Production models of multiple products using a single machine under quality screening and reworking policies

2019 ◽  
Vol 14 (1) ◽  
pp. 232-259 ◽  
Author(s):  
Ata Allah Taleizadeh ◽  
Mahshid Yadegari ◽  
Shib Sankar Sana
Keyword(s):  
Single Machine ◽  
Manufacturing Systems ◽  
Production Systems ◽  
Production Costs ◽  
High Tech ◽  
Screening Process ◽  
Automatic Production ◽  
Content Type ◽  
Economic Production ◽  
Imperfect Items

Purpose The purpose of this study is to formulate two multi-product single-machine economic production quantity (EPQ) models by considering imperfect products. Two policies are assumed to deal with imperfect products: selling them at discount and applying a reworking process. Design/methodology/approach A screening process is used to identify imperfect items during and after production. Selling the imperfect items at a discount is examined in the first model and the reworking policy in the second model. In both models, demand during the production process is satisfied only by perfect items. Data collected from a case company are used to illustrate the performance of the two models. Moreover, a sensitivity analysis is carried out by varying the most important parameters of the models. Findings The case study in this research is used to demonstrate the applicability of the proposed models, i.e. the EPQ model with salvaging and reworking imperfect items. The models are applied to a high-tech un-plasticized polyvinyl chloride (UPVC) doors and windows manufacturer that produces different types of doors and windows. ROGAWIN Co. is a privately owned company that started in 2001 with fully automatic production lines. Finally, the results of applying the different ways of handling the imperfect items are discussed, along with managerial insights. Originality/value In real-world production systems, manufacturing imperfect products is unavoidable. That is why, it is important to make a proper decision about imperfect products to reduce overall production costs. Recently, applying a reworking strategy has gained the most interest when it comes to handling this problem. The principal idea of this research is to maximize the total profit of manufacturing systems by optimizing the period length under some capacity constraints. The proposed models were applied to a company of manufacturing UPVC doors and windows.

A revised method for allocating the optimum number of similar machines to operators

2016 ◽  
Vol 65 (2) ◽  
pp. 223-244 ◽  
Author(s):  
Yossi Hadad ◽  
Baruch Keren
Keyword(s):  
Binomial Distribution ◽  
Manufacturing Systems ◽  
Real Life ◽  
Optimal Number ◽  
Production Costs ◽  
Optimum Number ◽  
Content Type ◽  
Manufacturing Operations ◽  
Machine Interference

Purpose – The purpose of this paper is to propose a method to determine the optimal number of operators to be assigned to a given number of machines, as well as the number of machines that will be run by each operator (a numerical partition). This determination should be made with the objective of minimizing production costs or maximizing profits. Design/methodology/approach – The method calculates the machines interference rate via the binomial distribution function. The optimal assignment is calculated by transformation of a partition problem into a problem of finding the shortest path on a directed acyclic graph. Findings – The method enables the authors to calculate the adjusted cycle time, the workload of the operators, and the utility of the machines, as well as the production yield, the total cost per unit, and the hourly profit for each potential assignment of operators to machines. In a case study, the deviation of the output per hour of the proposed method from the actual value was about 2 percent. Practical implications – The paper provides formulas and tables that give machine interference rates through the application of binomial distribution. The practicability of the proposed method is demonstrated by a real-life case study. Originality/value – The method can be applied in a wide variety of manufacturing systems that use many identical machines. This includes tire presses in tire manufacturing operations, ovens in pastry manufacturing systems, textile machines, and so on.

Assessing the implementation feasibility of intelligent production systems based on cloud computing, industrial internet of things and business social networks

Kybernetes ◽  
2021 ◽  
Vol ahead-of-print (ahead-of-print) ◽  
Author(s):  
Jiabao Sun ◽  
Ting Yang ◽  
Zhiying Xu
Keyword(s):  
Social Networks ◽  
Cloud Computing ◽  
Internet Of Things ◽  
Resource Sharing ◽  
Manufacturing Systems ◽  
Production Systems ◽  
Industrial Internet Of Things ◽  
Content Type ◽  
Industrial Internet ◽  
The Impact

PurposeThe increasing demands for customized services and frequent market variations have posed challenges to managing and controlling the manufacturing processes. Despite the developments in literature in this area, less consideration has been devoted to the growth of business social networks, cloud computing, industrial Internet of things and intelligent production systems. This study recognizes the primary factors and their implications for intelligent production systems' success. In summary, the role of cloud computing, business social network and the industrial Internet of things on intelligent production systems success has been tested.Design/methodology/approachIntelligent production systems are manufacturing systems capable of integrating the abilities of humans, machines and processes to lead the desired manufacturing goals. Therefore, identifying the factors affecting the success of the implementation of these systems is necessary and vital. On the other hand, cloud computing and the industrial Internet of things have been highly investigated and employed in several domains lately. Therefore, the impact of these two factors on the success of implementing intelligent production systems is examined. The study is descriptive, original and survey-based, depending on the nature of the application, its target and the data collection method. Also, the introduced model and the information collected were analyzed using SMART PLS. Validity has been investigated through AVE and divergent validity. The reliability of the study has been checked out through Cronbach alpha and composite reliability obtained at the standard level for the variables. In addition, the hypotheses were measured by the path coefficients and R2, T-Value and GOF.FindingsThe study identified three variables and 19 sub-indicators from the literature associated that impact improved smart production systems. The results showed that the proposed model could describe 69.5% of the intelligence production systems' success variance. The results indicated that business social networks, cloud computing and the industrial Internet of things affect intelligent production systems. They can provide a novel procedure for intelligent comprehensions and connections, on-demand utilization and effective resource sharing.Research limitations/implicationsStudy limitations are as below. First, this study ignores the interrelationships among the success of cloud computing, business social networks, Internet of things and smart production systems. Future studies can consider it. Second, we only focused on three variables. Future investigations may focus on other variables subjected to the contexts. Ultimately, there are fewer experimental investigations on the impact of underlying business social networks, cloud computing and the Internet of things on intelligent production systems' success.Originality/valueThe research and analysis outcomes are considered from various perspectives on the capacity of the new elements of Industry 4.0 for the manufacturing sector. It proposes a model for the integration of these elements. Also, original and appropriate guidelines are given for intelligent production systems investigators and professionals' designers in industry domains.

Robustness assessment in production systems

2021 ◽  
Vol 32 (4) ◽  
pp. 932-951
Author(s):  
Christian Stockmann ◽  
Herwig Winkler ◽  
Martin Kunath
Keyword(s):  
Flow Shop ◽  
Production Systems ◽  
Production Costs ◽  
Flow Shop Scheduling ◽  
Holistic View ◽  
Content Type ◽  
Precise Understanding ◽  
Assessment Approach ◽  
Resource Requirements ◽  
The One

PurposeThe concept of robustness in manufacturing is not easy to capture and even harder to quantify. This paper elaborates an approach to assess robustness in production systems from a holistic input-throughput-output perspective using a pragmatic robustness indicator.Design/methodology/approachFirst, in order to have a precise understanding of what needs to be measured, a concept of robustness in production systems is defined based on a literature overview. Three different aspects are considered to be essential to comprehensively describe robustness in production: the deviations of input resources, of performance and of output. These aspects are translated into an aggregated indicator based on developments of production costs, order delays and output volumes. The indicator-based assessment approach is eventually applied to a flow-shop scheduling case study in the chipboard industry.FindingsThe study shows that an assessment of robustness should not solely focus on a single aspect of a production system. Instead, a holistic view is required addressing the tradeoffs that robustness must balance, such as the one between the realized performance, the corresponding resource requirements and the resulting output. Furthermore, the study emphasizes that robustness can be interpreted as a superior system capability that builds upon flexibility, agility, resilience and resistance.Research limitations/implicationsFirst, the paper is a call to further test and validate the proposed approach in industry case studies. Second, the paper suggests a modified understanding of robustness in production systems in which not only the deviation of one single variable is of interest but also the behavior of the whole system.Practical implicationsThe approach allows practitioners to pragmatically evaluate a production system’s robustness level while quickly identifying drivers, barriers and tradeoffs.Originality/valueCompared to existing assessment approaches the proposed methodology is one of the first that evaluates robustness in production systems from a holistic input-throughput-output perspective highlighting the different tradeoffs that have to be balanced. It is based upon a comprehensive concept of robustness which also links robustness to adjacent capabilities that were otherwise only treated separately.

A model for reliability analysis of multi-state manufacturing systems

2014 ◽  
Vol 31 (8) ◽  
pp. 938-949 ◽  
Author(s):  
Seyed Ahmad Niknam ◽  
Rapinder Sawhney
Keyword(s):  
Reliability Analysis ◽  
System Reliability ◽  
Design Methodology ◽  
Manufacturing Systems ◽  
Manufacturing System ◽  
Production Systems ◽  
Case Scenario ◽  
Worst Case ◽  
Content Type ◽  
Proposed Model

Purpose – The purpose of this paper is to investigate the reliability analysis of a multi-state manufacturing system with different performance levels. In, fact, reliability assessment of manufacturing systems gives a reasonable demonstration of system performance. Design/methodology/approach – This research utilizes a multi-state system reliability analysis to develop a new metric for evaluating production systems. Findings – The proposed model provides a sensible measure to assess the system situation against the best-case scenario of a production line. Originality/value – The proposed model incorporates not only failures that stop production but also deals with partial failures where the system continues to operate at reduced performance rates. The analyses are represented in a best-case vs worst-case situation. Each of these cases provides insight for managers with respect to planning operation and maintenance activities.

scholarly journals An Economic Analysis of Two Grafted Tomato Transplant Production Systems in the United States

2010 ◽  
Vol 20 (4) ◽  
pp. 794-803 ◽  
Author(s):  
Cary L. Rivard ◽  
Olha Sydorovych ◽  
Suzanne O'Connell ◽  
Mary M. Peet ◽  
Frank J. Louws
Keyword(s):  
United States ◽  
Production Systems ◽  
Indirect Costs ◽  
The United States ◽  
Production Costs ◽  
Labor Costs ◽  
Commercial Farming ◽  
Economic Production ◽  
Certified Organic ◽  
The Cost

The grafting of herbaceous vegetables is an emerging development in the United States. This report provides an estimate of the variable costs of grafting within U.S. tomato (Solanum lycopersicum) transplant production systems. Grafted and nongrafted plants were propagated at two commercial farming operations in Ivanhoe, NC (NC) and Strasburg, PA (PA) and the farm in NC produced certified organic transplants. Detailed economic production sequences were generated for each site, and grafted and nongrafted transplant production costs were $0.59 and $0.13 in NC, and $1.25 and $0.51 in PA, respectively. Direct costs associated with grafting (e.g., grafting labor, clips, chamber, etc.) accounted for 37% to 38% of the added cost of grafting, and grafting labor was 11.1% to 14.4% of the cost of grafted transplant production. Seed costs represented 52% and 33% of the added cost of grafting at the two sites, and indirect costs (e.g., soil, trays, and heating) accounted for 10% and 30% of the added cost of grafting. Our findings suggest that under current seed prices and with similar production practices, the feasibility of grafting in the United States is not disproportionately affected by domestic labor costs. Additionally, the economic models presented in this report identify the cost of production at various transplant stages, and provide a valuable tool for growers interested in grafted tomato transplant production and utilization.

The impact of reconfigurability on the operational performance of manufacturing systems

2019 ◽  
Vol 31 (1) ◽  
pp. 145-168 ◽  
Author(s):  
Isabela Maganha ◽  
Cristovao Silva ◽  
Luis Miguel D. F. Ferreira
Keyword(s):  
Manufacturing Systems ◽  
Production Systems ◽  
Operational Performance ◽  
Future Research ◽  
Reconfigurable Manufacturing ◽  
Manufacturing Companies ◽  
Clustering Methods ◽  
Content Type ◽  
Core Characteristics ◽  
The Impact

Purpose The purpose of this paper is to investigate the current level of reconfigurability implementation and its impact on manufacturing systems’ operational performance empirically. Design/methodology/approach This study is based on a questionnaire survey. Statistical analysis procedures were adopted to accomplish its objectives, namely, clustering methods based on cluster centroids. An ANOVA analysis was used to test for cluster differences among the variables. Findings The results show that the manufacturing companies surveyed can be divided into three clusters, with different levels of reconfigurability implemented. The implementation of the core characteristics of reconfigurability depends on the product’s complexity and demand variability, in terms of volume and product mix, as these have an impact on the operational performance, in terms of quality, delivery and flexibility. Research limitations/implications The data for this survey were collected from manufacturing companies based in Portugal. Therefore, the replication of this questionnaire in other countries is recommended for future research to confirm its findings. Practical implications The questionnaire developed could be used by managers to assess the level of reconfigurability of their production systems and for internal/external benchmarking. The findings may help managers to decide which core characteristics should be implemented in their manufacturing systems. Originality/value The majority of the research addressing performance issues in reconfigurable manufacturing systems has been applied to case studies. This research reports an empirical investigation using a questionnaire-based methodology to provide generalisable empirical evidence.

Adaptable High-Tech Mechatronic Equipment with Laser Scanning for Multicontrol 3D of Complex Components from Automotive Industry

2015 ◽  
Vol 772 ◽  
pp. 293-298
Author(s):  
Adrian Cătălin Voicu ◽  
Gheorghe Ion Gheorghe
Keyword(s):  
Systems Engineering ◽  
Automotive Industry ◽  
Manufacturing Systems ◽  
Laser Scanning ◽  
Process Management ◽  
Single Step ◽  
Production Costs ◽  
High Tech ◽  
Production Environment ◽  
Manufacturing Networks

Progressive replacement of traditional tools with intelligent technological equipment becoming more complex is one of the most important aspects of the development of production processes in all industrial fields. Intelligent measurement and integrated dimensional control are needed to ensure the quality of the product or industrial manufacturing process, whatever the field. Because the automotive industry is one of the most important industries in the world, manufacturing systems engineering, control methods and techniques, and assurance of quality, present particular interest by the economic results, in particular the reduction of working time and production costs. In a perfect world or in an integrated production environment, the new 3D measurement systems, by providing the quality control integrated into the production line would be able to measure all the necessary parameters in a single step, without errors and render the results in the same way to the manufacturing networks with computers, in formats useful for CNC machines control and process management.

A methodology for the reconfiguration process in manufacturing systems

2014 ◽  
Vol 25 (6) ◽  
pp. 891-915 ◽  
Author(s):  
Ibrahim H. Garbie
Keyword(s):  
System Design ◽  
Manufacturing Systems ◽  
Material Handling ◽  
Manufacturing System ◽  
Production Systems ◽  
Systems Design ◽  
Production Volume ◽  
Plant Layout ◽  
Content Type ◽  
Handling System

Purpose – The purpose of this paper is to propose a “Reconfiguration Methodology” in manufacturing systems that they can become more economically sustainable and can operate efficiency and effectively. This methodology will allow customized flexibility and capacity not only in producing a variety of products (parts) and with changing market demands, but also in changing and reengineering the system itself. Design/methodology/approach – Reconfigurable manufacturing system (RMS) is a philosophy or strategy which was introduced during the last decade to achieve agility in manufacturing systems. Until now, the RMS philosophy was based changing activities such routing, planning, programming of machines, controlling, scheduling, and physical layout or materials handling system. But the RMS concept can be based on the needed reconfiguration level (NRL), operational status of production systems, and new circumstances (NC). The NRL measure is based on the agility level of the manufacturing systems which is based on technology, people, management, and manufacturing strategies. The components of the manufacturing system design (MSD) consist of production system design, plant layout system, and material handling system. Operational status of production systems includes machine capability (flexibility) and capacity (reliability), production volume or demand, and material handling equipment in addition to the plant layout. The NC are also consisting of new product, developing the existing ones, and changing in demand. Findings – Reconfiguration manufacturing systems from one period to another period is highly desired and is considered as a novel manufacturing philosophy and/or strategy toward creating new sustainable manufacturing systems. A new reconfiguration methodology for the manufacturing systems will be analyzed and proposed. Two Case studies will be introduced. Originality/value – The suggestion of a new methodology of reconfiguration including the NRL (configurability index) and the operational status of manufacturing systems with respect to any circumstance is highly considered. The reconfiguration methodology also provides a framework for sustainability in the manufacturing area which mainly focussed on manufacturing systems design.

Building a virtual factory: an integrated design approach to building smart factories

2021 ◽  
Vol ahead-of-print (ahead-of-print) ◽  
Author(s):  
Emre Yildiz ◽  
Charles Møller
Keyword(s):  
Wind Turbine ◽  
Manufacturing Systems ◽  
Production Systems ◽  
Integrated Design ◽  
Manufacturing Plant ◽  
Design And Development ◽  
Content Type ◽  
Virtual Factory ◽  
Integrated Design Approach ◽  
Analysis Design

Purpose The complexity of manufacturing systems, on-going production and existing constraints on the shop floor remain among the main challenges for the analysis, design and development of the models in product, process and factory domains. The potential of different virtual factory (VF) tools and approaches to support simultaneous engineering for the design, and development of these domains has been addressed in the literature. To fulfil this potential, there is a need for an approach which integrates the product, process and production systems for designing and developing VF and its validation in real-life cases. This paper aims to present an integrated design approach for VF design and development, as well as a demonstration implemented in a wind turbine manufacturing plant. Design/methodology/approach As the research calls for instrumental knowledge to discover the effects of intervention on the operations of an enterprise, design science research methodology is considered to be a well-suited methodology for exploring practical usefulness of a generic design to close the theory–practice gap. The study was planned as an exploratory research activity which encompassed the simultaneous design and development of artefacts and retrospective analysis of the design and implementation processes. The extended VF concept, architecture, a demonstration and procedures followed during the research work are presented and evaluated. Findings The artefacts (models and methods) and the VF demonstrator, which was evaluated by industry experts and scholars based on the role of the VF in improving the performance in the evaluation and reconfiguration of new or existing factories, reduce the ramp-up and design times, supporting management decisions. Preliminary results are presented and discussed. Research limitations/implications The concept VF model, its architecture and general methodology as an integrated design and development approach, can be adopted and used for VF design and development both for discrete and continuous manufacturing plants. The development and demonstration were limited, however, because real-time synchronisation, 3D laser scanning data and a commonly shared data model, to enable the integration of different VF tools, were not achievable. Originality/value The paper presents a novel VF concept and architecture, which integrates product, process and production systems. Moreover, design and development methods of the concept and its demonstration for a wind turbine manufacturing plant are presented. The paper, therefore, contributes to the information systems and manufacturing engineering field by identifying a novel concept and approach to the effective design and development of a VF and its function in the analysis, design and development of manufacturing systems.

Improving performance in manufacturing firms

2020 ◽  
Vol 28 (4) ◽  
pp. 47-49
Keyword(s):  
Lean Manufacturing ◽  
Production Systems ◽  
Manufacturing Firms ◽  
Production Costs ◽  
Maximum Effect ◽  
Content Type ◽  
Pertinent Information ◽  
Increase Productivity ◽  
Productivity And Competitiveness

Purpose This paper aims to review the latest management developments across the globe and pinpoint practical implications from cutting-edge research and case studies. Design/methodology/approach This briefing is prepared by an independent writer who adds their own impartial comments and places the articles in context. Findings Manufacturing firms try to maintain a scale of economy, whereby there is a productivity ratio of output to input – maximizing output and reducing production costs. A drop in demand can lead to increased value of production costs, and thus scale inefficiency. To compensate, firms use mass production systems as well as lean manufacturing philosophies. Investing in research and development can increase innovation and technological changes which can increase productivity and competitiveness. Such changes need to be employed long-term and holistically for maximum effect. Originality/value The briefing saves busy executives and researchers hours of reading time by selecting only the very best, most pertinent information and presenting it in a condensed and easy-to-digest format.

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