A methodology for selecting assembly systems feeding policy

Abstract

Purpose -Assembly systems require uninterrupted components' availability to feed workstations. This paper aims to propose a methodology to help managers in evaluating and selecting the most suitable policy for materials delivery to the shop floor. The analysis focuses on three basic policies, namely kitting, just in time kanban-based continuous supply and line storage, even including class-based hybrid policies. Design/methodology/approach -Descriptive models are developed to design components' delivery systems and to compute their performances. Empirical criteria are utilized to associate specific policies to components classes in order to implement customized hybrid line feeding policies. A case study is then included to exemplify the method application and to show its capabilities as a decision making tool. Findings -Hybrid feeding policies may be preferable to a single feeding policy common to all components. This is shown in a representative case study. However, in general there is a priori superior method and only a comparison of alternative feeding policies based on objective performance measures can determine the best approach in specific industrial applications.Research limitations/implications -The methodology is aimed at preliminary sizing and selection of alternative line feeding systems in deterministic environments. It is not intended for detailed performance analysis of assembly systems. Practical implications -Production managers are given quantitative decision tools to properly select the components' delivery method at an early decision stage. This allows trade-offs between alternatives to be explored in order to deploy customized feeding policies differentiated on components basis to better fit specific company requirements. Originality/value -The paper extends previous descriptive models for line feeding systems and includes the possibility of hybrid policies.

Dynamic material flow control in mixed model assembly lines

“…For example, Caputo and Pelagagge (2011) investigated the part feeding policy where their analysis focused on three basic policies, namely kitting, just in time kanban-based continuous supply and line storage. Some guidelines and decision tools were provided to assist production managers in the selection of proper policies for components delivery to assembly systems.…”

Preventing ergonomic risks with integrated planning on assembly line balancing and parts feeding

“…It may be as often as once in a one-minute cycle. For example, when a proper automated feeding system, which is able to supply the material rapidly, has been set up, or when the kitting area is very close to the corresponding assembly stations, as in the case of the fishbone supermarket (Battini et al 2009;Caputo and Pelagagge 2011). In some other arrangements, the periodicity of kits exchange may be less frequent, once in several cycles.…”

“…Hua and Johnson (2010) and Hanson and Brolin (2011) study the transfer from direct supply to indirect supply qualitatively and discuss them on case studies from electronics and automotive industries. Caputo and Pelagagge (2011) propose descriptive models to design the best policies and delivery systems for assembly systems, also extending them with economic considerations (Caputo, Pelagagge, and Salini 2015) and by taking into account parts features (Caputo, Pelagagge, and Salini 2016). Mixed-integer optimisation models on how to select between several modes of parts supply are elaborated by Limère et al (2012), Limère, Van Landeghem, and Goetschalckx (2015) and Sali and Sahin (2016).…”

An Exploration of Methods to Improve Process Flow in a Remanufacturing Cell

“…Also if there are large amount of product families to be catered for the cost of maintaining these kanbans may be prohibitive (Harrison, 1995); Harrod and Kanet (2013, p. 621) also state that one of the main deficiencies of operating a kanban system is that the system often fails due to the fact that competing jobs are not prioritised, leading to a queue at a work centre. Caputo and Pelagagge (2011) advocate kitting operations as being a better strategic fit to feed assembly operations. They state that the issues normally seen with kanban operations are not associated with kitting as this system ensures only the correct amount of parts required to build an order are present on the line at one time.…”

“…In this respect Sundin (2006) advocates providing as much visibility as possible to the remanufacturing operation to promote flow, whilst Irani (2011) promotes modification of lean tools to suit the needs of the remanufacturing operation. Caputo and Pelagagge (2011) advocate the use of a kitting system to feed assembly operations. The remanufacturing cell currently makes limited use of this system, and it has proven to be advantageous in reducing waste.…”