Extension of Manufacturing System Design Decomposition to Implement Manufacturing Systems That are Sustainable

Cochran, David S.; Hendricks, Steve; Barnes, Jason; Bi, Zhuming

doi:10.1115/1.4034303

Cited by 38 publications

(12 citation statements)

References 32 publications

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“…Most assembly line balancing is required to meet two major constraints: the desired takt time and a required throughput (Cochran, Hendricks, Barnes, & Bi, 2016). The takt time can be correlated to the demand rate.…”

Section: Literature Reviewmentioning

confidence: 99%

Assembly line design using a hybrid approach of lean manufacturing and balancing models

Qattawi

Madathil

2019

Production & Manufacturing Research

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This manuscript presents a method to design automotive production assembly lines that integrate lean manufacturing approaches and line balancing algorithms. In this work, we develop a clustering algorithm and task mutuality index for the assembly tasks to redesign and rebalance an assembly production line with a fixed layout and machinery. Moreover, we consider the product demand variability and the introduction of new product models. This paper describes the current and the future states of an automotive engines assembly production line using quantitative performance parameters and assembly tasks content flow charting, along with the analysis and results obtained from the proposed approach. The results show a reduction in required modeling and optimization efforts and a reduction in the required time to generate a feasible redesign of an assembly line while reaching the required takt time based on the demand forecast.

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Section: Literature Reviewmentioning

confidence: 99%

Assembly line design using a hybrid approach of lean manufacturing and balancing models

Qattawi

Madathil

2019

Production & Manufacturing Research

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“…Recently, AD theory is also actively researched and applied within the "hot" topics like sustainability and Industry 4.0. Cochran et al (2016) offered an extension of AD theory to ensure that leaders, managers, and engineers can sustain manufacturing systems throughout the product lifecycle. Gualtieri et al (2018) designed a collaborative human-robot workstation using AD theory for the new context of Industry 4.0.…”

Section: Literature Reviewmentioning

confidence: 99%

A computer-aided approach improving the Axiomatic Design theory with the distributed design resource environment

Chen

et al. 2019

AIEDAM

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In the traditional Axiomatic Design (AD) theory, the mapping from the functional domain to the physical domain is based on the designers’ own knowledge and experience, and there is no systematical approach including the design resources provided outside the designers themselves’ access. Thus, the raw materials for the design process are largely limited, which means they can hardly support the designers’ increasingly creative and innovative conceptions. To help AD theory better support the design process, this paper proposes a computer-aided approach for the mapping from the functional domain to the physical domain within a distributed design resource environment, which consists of numerous design resources offered on the Internet by the providers widely distributed in different locations, institutes, and disciplines. To prove the feasibility of this proposed approach, a software prototype is established, and a natural leisure hotel is designed as an implementation case.

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“…According to the literature, only less than 10% of the industries that implement lean are able to sustain the system design after three years [13,14,16]. The question arises that if all the tools that can help a system to become lean are available, what is missing to make the use of these tools sustainable [17]?…”

Section: Literature Reviewmentioning

confidence: 99%

“…Rather, lean can be defined as, "the result of a system design that is tailored to meet customer needs." Meeting customer needs involves eliminating non-value added activities by employing the right tone and by understanding the pathdependency of implementing solutions within the system design [13][14][15].…”

Section: Introductionmentioning

confidence: 99%

Guiding Manufacturing Enterprises to Achieve Long-Term Business Sustainability Using the Collective System Design Approach

2018

Self Cite

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This paper addresses several issues discovered by working with different industries attempting to sustain their business enterprise and to become “Lean.” The three key points addressed by the paper are: 1) Designing a new system or re-designing an existing system should focus on collecting a complete set of customer needs and deriving functional requirements from those needs. 2) Illustrating the path-dependency or sequence of implementation of Physical Solutions (PSs) to achieve Functional Requirements (FRs) of partially coupled designs. 3) Lean is not what we implement as a system, rather lean is what we become as a result of meeting customer needs with the utilization of the least amount of resources possible in a sustained manner. When lean is viewed as a set of tools to implement, the people in an enterprise will face ever-increasing diffculty in long-term business sustainability. The primary problems arise early in the design/re-design phase due to the lack of a clear set of system functional requirements. Without clearly defined system FRs, driven by recognizing customer needs/concerns, an enterprise will implement point solutions in an attempt to improve part(s) of a system. The Manufacturing System Design Decomposition (MSDD), a product of Axiomatic Design (AD), illustrates the path-dependency among the solutions of the associated requirements of any manufacturing facility. The MSDD provides a system-wide view and a clear sequence for system design implementation. The Collective System Design approach is discussed to provide the steps for senior leadership to re-design an existing system or to design a new system that results in long-term sustainability and become “lean.”

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Extension of Manufacturing System Design Decomposition to Implement Manufacturing Systems That are Sustainable

Cited by 38 publications

References 32 publications

Assembly line design using a hybrid approach of lean manufacturing and balancing models

Assembly line design using a hybrid approach of lean manufacturing and balancing models

A computer-aided approach improving the Axiomatic Design theory with the distributed design resource environment

Guiding Manufacturing Enterprises to Achieve Long-Term Business Sustainability Using the Collective System Design Approach

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