Purpose: Use mathematical models of Mixed Integer Linear Programming oriented to cellular distribution and aggregate production planning in order to obtain the appropriate product family for each manufacturing cell and from this, minimize production and material handling costs through the allocation of production resources.Design/methodology/approach: This article develops two mathematical models in LINGO 18.0 software, performing the computational calculation to obtain the best efficiency in cell formation at minimum production cost.Findings: The mathematical model oriented to the formation of manufacturing cells allows a grouping of products and machines with 82.5% group efficiency. By reallocating machines to each cell and redistributing facilities, the cost of material handling is reduced by 35.1%, and the distance traveled in product manufacturing is reduced by 26.6%. The mathematical model of aggregated planning provides information on production resource requirements such as personnel, machinery, distances traveled, as well as the cost generated by the need to outsource part of the production, inventory maintenance and overtime work.Research limitations/implications: It is necessary to clearly define the capacity variables. The model does not take into account the cost of mobilizing machines and readjusting facilities.Practical implications: The case study company can adequately plan production and efficiently manage its resources.Social implications: The study can be applied to other textile SMEs.Originality/value: The aggregate production planning model requires the assignment of the mathematical model of manufacturing cell formation in order to calculate the resource requirements needed to meet a demand.
This paper discusses the management of the quality system in a coachwork company based on the ISO 9001 standard, version 2015 and it aims directing and controlling the productive processes to ensure compliance with the operation parameters and to achieve the expected effects. The development of this action research comprises: (i) description of the manufacturing processes, (ii) diagnosis of the ISO 9001:2015 requirements, (iii) documentation structure of the QMS and (iv) development of the Quality Route method as an improvement for critical processes which generate non-compliant results. The proposed continuous improvement model aims to adapt the company to current market needs and meet the customers' necessities, allowing the enterprise to increase its productivity and profitability thanks to the systematic optimization and development of its processes. This encourages a specific management and generates positive changes in the organization, maintaining a vision of improvement and continuous innovation, in search of assurance of the quality of the products/services. In the application allows to compare with the initial situation made to the manufactured product, and it is found that the percentage of defects decreased from 72.0% to 36.0%. The method of the Quality Route based on the Deming cycle with its stages; plan, do, check and act, implemented as a continuous improvement action in body manufacturing processes, allows solving problems from identified improvement opportunities, establishing a quality control system in the manufacturing phases of the product, through the execution of visual inspections and use of records.
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