughout a simulation model. The analysis takes into account the comparisons of overall performances of the system models with the holonic scheduling and conventional scheduling approaches. Simulation results indicate that the holonic manufacturing scheduling and control can significantly increase the uptime efficiency and the production rate of the flow-line manufacturing system.     

基于最大偏差原则的群体性事件应急管理绩效评价模型

群体性突发事件应急管理绩效评价具有价值判断冲突性、结构嵌入性和语义模糊性等非常规特征。针对群体性突发事件的矛盾对抗性特征,根据"着重解决群众反映意见较大的突出问题"的善后处置原则,构建了基于最大偏差原则的多属性评价模型。首先,在社会结构、应急策略和评价指标等多重维度下,构建了件应急管理绩效评价指标体系,包括效率、公平、收敛性、稳定性和适应性。其次,针对价值判断冲突特征,提出基于最大偏差原则的二元语义信息处理方法:偏差越大,表明该属性能够更好的反映出事态冲突性,应赋予越高的权重。最后,结合某住宅小区锅炉房拆迁案例的全样本调查数据进行实证分析。结果表明,相对于模糊综合评价模型和最小偏差原则的二元语义模型,基于最大偏差原则更能反映出群体性突发事件应急管理绩效评价的价值冲突性。     

基于非均匀性语言标度和DLWA算子的动态绩效模糊群决策研究

基于企业人力资源管理(HRM)系统中职能管理部门年度绩效考核决策评价和选优序列生成过程中的数据的不确定性、随机性和模糊性,通过设计季度绩效多维度模糊评价体系,采用非均匀加性语言评估标度定性的多维度评价,构建动态加性语言判断矩阵模型,利用DLWA算子等语言信息集成算子,集成多个决策者不同时期绩效指标评价数据,并整合不同决策者的偏好度,综合呈现年度部门业绩选优序列,优化提升职能管理部门绩效考核决策的精确性、公平性和可信度。     

Fuzzy integrated QFD,FMEA framework for the selection of lean tools in a manufacturing organisation

Lean Manufacturing (LM) is a well-established system to improve performance of any manufacturing industry by eliminating wastes through globally accepted tools and techniques. Industries are trying to adapt lean principles in order to optimise the resources like people, equipment, material and schedule for being efficient in the competitive market. This paper proposes an integrated approach for selecting appropriate lean tools in reliable lean perspective to enhance these critical resources. The approach exercise a hybrid model which uses fuzzy QFD to prioritise the critical resources in relation with identified wastes and fuzzy FMEA to assess the risk associated with each sub elements to address lean implementation. For waste identification, plant layout and Value Stream Mapping are considered. The model is demonstrated based on the data collected from a manufacturing industry to illustrate the application. Significant improvements are quantified with the help of future state map and plant layout.     

Managing Quality in the E‐Service System: Development and Application of a Process Model

In this paper, we develop a process model for assessing and managing e‐service quality based on the underlying components of the e‐service system and, in turn, address the growing need to look in more detail at the system component level for sources of poor quality. The proposed process model is comprised of a set of entities representing the e‐service system, a network defining the linking between all pairs of entities via transactions and product flows, and a set of outcomes of the processes in terms of quality dimensions. The process model is developed using Unified Modeling Language (UML), a pictorial language for specifying service designs that has achieved widespread acceptance among e‐service designers. Examples of applications of the process model are presented to illustrate how the model can be use to identify operational levers for managing and improving e‐service quality.     

基于Heronian平均算子的Pythagorean模糊不确定语言决策方法

针对评价信息为Pythagorean模糊不确定语言数、属性权重未知且属性间相互影响的多属性决策问题,提出一种基于灰色关联法和Heronian平均算子的决策方法。首先,提出Pythagorean模糊不确定语言Heronian平均（PFULHM）算子和Pythagorean模糊不确定语言几何Heronian平均（PFULGHM）算子,并证明其满足幂等性、单调性、有界性及可交换性。考虑到属性权重之间重要程度的差异,定义了Pythagorean模糊不确定语言加权Heronian平均（PFULWHM）算子和Pythagorean模糊不确定语言加权几何Heronian平均（PFULWGHM）算子。其次,将灰色关联法运用到Pythagorean模糊不确定语言环境中求解属性权重。最后,提出基于PFULWHM算子和PFULWGHM算子的决策方法,并通过算例分析说明本文提出方法的有效性。     

Integrating MRP and finite capacity planning

Traditional production control systems based on the manufacturing resource planning concept do not sufficiently support the planner in solving capacity problems, ignore capacity constraints and assume that lead times are fixed. This leads to problems on the shop floor, that cannot be resolved in the short term. This paper focuses on solving these capacity problems by improving capacity planning at the material requirements planning MRP level through integration of MRP and finite capacity planning. This results in a planning method for simultaneous capacity and material planning. The planning method is based on a new and more accurate primary process model, giving the planning algorithm more flexibility in solving capacity problems. The algorithm is based on advanced scheduling techniques and uses aggregated information, thus combining speed and accuracy. The algorithm is designed to use the available flexibility: alternative routeings, safety stock, and replanning of production orders and requirements. This paper also discusses such related issues as robustness, memory and the role of the human planner.     

基于同质设备多台配置的独立生产单元构建决策

单元化生产作为一种较好实现生产柔性与生产效率融合的先进生产方式,在变种变量需求环境下它已被大量生产企业特别是装配式生产企业所采用。生产单元构建问题是单元化生产系统设计的关键问题和首要问题,也是单元化生产研究领域的一个热点。本文研究设备易复制情形下,通过配置多台同质设备来实现生产单元间无物料移动,并保证生产单元间工作量均衡的独立生产单元构建问题。本文在综合考虑换装时间、加工顺序、设备生产能力、产品需求量等多个实际生产要素的基础上,建立了以平均总流程时间和各生产单元总流程时间与平均总流程时间偏差最小为目标的数学模型,并开发了一个启发式算法来求解数学模型,最后通过数值算例验证了模型和算法的有效性。     

The impact of modular platforms on automobile manufacturing networks

This paper explores the impact on automobile manufacturing networks of adopting modular platforms to replace the standard platforms used to date. Analysis of European manufacturers’ production networks shows that the use of modular architecture improves coordination by increasing manufacturing mobility and thriftiness ability. The changes resulting from this new modular approach also allow manufacturing capacity to be reorganised and overcapacity to be partially eliminated. From the point of view of production systems, the adaptation of manufacturing processes and facilities to this new architecture should aim to increase flexibility by integrating production around a single platform, allowing for different dimensions and for a larger number of models to be produced in a single plant.     

BUSINESS STRATEGY,MANUFACTURING FLEXIBILITY,AND ORGANIZATIONAL PERFORMANCE RELATIONSHIPS: A PATH ANALYSIS APPROACH

It has been argued in the literature that business strategy and manufacturing flexibility independently affect the performance of an organization. However, no empirical examination of the interrelationship among these three constructs has been performed. In this paper, based on a field study of 269 firms in the manufacturing industry, the identified constructs have been used to test a theoretical model using path analysis techniques. Our results indicate that business strategy contributes both directly and indirectly to organizational performance. The findings provide evidence of direct effects of (i) business strategy on manufacturing flexibility and (ii) manufacturing flexibility on organizational performance.     

A methodology for the design of manufacturing systems using group technology

The primary objectives in implementing computer integrated manufacturing systems (CIMS) are to improve quality, enhance flexibility, and increase productivity. One of the approaches used to achieve these objectives is to organize and group the production machines into manufacturing cells using group technology concepts. Cellular manufacturing allows small batch production to gain economic advantages similar to mass production while maintaining the flexibility of job shop production. This paper presents a methodology which uses design and manufacturing attributes to form manufacturing cells in a computer integrated manufacturing setting. The methodology is implemented in two phases. In phase I, parts are grouped into part families based on their design and manufacturing attributes. In phase II of the methodology, the machines are grouped into manufacturing cells based on relevant operational costs, and the various cells are assigned part families using an optimization technique. The optimization technique employs integer programming to minimize the total operational costs.     

Coping with Group Behaviors in Uncertain Quality Function Deployment

Quality function deployment (QFD) is a planning and problem‐solving tool gaining wide acceptance for translating customer needs (CNs) into technical attributes (TAs) of a product. It is a crucial step to derive the prioritization of TAs from CNs in QFD. However, it is not so straightforward to prioritize TAs due to two types of uncertainties: human subjective perception and user variability. The main focus of this article is to propose a group decision‐making approach to uncertain QFD with an application to a flexible manufacturing system design. The proposed approach performs computations solely based on the order‐based semantics of linguistic labels to eliminate the burden of quantifying qualitative concepts in QFD. Moreover, it incorporates the importance weights of users and the concept of fuzzy majority into aggregations of individual fuzzy preference relations of different TAs in order to model the group behaviors in QFD. Finally, based on a quantifier‐guided net flow score procedure, the proposed approach derives a priority ranking with a classification of TAs into important and unimportant ones so as to provide a better decision‐support to the decision‐maker. Due to the easiness in articulating preferential information, our approach can reduce the cognitive burden of QFD planning team and give a practical convenience in the process of QFD planning.     

一种基于TOPSIS的混合型多属性群决策方法

本文针对具有语言型和直觉模糊数两种评价信息的混合型多属性群决策问题,提出了一种基于TOPSIS的决策方法。首先,定义了新的函数,可将不同粒度的语言评价信息转换成直觉模糊数。其次,在直觉模糊数熵值的基础上,提出了一种新的专家权重确定模型。再次,利用IFWA算子在把个体决策矩阵集结为群体决策矩阵后,基于TOPSIS分别计算群体评价值到正理想解和负理想解的距离,从而得到方案集的排序。最后,在ERP选优问题中的应用,验证了方法的有效性。