A systematic approach to model human system in cellular manufacturing (original) (raw)
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Static modeling using system dynamic modeling tools support in decomposing complex cellular manufacturing operation into a visual map that allows for a systematic way to conceptualize the business processes. Dynamic simulation modeling enables the behavioral effects of the critical manufacturing resources to be evaluated in order to predict the performance of the manufacturing system. In this paper, the use of system dynamic and simulation modeling tools has been integrated to facilitate the study of cellular manufacturing resource configuration and deployment activities. The case study application allows for the testing of the integrated modeling concept on a new product introduction change process. The integrated tools synergize the company management’s effort to effectively analyze and manage the dynamics and complexity of the cellular manufacturing operation.
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The performance of direct workers has a significant impact on the competitiveness of many manufacturing systems. Unfortunately, system designers are ill equipped to assess this impact during the design process. An opportunity exists to assist designers by expanding the capabilities of popular simulation modelling tools, and using them as a vehicle to better consider human factors during the process of system design manufacture. To support this requirement, this paper reports on an extensive review of literature that develops a theoretical framework, which summarizes the principal factors and relationships that such a modelling tool should incorporate.
A PRACTICAL METHODOLOGY FOR CELLULAR MANUFACTURING SYSTEMS DESIGN -AN INDUSTRIAL STUDY
The product oriented organization of manufacturing systems based on group technology cells, typical of lean production, is a very effective organization to timely meet customer requirements and take full advantage of production resources. Frequently it has been pointed out that studies on cellular manufacturing systems tend to be theoretical and addressing only a few of the relevant practical issues. In this paper, a comprehensive industrial study for reconfiguring a production system into a product oriented manufacturing system, based on GT cells, carried out in a company manufacturing leather goods, it is reported. This study take into account all important and necessary issues, for system reconfiguration, namely capacity requirements, actual and expected future demand, existing resources and required and available physical space. A practical methodological approach for part family formation, machines allocation to cells and cellular layout planning are put forward. Procedures for dealing with exceptional elements towards minimizing intercellular workflow and for streamlining material flow within cells and across cells are also described and implemented. In this particular study separating kits of raw parts at the beginning of parts processing and joined them together again at the end of processing was a requirement that needed to be addressed and made reliable to avoid severe mistakes when assembling parts into final products. This requirement was an additional motivation for organizing production into cells leading to a much more reliable kitting operation greatly due to the streamlined and synchronized work flow of parts achieved. The study proposes reorganizing the system into three autonomous GT cells and a gateway work centre, with resources practically reduced to the minimum required based on product demand. The study compares the initial configuration solution with the proposed one showing advantages of the proposed solution under a few evaluation issues, namely in relation to work flow organization, movement of materials and reliability of the parts kitting for final assembly.
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Shorter product life cycles, unpredictable demand patterns and the ever-shrinking time to market, have been constantly keeping the manufacturing firms under a lot of pressure. To face these challenges the manufacturing organizations have been shifting to Cellular Manufacturing (CM) due to its benefits of reducing manufacturing costs, increasing flexibility and delivering orders on time. Despite having several benefits, designing a Cellular Manufacturing System (CMS) for a real-life application is a tough ask. The main challenge is the part-machine grouping in cells. It becomes even more challenging when the group scheduling (GS) problem is handled alongside the part-machine clustering. To take up this challenge, an integrated model is developed during this research which handles the machine-part grouping and the GS problems, simultaneously. To optimize the multiple objectives of maximizing Grouping Efficacy (GE) and minimizing Makespan (Cmax), concurrently, a Hybrid Genetic Algorith...
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This article considers some of the human resource management implications of the Japanese manufacturing system. The paper draws on case studies undertaken in England between 1985 and 1988. The paper presents a framework for analyzing the effects of Japanese methods. It is found that the Japanese system resulted in an enhancement of manual engineering skills. Further, it is argued that Japanese practices can coexist alongside traditional industrial relations systems, but because of uncertainty and high dependency on constituents, new organizational control configurations need to be developed.
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Journal of Manufacturing Systems, 2005
The process of manufacturing system design frequently includes modeling, and usually, this means applying a technique such as discrete event simulation (DES). However, the computer tools currently available to apply this technique enable only a superficial representation of the people that operate within the systems. This is a serious limitation because the performance of people remains central to the competitiveness of many manufacturing enterprises. Therefore, this paper explores the use of probability density functions to represent the variation of worker activity times within DES models.