CERES :: Browsing by Author "Kay, John M."

Browsing by Author "Kay, John M."

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Open Access
The application of the Theory of Constraints Thinking Process to manufacturing managers in implementing change
(Cranfield University, 1999-05) Hutchin, Charles E.; Chaharbaghi, K.; Kay, John M.
This research is concerned with the problems faced by managers within manufacturing when they are expected to successfully implement a major change within their organisation. It uses, as the vehicle for the research, the Theory of Constraints Thinking Process (TOC/TP) first developed by Dr Goldratt between 1986 and 1994. The TOC is used by managers to determine what requires to be changed within their organisation and then to develop both the solution and the implementation strategy. The research has used the access obtained by the researcher to examine the approaches adopted by manufacturing managers in implementing improvement projects, which involve significant change. The primary focus of the research was to confirm the existence of a significant barrier to change and to determine whether this was a function of the individual. Once the obstacle had been identified in specific situations, the second step was to consider whether the obstacle could be described in a generic form with application to a much wider range of change environments. The final stage was to replicate the exploratory stage in other companies in other countries through the involvement of colleagues of the researcher and then consider what might be included in any change project, which would overcome the obstacle so defined. The primary method of data collection was through the application of action research and the development of the data in the form of case studies. The number and types of companies that took part in the study and the range of countries was intended to ensure a reasonable spread of data. The results suggest that one of the key obstacles to change is that outlined in the research problem and that the TOC/TP, through the use of the cloud technique, can describe this obstacle and give direction to the way of successfully dealing with it.
Open Access
Critical path analysis type scheduling in a finite capacity environment
(Cranfield University, 1992-09) Almeida, Dagoberto Alves De; Galgut, P. E.; Kay, John M.
In order to cope with more realistic production scenarios, scheduling theory has been increasingly considering assembly job shops. Such an effort has raised synchronization of operations and components as a major scheduling issue. Most effective priority rules designed for assembly shops have incorporated measures to improve coordination when scheduling assembly structures. However, by assuming a forward loading, the priority rules designed by these studies schedule all operations as soon as possible, which often leads to an increase of the workin- progress level. This study is based on the assumption that synchronization may be improved by sequencing rules that incorporate measures to cope with the complexity of product structures. Moreover, this study favours the idea that, in order to improve synchronization and, consequently, reduce waiting time, backward loading should be considered as well. By recognizing that assembly shop structures are intrinsically networks, this study investigates the feasibility of adopting the Critical Path Method as a sequencing rule for assembly shop. Furthermore, since a Critical Path type scheduling requires a precise determination of production capacity, this study also includes Finite Capacity as a requisite for developing feasible schedules. In order to test the above assumptions, a proven and effective sequencing rule is selected to act as a benchmark and a simulation model is developed. The simulation results from several experiments showed significant reduction on the waiting time performance measure due to the adoption of the proposed critical path type priority rule. Finally, a heuristic procedure is proposed as a guideline for designing scheduling systems which incorporate Critical Path based rules and Finite Capacity approach.
Open Access
A decision support tool based on QFD and FMEA for the selection of manufacturing automation technologies
(Elsevier, 2008-08) Almannai, B.; Greenough, Richard M.; Kay, John M.
With the advent of the new challenge to design a more lean and responsive computer-integrated manufacturing system, firms have been striving to achieve a coherent interaction between technology, organisation, and people to meet this challenge. This paper describes an integrated approach developed for supporting management in addressing technology, organisation, and people at the earliest stages of manufacturing automation decision-making. The approach uses both the quality function deployment (QFD) technique and the failure mode and effects analysis (FMEA) technique. The principal concepts of both applications are merged together to form a decision tool; QFD in its ability to identify the most suitable manufacturing automation alternative and FMEA in its ability to identify the associated risk with that option to be addressed in the manufacturing system design and implementation phases. In addition, this paper presents the results of a practical evaluation conducted in industry.
Open Access
Development of a joint TQM&IlT implementation model
(1997-02) Georgousis, Ioannis D.; Kay, John M.
This study investigates the impact of the joint TQM and JIT approach on the performance of manufacturing organisations. The final objective is the development of a Joint TQM&JIT Implementation Model, based on the results of the investigation. The Model will contain a series of activities and operations that will lead to process and product improvement, based on the principles of the joint implementation approach. Many studies and researches have been conducted in order to investigate and clarify the details and the potential benefits of each system. However, few studies looked at the operations that are necessary for a successful joint TQM and JIT approach; and even if they did it, they did not analyse the manufacturing process systematically. The present study attempts to give an answer to this problem and, moreover, to produce a systematic, analytical, and clear implementation plan. The literature review and the industrial survey showed that there is a very close link between TQM and JIT; what is missing is a detailed implementation plan. The TQM&JIT Model tries to satisfy the musts and the wants of every manufacturing organisation which wishes to be competitive and world-class in the contemporary demanding markets, using the quality of the products and the low manufacturing cost as weapons. Furthermore, the Model details the sequence of the activities that should be followed in order to get completely beneficial results. It determines the production areas that should be improved, but also determines the role of everyone within the company towards that objective. The flowchart that presents the network of the activities is very simple and very clear, and this is perhaps the major advantage of the Joint TQM&JIT Implementation Model. A series of performance measures for each step of the Model has also been developed, in order to ensure the completion of each implementation stage.
Open Access
Development of a strategically driven production facilities management (PFM) framework
(Cranfield University, 2000-06) Liu, Wei-Chung; Kay, John M.; Groves, Gwyn
This thesis presents the results of a programme of research into the development and evaluation of a strategically driven Production Facilities Management (PFM) framework. PFM is the activity of managing production facilities to fully realise the corporate strategic objectives of a manufacturing organisation. Companies with strategies tend to be more successful than companies without them. The concept of manufacturing strategy is an approach to enhance the consistency between the manufacturing function and the direction of the organisation. Consequentially, PFM is the means to ensure these strategic requirements can be fully realised from the facilities management viewpoint. Through the literature review, it was seen that there is a lack of a link between manufacturing strategy and the management of production facilities. From questionnaire surveys and interviews at companies in the manufacturing sector, it was found that the issue of linking facilities management with corporate strategy has been ignored. Therefore, this programme of research not only investigates the context and contents in formulating an appropriate manufacturing strategy in a manufacturing environment but also reviews the most popular methods in relation to maintenance management and performance assessment of the facilities. This programme describes the development of a strategically driven, step-by-step approach that helps a company to capture the strategic requirements of the manufacturing function, measure the performance of existing production facilities and supports the decision-making analysis tasks. The primary contribution of the work presented in this thesis was the development of an implementation framework and an associated implementation workbook which comprise a set of stages and implementation sections that a user can use to carry out the process of capturing the strategic requirements and realise them with support from an appropriate PFM framework and a systematic, step-by-step implementation process.
Open Access
Development of an integrated manufacturing performance measurement and evaluation framework
(Cranfield University, 2000) Huang, Kuang-Chung; Kay, John M.
With the end of the Cold War and the subsequent reduction in defence spending, the Taiwanese defence industry has encountered great difficulties. Recently, the Government announced that at the end of 2006, all military plants should move from the public sector to the private sector. The aim being not only to maintain a manufacturing capability sufficient to ensure the technical competence and resources necessary for an effective and timely response to a mobilisation but also to reduce government infrastructure costs. However, unless the military plants take more aggressive action to assess their management and manufacturing weaknesses effectively, their modernisation efforts will not succeed. This research is concerned with the development of a methodology for manufacturing performance measurement and evaluation to help Taiwanese military plants develop and maintain a competitive advantage. The basic concept of the proposed framework is based on the Balanced Scorecard concept. However, the structure and procedures have been further developed to reflect Taiwan's specific requirements. In particular, the proposed framework provides a structure and tools to tackle a number of key requirements, such as the need to provide both internal and external measures as a means of both qualitatively and quantitatively prioritising and evaluating manufacturing strategic concerns, and the need to show continuously where improvement needs to be made. Industrial case studies have shown that the proposed framework is both feasible and effective when applied within the particular environment of Taiwanese military plants. In addition the proposed framework has highlighted some theoretical and practical problems associated with the design and development of manufacturing performance measurement and evaluation framework. Due to its generic nature, through interviews with three UK companies, it was demonstrated that the proposed framework could also be applied to other societies and industries, either public or private, to solve their manufacturing performance measurement and evaluation problems.
Open Access
Dimensioning of an automotive final assembly shop using a system of key performance indicators
(2006-01) Gruneisl, Markus; Kay, John M.
All worldwide operating automobile manufacturers are on the constant search for the optimum between desirable flexibility on that one hand and required cost productivity on the other hand. In particular, the planning of a new final assembly shop of a car manufacturer is a big challenge since a huge number of influencing factors must be taken into consideration, so that in the end a best-practice final assembly shop with the desired attributes is created. To minimise the risk of bad planning, the length of time for the planning process should be shortened and at the same time the planning exactness should be improved with the help of new tools. This research project demonstrates that in the early stages of the planning process key performance indicators could be a proper instrument to achieve the the desired effects. Even if key performance indicators have been used in many areas of industry over several decades, this is the first research project which deals in this degree of accuracy with the dependencies between the different key performance indicators during the factory planning process for a new final assembly shop of a car manufacturer. Following the basic idea of 'System Thinking', numerous key performance indicators were linked to each other in an adaptable system of key performance indicators. During this research project, the developed model was successfully evaluated with four locations of the research partner BMW Group. Since the results are all between ± 20%, which is a sufficient exactness for this planning stage, there is great confidence that this general system of key performance indicators could also be important to other automobile manufacturers. The findings of this research project should serve as a basis for other researchers in this field to enhance the scarce theories about the dependencies. Besides, the software 'Powersim' and the chosen approach of 'System Thinking' doubtless can be transferred to other industrial areas with similar challenges.
Open Access
Evaluation of a manufacturing task support system using the Task Technology Fit Model
(Production and Operations Management Society, 2001) Tjahjono, Benny; Fakun, D.; Greenough, Richard M.; Kay, John M.
This paper presents an exploratory study of a Task Support System (TSS) supporting manufacturing task operations. The study investigated the degree to which a TSS, in use in a company, actually supports the task of the shop floor personnel. The approach has been to adopt the Task-Technology Fit (TTF) instrument to measure the degree of fitness between the TSS and the associated task. The analysis gives an indication of the state of the TSS and the potential improvements that can be made. The study also shows that the instrument can be used as a foundation for the development of a hypermedia TSS and a benchmarking tool for a TSS.
Open Access
An exploration of policies and practices used to showcase production facilities
(Professional Engineering Publishing, 2008-09-01T00:00:00Z) Baines, Tim S.; Ball, Peter D.; Cooper, S.; Dawson, P.; Wilkinson, S.; Woods, M.; Kay, John M.
Manufacturers who seek innovative ways in which to differentiate their products and services should not overlook the value of showcasing their production facilities. By careful design, visitors can be exposed to a series of experiences that can help to emphasize the value built into products. This topic has, however, received almost no attention by manufacturing researchers. Therefore, this paper describes a study of six manufacturers and, from this, proposes a set of guidelines for showcasing production facilities. Although exploratory, this work provides both a guide to manufacturers and a platform for more in-depth research. The guidelines and the case studies on which they are based are all described within the paper.
Open Access
Global sourcing practices: a framework to improve sourcing strategy implementation
(Cranfield University, 2009-08) Mohamad, Marini Nurbanum Binti; Julien, Denyse; Kay, John M.
The aim of the research reported in this thesis is to gain understanding of global sourcing practices of companies in the UK and to develop a framework to improve sourcing strategy implementation. This research was conducted by carrying out literature review, analysis of case studies through semi-structured interviews, analysis of an online-based survey, development of a global sourcing framework, feedback process and finally the refinement of the framework. The global sourcing practices, in terms of eight critical success factors, which were identified through literature, was investigated through case studies. This research also provides insights into how critical certain factors are to the effectiveness of the company‟s sourcing strategy and how broadly were those factors actually implemented. The gaps between the perceived importance of global sourcing practices and the actual implementation were explored through survey. The information gathered from the literature, case studies and survey provided the input to develop a global sourcing framework. As more and more studies create awareness of the critical success factors that are important for implementing a global sourcing strategy, there is a need for a framework to be developed to help a company identify areas where they can improve in terms of implementation of the sourcing strategy. The global sourcing framework was developed to assess the current sourcing level of companies, providing guidance for companies to identify the areas for improvement in their approach to global sourcing and helping companies determine where they need to be in terms of the global sourcing strategy and having it aligned with their corporate strategy. The framework has been validated and found to be feasible, usable and useful to improve a company‟s sourcing strategy.
Open Access
How companies embed non-quantifiable product qualities through their product development process
(Cranfield University, 2006-06) Guldbrandsen, Marianne Norden; Deasley, Peter J.; Kay, John M.
Many consumer products have reached a high level of technical product quality. Rapid adoption of new technologies and access to a global market means that markets are getting saturated. This means that technical differentiation is often not enough to sell a product and products compete more and more on intangible product qualities - these are meant to delight, bring pleasure, be easy to use and to create an experience. These qualities are often difficult to measure in the product using scientific descriptions and numerical measures. This research studies these Non-Quantifiable Product Qualities and the thesis presents research into how companies embed these Non-Quantifiable Product Qualities into their products in an attempt to satisfy their customers. The aim of this research was to gain insight into how large manufacturing companies embed product qualities that are difficult to quantify, by studying their product development process. This was done in two stages, firstly an exploratory study into five case organisations, secondly an in-depth study into three of the original five companies. Fifty interviews with designers, engineers and marketers formed the main source of data, supplemented with observations and document analysis. In the exploratory stage nine initial themes emerged out of data analysis, which then informed the data collection in the descriptive stage. The final output is seven confirmed themes, with 43 major findings and three conceptual models, that describe how companies embed Non-Quantifiable Product Qualities through their product development process. The research has found that the researched companies have some common strategies for embedding Non-Quantifiable Product Qualities. One example is that they will typically seek to translate an emotional response in the customer into measurable product qualities that will evoke such response. It is also common to seek out customer reaction to products during development to ensure successful embedding of Non-Quantifiable Product Qualities.
Open Access
An implementation model of a quality management information scheme for cellular manufacturing environments
(Cranfield University, 1995-10) Gundogan, Mete; Kay, John M.
As today's global competition grows in manufacturing industries companies are forced to work smart in all areas of operations, starting with suppliers and ending with customers. This competition in general requires firms to improve market responsiveness, product quality, use computerised information systems for production planning and control, have more rapid changeovers, reductions in setup times, work-in-progress reduction and hence throughput time reduction. In order to accomplish these formidable tasks, there are a number of management philosophies available for manufacturing companies. These include just-in-time, flexible manufacturing systems, computer integrated manufacturing, total quality management, concurrent engineering. Implementation of these philosophies, however, requires mass mobilisation encompassing many areas of operations such as production, sales and marketing, suppliers, finance, customer servicing, product design and method engineering, maintenance, personnel and training, etc. This thesis details a study which evaluates the total quality management philosophy in cellular manufacturing environment. Following this evaluation, a quality management information scheme, which is structured and integrated, has been produced using the Manufacturing Systems Analysis and Design Method. In order to manage smoothly this mobilisation and incorporate the scheme to other integrated functional areas, a new approach namely the Activity Based Implementation (ABI) has also been produced. Justification of the model from various points of view has shown that the model is expected to address a considerable gap in the area concerned. The model was designed to be used as an integrated part of a system or as a stand-alone scheme by quality practitioners, the management board of organisations implementing TQM and quality management researchers.
Open Access
The implementation of Just In Time manufacturing through team leaders
(Cranfield University, 1995-09) Carr, P. D.; Groves, Gwyn; Kay, John M.
This thesis examines the implementation of Just In Time manufacturing through team leaders. Western industry has failed to achieve the performance benefits experienced in Japan with the introduction of Just In Time, a manufacturing system based on the relentless elimination of waste. Criticism is emerging of the experience of employees of Just In Time. It is argued that stress levels are high and motivation is low. However, Just In Time relies on a new, more active, role for employees. A contradiction is apparent between the needs of Just In Time, in terms of the role played by employees, and the reality of their experience of a Just In Time working environment. Resolving this contradiction, while improving industrial performance, is the subject of this research. The research draws on knowledge from a wide range of fields. Work on Just In Time is combined with work on employee motivation, and the management of change. The role of the team leader emerges as a critical factor in the review of the literature. The implementation of Just In Time, through a focus on team leaders, utilising knowledge gained from socio-technical systems is tested in a year long, action research project with Alcan Aluminiurn at their Banbury extrusions factory. Survey evidence is gathered to analyse its impact. The results suggest that companies will benefit from the utilisation of the approach developed; the implementation of Just In Time through team leaders. There is substantial scope for further work to develop this approach to the implementation of Just In Time and to explore its application in other forms of change.
Open Access
Improving the process of designing cellular manufacturing systems
(Cranfield University, 1996-10) Nimmons, T. A. K.; Williams, G. M.; Kay, John M.
Cellular manufacturing is an important approach to the organisation of production. Large benefits are claimed over traditional functional organisation, and it is compatible with prominent manufacturing theories, such as just-in-time, total quality management, and computer integrated manufacturing. Several very successful applications of cellular manufacturing have been reported, but a wide range of performance improvements has also been observed. Many benefits ofcellular manufacturing do not arise directly from changing the organisation and layout ofdirect production resources, but from changes to the way the production process is operated, managed and controlled, that are made possible by the cellular organisation. Underachievement occurs when companies do not identify and exploit such opportunities. This research aims to address the problem by providing a system wide concept of cellular manufacturing and an improved process to support the design of a cellular manufacturing system based on this concept. A review of the theory and practice of cellular manufacturing is presented. A model is proposed, which comprises a general set of mutually compatible, production system wide, production system features for supporting or exploiting self-contained groupings of manufacturing resources. A subset of the features from the general model will be appropriate to a particular application of cellular manufacturing. Current processes for designing cellular manufacturing systems do not adequately support the application of such a concept. In particular, tailoring the general concept ofcellular manufacturing to a specific situation is identified to be an important but widely neglected design activity. A process is defined that makes concept design explicit, and a matrix-based tool developed to relate the features of cellular manufacturing to a company's performance improvement objectives. The value ofthis novel approach to designing cellular manufacturing systems is determined to be in facilitating the generation and communication of insight into the nature ofcellular manufacturing, encouraging a comprehensive appraisal of the concept and its impact throughout the production system, and focusing limited resources where they will be most effective.
Open Access
Information systems - a methodology for capturing user requirements.
(2000-04) Ince, Michael; Kay, John M.
Systems development has been a topic of discussion for many years, with the growth of the Information Technology (IT) industry. Many organisations use systems to allow them to have more control over the processes that are carried out on a daily basis. The Systems Development Life Cycle (SDLC) has had a major impact on the way that systems are developed. It provides a structure that begins with identifying the feasibility of the project to be completed, and guides the project through implementation and maintenance of the system. It has been suggested that the lack of user involvement during this development process is a major cause of this failure in the systems that are developed. This research addresses this problem by reviewing the most popular methods and examining the concept of user involvement. An industrial perspective also assists in generating key issues in systems development. These, together with the lessons learned during the literature review form the basis of the development of a new approach. The new approach proposed in this thesis (URCAM, User requirements Capturing Method) comprises a set of stages and phases that a developer can use to carry out the process of capturing user requirements. While learning from the weaknesses of the existing methods, the proposed method considers their strengths. URCAM was evaluated during a systems development project at BICC General Cables. The results of the evaluation suggested that the method would produce higher quality information than verbal communication. However, the major strengths of the method are that it offers the developer a guide that they could follow from identifying the types of users who would be involved, to the sign-off, of the final specification. URCAM forms are also presented, which offer the user an opportunity to write down information. The results suggest that this method helps the user to feel more involved and increases their willingness to use the implemented system.
Open Access
Life-cycle-Based (LCB) online acquisition framework for supporting Mass Customisation (MC) in practice.
(2006-09-01T00:00:00Z) Tang, S. J.; Tjahjono, Benny; Kay, John M.
Mass Customisation (MC) has been perceived in many articles as a strategy of choice for any company. However, Mass Customisation (MC) can be easily discussed at a strategic level; but it is rather more complicated to undertake it organisationally and operationally. The aim of this paper is to explore an effective framework that can support the development of Mass Customisation approaches. Two main contributions are addressed in this paper. One is to prove the insufficiency of current Value-Chain-Based (VCB) MC approaches by using empirical evidence; the other is to propose an online Life-Cycle-Based (LCB) acquisition framework which can be used for developing more comprehensive MC approaches.
Open Access
A Methodological Approach to Process Intensification
(Cranfield University, 2000-04) Wood, Mark D.; Kay, John M.; Green, Andrew
A methodological approach to process intensification (PI) has been developed to aid in the design of intensified chemical processes. Current process development procedures fail to consider if, and how, a chemical process can be intensified, resulting in limited application of PI in the chemicals industry. The PI methodology has been developed to meet these needs, focusing upon the chemical reaction stages of a process. The PI methodology is a paper-based tool, based around a flowsheet known as the framework. Throughout development, the methodology was applied to industrial case studies which revealed considerations that should be included in the methodology and aided in determining its format. Each section of the framework contains checklists and procedures detailing the information required and the decisions to be made by the participants, who should be in a multi-disciplinary team. Examination of chemical reaction kinetics and the effects of mixing upon the reaction are key aspects of the methodology that are normally not examined during process development. Incorporated within the methodology is a PI experimental protocol designed to model PI operation in the laboratory. Mixing theory was reviewed to identify that the protocol approach should be based upon recreating the mixing conditions experienced in a full scale plant within a small scale laboratory stirred vessel. The developed laboratory protocol utilises semi-batch operation in a highly-mixed stirred vessel of 10cm diameter and height with twin pitched-blade turbine impellers. Turbulent energy dissipation rates of 150 W/kg can be achieved in the vessel. Experiments were run, showing that the performance of static mixer reactors can be predicted through the application of the protocol, though future work is required to develop this laboratory protocol approach into a rigorous experimental tool.
Open Access
Modelling in the evaluation of a manufacturing strategy
(Cranfield University, 1994-12) Baines, Tim S.; Kay, John M.; Hamblin, D. J.
This thesis describes research that has developed the principles of a modelling tool for the analytical evaluation of a manufacturing strategy. The appropriate process of manufacturing strategy formulation is based on mental synthesis with formal planning processes supporting this role. Inherent to such processes is a stage where the effects of alternative strategies on the performance of a manufacturing system must be evaluated so that a choice of preferred strategy can be made. Invariably this evaluation is carried out by practitioners applying mechanisms of judgement, bargaining and analysis. Ibis thesis makes a significant and original contribution to the provision of analytical support for practitioners in this role. The research programme commences by defining the requirements of analytical strategy evaluation from the perspective of practitioners. A broad taxonomy of models has been used to identify a set of potentially suitable techniques for the strategy evaluation task. Then, where possible, unsuitable modelling techniques have been identified on the basis of evidence in the literature and discarded from this set. The remaining modelling techniques have been critically appraised by testing representative contemporary modelling tools in an industrially based experimentation programme. The results show that individual modelling techniques exhibit various limitations in the strategy evaluation role, though some combinations do appear to provide the necessary functionality. On the basis of this comprehensive and in-depth knowledge a modelling tool ' has been specifically designed for this task. Further experimental testing has then been conducted to verify the principles of this modelling tool. Ibis research has bridged the fields of manufacturing strategy formulation and manufacturing systems modelling and makes two contributions to knowledge. Firstly, a comprehensive and in-depth platform of knowledge has been established about modelling techniques in manufacturing strategy evaluation. Secondly, the principles of a tool that supports this role have been formed and verified.
Open Access
A practical decision support tool for the design of automated manufacturing systems: incorporating human factors alongside other considerations in the design
(2005-09) Al-Mannai, Bader Darwish; Greenough, Richard; Kay, John M.
The way in which a manufacturing system is designed is a crucial determinant of its ability to meet the current competitive challenges. The existing literature and research findings draw attention to the importance of addressing human factors in the design of the manufacturing systems to face these challenges. However, the evidence gathered from the literature clearly illustrates that organisations are not fully incorporating human factors (macro- and micro-ergonomics) in the design of manufacturing systems. In addition, the current system design practices tend to relegate ergonomics evaluation to post-design, leaving ergonomists little opportunity to make significant and important changes. This thesis details a study which investigates the role of human factors in manufacturing systems design and how it can be integrated into automated manufacturing decision-making. Focus is given to the area of manufacturing automation selection within workstation and cell design. The aim of this research is to support manufacturing systems designers to better incorporate human factors in manufacturing systems design. A research programme has been designed to fulfil this aim. It consisted of three phases: industrial survey, decision support tool formulation, and practical evaluation. The first phase involved conducting interviews with leading manufacturing organisations in the United Kingdom to determine the work practice in industry and the need for' improvements. The second phase comprised the design and development of the decision support tool in a workbook and software application. The final phase was the evaluation of the tool in collaboration with industry. Overall the outcome of this research was a novel structured approach that deploys both the Quality Function Deployment and Failure Mode and Effect Analysis methods to incorporate human factors alongside technical, organisational, and economical factors in the decision-making process of manufacturing systems design, thereby allowing the consideration of human factors at the feasibility study stage.
Open Access
Prediction of manufacturing flexibility by the use of simulation modelling
(Cranfield University, 1997-01) Matupi, Newton B.; Kay, John M.
Flexibility is seen as a desirable attribute of a manufacturing system. Virtually every manufacturing organisation wants it, but find it difficult to define, predict or measure. Most researchers look inwards to try to obtain measures. This research defines a framework that provides a structured methodology for developing flexibility requirements. The framework ensures that the flexibility requirements are derived from manufacturing objectives that relate to business strategy. This way flexibility becomes an issue that is driven by the business needs and not just by the advances in technology. Through the framework all the important factors of the business as a whole are considered in the design of the manufacturing system. The research examines the tactical level of decision making in detail. A simulation model was developed to predict the performance of a manufacturing system faced with various types of flexibility requirements. The model was used to convert potential flexibility to demonstrated flexibility, thereby predicting the manner in which the manufacturing system might perform. The results from the model showed the performance of the whole system and these were related to the contribution that flexibility makes to the overall manufacturing objectives. However, it was also observed that different types of models may be required depending on the nature of the decisions. Through the development of the mechanism for evaluating flexibility requirements, it was observed that much time was invested in the definition of flexibility requirements and how these contributed to the manufacturing strategy. This shows that much time needs to be spent on the definition of flexibility requirements before evaluation can take place.