Implementation of a Flexible Manufacturing System in a production cell of the automotive industry: decision and choice

Sellitto, Miguel Afonso; Mancio, Vagner Gerhardt

doi:10.1590/0103-6513.20180092

Cited by 8 publications

(4 citation statements)

References 51 publications

(52 reference statements)

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“…Although literature has asserted that automotive supply chains are lean, the ability to respond quickly and flexibly to sudden changes in a market environment is increasingly important (Qamar and Hall 2018 ; Sellitto and Mancio 2019 ). Like TW, AM is a socio-technical system blending soft and hard elements.…”

Section: Literature Reviewmentioning

confidence: 99%

Contextual factors on Toyota Way and Agile Manufacturing: an empirical investigation

Vanichchinchai

2023

Oper Manag Res

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This research aims to examine the differences across selected contextual factors on the Toyota Way (TW), agile manufacturing (AM) and their sub-elements. These factors include firm size, nationality of firms, production approaches, IATF 16949 - an international quality management certification in the automotive industry, supplier tiers in supply chains, export levels, and import levels. A survey instrument was developed based on literature, then verified by experts and statistical techniques. ANOVA and independent samples t-test were used to explore the differences across contextual factors of 216 automotive part manufacturers on TW, AM, and their elements. It revealed that there were significant differences across firm size, nationality of firms, and export levels on overall TW, AM and most sub-elements. Insignificant differences across production approaches and IATF 16949 on overall TW, AM and their sub-elements were found. Firms with different contextual factors require different levels of TW, AM and sub-elements. Managers should apply TW and AM elements at suitable levels in accordance with their organizational contexts.This is one of the first studies to empirically investigate the differences across the contextual factors on TW, AM and sub-elements in the same paper from a socio-technical perspective. This study can be used as a basis for further research on integrative practices between lean and agile (leagile) manufacturing.

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Section: Literature Reviewmentioning

confidence: 99%

Contextual factors on Toyota Way and Agile Manufacturing: an empirical investigation

Vanichchinchai

2023

Oper Manag Res

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“…To solve the deadlock, we have chosen to use the AHP method. The method has already been employed in ambiguous situations regarding manufacturing strategic issues (Sellitto and Mancio, 2019). In the current case, experienced practitioners estimated the most likely consequences of each alternative and built a ranking to support the choice.…”

Section: Decision Analysismentioning

confidence: 99%

Workload Control and Order Dispatching Rules

Couto

Sellitto

2022

Period. Polytech. Soc. Man. Sci.

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The purpose of this study is to choose an order dispatching rule and measure the work-in-process and lead-time in the production process of a conveyor chain manufacturer. The main strategic issue for the manufacturer is dependability, which requires meeting deadlines and managing internal lead-times. The study integrates two techniques, workload control (WLC) and an analytical hierarchy process (AHP), respectively systems for production planning and control, and multi-criteria decision support, both widely used in handling manufacturing strategic issues. The research method is a field experiment. Supported by the AHP and according to strategic criteria, practitioners selected the early due date rule (the order with the closest due date comes first) to release 231 orders. Then, employing a methodology designed to support WLC applications, the study measured key parameters that provide information regarding the overall performance of the manufacturer, the input rate, work-in-process, lead-time, throughput performance, and the level of safety stock. Using the model and a graphical tool derived from queuing theory, the throughput diagram, the study provides evidence that, although the manufacturing process is satisfactorily balanced and achieves acceptable performance, the level of safety stock is small and should be increased to prevent starvation on the shop floor.

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“…On the other hand, routing flexibility relates to the ability of a cellular system to process parts on different machine cells, thereby providing the necessary versatility to handle diverse product lines and production requirements. Companies can better respond to changing market conditions, maximize resource usage, and boost profits by building demand and route flexibility into their production processes [ 7 ].…”

Section: Introductionmentioning

confidence: 99%

Cell formation and layout design using genetic algorithm and TOPSIS: A case study of Hydraulic Industries State Company

Dhayef,

Al-Zubaidi,

Al-Kindi

et al. 2024

PLoS ONE

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Cell formation (CF) and machine cell layout are two critical issues in the design of a cellular manufacturing system (CMS). The complexity of the problem has an exponential impact on the time required to compute a solution, making it an NP-hard (complex and non-deterministic polynomial-time hard) problem. Therefore, it has been widely solved using effective meta-heuristics. The paper introduces a novel meta-heuristic strategy that utilizes the Genetic Algorithm (GA) and the Technique of Order Preference Similarity to the Ideal Solution (TOPSIS) to identify the most favorable solution for both flexible CF and machine layout within each cell. GA is employed to identify machine cells and part families based on Grouping Efficiency (GE) as a fitness function. In contrast to previous research, which considered grouping efficiency with a weight factor (q = 0.5), this study utilizes various weight factor values (0.1, 0.3, 0.7, 0.5, and 0.9). The proposed solution suggests using the TOPSIS technique to determine the most suitable value for the weighting factor. This factor is critical in enabling CMS to design the necessary flexibility to control the cell size. The proposed approach aims to arrange machines to enhance GE, System Utilization (SU), and System Flexibility (SF) while minimizing the cost of material handling between machines as well as inter- and intracellular movements (TC). The results of the proposed approach presented here show either better or comparable performance to the benchmark instances collected from existing literature.

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Implementation of a Flexible Manufacturing System in a production cell of the automotive industry: decision and choice

Cited by 8 publications

References 51 publications

Contextual factors on Toyota Way and Agile Manufacturing: an empirical investigation

Contextual factors on Toyota Way and Agile Manufacturing: an empirical investigation

Workload Control and Order Dispatching Rules

Cell formation and layout design using genetic algorithm and TOPSIS: A case study of Hydraulic Industries State Company

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