Reconfigurable production system design – theoretical and practical challenges

Abstract

Purpose -The purpose of this paper is to explore theoretical and practical challenges to achieve reconfigurable production system designs. Design/methodology/approach -The empirical material of this paper includes a multiple-case study with an embedded design (Yin) including four cases, where each case represents a production system design project. The consideration of reconfigurability and its characteristics in the production system design projects was studied. To enhance validity, two real-time studies were combined with two retrospective studies (Leonard-Barton). Findings -For more than a decade foresight reports have pointed out the need for responsiveness to change through reconfigurability in production system design. In order to achieve reconfigurable production systems, three challenges were identified: to use a structured design methodology, to gain knowledge in reconfigurability and its characteristics, and to include the reconfigurability knowledge in a structured design methodology. Still there is no comprehensive support available for reconfigurability in the production system design process. Research limitations/implications -Limitations are mostly related to the chosen methodology approach, and additional empirical studies to establish generic results are required. Practical implications -By combining knowledge from the production system design field with the reconfigurable manufacturing system field a potential of meeting identified challenges is pointed out. Originality/value -This paper adds to current knowledge by pointing out three main challenges to achieving reconfigurable production systems. The paper also contributes with ideas on how to respond to these challenges.

Collaborative routing of products using a self-organizing mechatronic agent framework—A simulation study

“…The key aspects of a reconfigurable system include: module mobility, diagnosability, integrability, convertibility, scalability, "automatibility", modularity and customization [20,21]. All these characteristics promote and support frequent and dynamic system changes that are hardly tackled by the traditional approaches and that address the need for mass customization and sustainability.…”

Reconfiguration schemes evaluation based on preference ranking of key characteristics of reconfigurable manufacturing systems

“…RMS integrability (I) refers to the ability to integrate components (manufacturing machines and control modules) through the interfaces possessed by the components and the capability to integrate a new technique or process into the current system [4]. During reconfiguration, uniform interface standards for the software and hardware of the machine tool modules would largely reduce the correction (software/hardware interface adjustment and control program adjustment) time and cost, which can even be zero.…”

“…They also stressed that an RMS must be designed at the outset to be reconfigurable; otherwise, the reconfiguration process will be lengthy. In addition, Professor Koren listed the six key characteristics that an RMS must possess [1,3,4], including modularity, integrability, customization, convertibility, diagnosability, and scalability. Only when a manufacturing system possesses these six key characteristics can it achieve the manufacturing goals of low cost, high quality, and rapid responsiveness.…”

“…An RMS is a manufacturing system created at the design stage to be capable of making rapid changes in the structure and hardware/software components to quickly adjust the production capacity and functionality in response to sudden changes in irregular market demand [3,4]. An RMS is designed around a part family and provides customized flexibility to manufacture all the members of the part family [1].…”

Reconfigurable manufacturing systems: Principles, design, and future trends

“…Mathematical definitions have been proposed for the RMS key characteristics [11], especially for scalability [12], convertibility [13], and an integrated multi-attribute reconfigurability index [14]. These characteristics and principles are applied to the design of different types of reconfigurable manufacturing systems, including machining systems, fixturing systems, assembly systems, and material handling systems [15,16], by using various models [17][18][19][20] and methodologies [21,22].…”