Mehmet Bulent Durmusoglu

A complete cellular manufacturing system design methodology based on axiomatic design principles

This paper provides a framework and a road map for people who are ready to transform their traditional production system from process orientation to cellular orientation, based on Axiomatic Design (AD) principles. A feedback mechanism for continuous improvement is also suggested for evaluating and improving the cellular design against pre-selected performance criteria. A complete implementation of the proposed methodology at a manufacturing company and resulting performance improvements are also provided.

Advances in assembly line parts feeding policies: a literature review

Purpose – The purpose of this paper is to present a literature review on parts feeding policies and to provide the components of parts feeding systems via a classification structure. Design/methodology/approach – This paper determines the scope and components of parts feeding systems via a classification structure under three main components such as the storage of parts, transport of parts and feeding policy. Afterward, it is focused on parts feeding policies and the related papers are reviewed and analyzed according to their feeding policy types, objectives, solution methodologies and the application types. Findings – A classification structure showing the components and scope of parts feeding systems is provided. Parts feeding policies are handled in detail and feeding policy types, objectives, solution methodologies and application types in the existing studies are presented in this paper. However, the paper highlights the open research areas and advances for academics and presents applied solution met...

A mathematical model and a heuristic approach for design of the hybrid manufacturing systems to facilitate one-piece flow

One-piece flow is a design rule that entails production in manufacturing cells on a ‘make one, check one, and move-on one’ basis (Black, J.T., 2007. Design rules for implementing Toyota Production System. International Journal of Production Research, 45 (16), 3639–3664), which reduces manufacturing lead time significantly. This paper proposes a sequential methodology comprised of a mathematical model and a heuristic approach (HA) for the design of a hybrid cellular manufacturing system (HMS), to facilitate one-piece flow practice. The mathematical model is employed in the cases of small- and medium-sized problems, and it attempts to minimise the total number of exceptional operations, while considering machine capacities and alternative machines. The machine-part matrix achieved by the mathematical model is input into the flow line design stage of the HA, where backflow within the cells is eliminated. However, for industrial problems, the proposed HA is utilised. After the formation of the cells by clustering, the HA attempts to eliminate exceptional operations of a given cellular configuration together with a functional structure by employing alternative machines, based on the decision rules developed. Later, unidirectional flow within the cells is achieved and the capacity and budget constraints are satisfied. A medium-sized problem is solved by using both of the approaches, namely, the model integrated with the flow-line design stage of the HA and the complete HA. The results are discussed and the limitations are explained.

Design of kitting system in lean‐based assembly lines

Purpose – The purpose of this paper is to develop a mathematical model for designing the kitting system by determining the optimum values of the related design parameters.Design/methodology/approach – Main assembly feeding systems are explained with their advantages and disadvantages. Related literature is reviewed and gaps are determined. To fill the void and to be beneficial for real life lean assembly systems, the elements of the kitting system are explained in detail and a mathematical model minimizing the cost consisting of Work In Process (WIP) and number of workers for the design of a kitting system is developed. A numerical example is presented to demonstrate the applicability of the model.Findings – This paper provides a mathematical model that provides the required design parameters for a kitting system such as the tour period, the number of workers and the quantities of the kits by minimizing WIP and labor costs.Originality/value – The paper provides a mathematical model for the design of a kit...

Axiomatic design of hybrid manufacturing systems in erratic demand conditions

In order to respond to part demands on time in an erratic demand environment, a complete road map for the design of hybrid cellular manufacturing systems (HMS) is proposed in this study, based on axiomatic design (AD) principles, such that all functional requirements of a complete HMS design are satisfied by the corresponding design parameters. With this methodology, first, a preliminary HMS is formed including exceptional operations. To facilitate one-piece flow within the cells of the HMS, these exceptions are eliminated by the proposed decision rules, where alternative machines are employed (Satoglu et al. 2010). Then, the sufficiency of current resource capacities is verified, using a simulation technique. In other words, stock accumulations are identified and then value stream through the system without any obstacles is ensured. These are achieved by means of procedures for identifying and eliminating the bottleneck resources. The proposed methodology is completed with the HMS layout design. This complete methodology based on AD principles is a unique aspect of this study. The methodology is applied on the data of an automotive supplier, and the results are discussed. Finally, using simulation models, it is shown that applying the proposed model results in a statistically significant improvement in lead time of the current available system.

Lot-splitting approach of a hybrid manufacturing system under CONWIP production control: a mathematical model

This paper discusses the advantages of lot splitting in hybrid manufacturing environments where cellular and functional layouts are combined under Constant Work in Process (CONWIP) production control. The proposed model fills a research gap in the related literature by applying lot splitting and pull production simultaneously. A linear CONWIP control mathematical model that minimises the average flow time is developed in case of lot splitting. The developed model has sequence-dependent set-up times. The demand level, coefficient of variation (CV) impact and set-up time reduction effect on CONWIP production control are also investigated. The model is solved using GAMS21.6 optimisation software; the optimal backlog list, the number and size of sublots are reported. The proposed model is compared with lot production under push control in different settings as well as with two different heuristics from the literature. Experimental results indicate that in all settings, the lot splitting is more advantageous than lot production in terms of average flow time. CV has a greater effect than set-up time reduction on average flow time.

Design methodology for a hybrid part feeding system in lean-based assembly lines

Purpose This paper aims to propose a combined methodology to help decision makers in evaluating and selecting the most effective part feeding system. Design/methodology/approach As a first step of the methodology, a hierarchical clustering analysis is applied to design a kitting or hybrid feeding system. Second, activity-based costing methodology is applied to determine which system is better according to their costs. Besides, sensitivity analysis is implemented to observe the behavior of the system in case of the takt time changes. Findings Using kitting systems purely can lead to problems because of the big and expensive parts in the mixed-model assembly systems. Therefore, the hybrid feeding policy can provide better solutions for such systems. Research limitations/implications A case study is conducted in a company and the most produced product of the company is considered to design the part feeding system. Results indicated that transportation cost has a large proportion on the total cost and the hybrid feeding policy may be a good solution to reduce this cost. Practical implications The paper includes implications for the design of hybrid feeding systems in lean-based assembly lines. The proposed methodology may be a practical tool for decision makers to design and decide on the part feeding policy. Originality/value Kitting design has not been studied yet to the best of the authors’ knowledge. Besides, there is no certain decision methodology indicating which system is better. In this study, different methods are combined as a new methodology with the purpose of industrial decision-making.

Lean Production Systems for Industry 4.0

Succeeding a cultural and people oriented transformation, Lean Producers adopts the philosophy of doing more with less by eliminating non-value-added activities from production processes to maintain effectiveness, flexibility, and profitability. With the context of Industry 4.0, new solutions are available for combining automation technology with Lean Production. Moreover, when effective resource (finance, labour, material, machine/equipment) usage is concerned, it is obvious that Industry 4.0 should be applied on lean processes. In this context, this chapter attempts to emphasize the interaction between Lean Production and Industry 4.0 and proposes a methodology which provides guidance for Industry 4.0 under lean production environment. Moreover, Industry 4.0 technologies and automation oriented Lean Production applications are also included.

Lean Transformation Integrated with Industry 4.0 Implementation Methodology

Succeeding a cultural and people-oriented transformation, lean producers adopt the philosophy of doing more with less by eliminating non-value-added activities from production processes to maintain effectiveness, flexibility, and profitability. In the context of Industry 4.0, new solutions are available for combining automation technology with lean production. Moreover, when effective usage of resources (finance, labor, material, machine/equipment) is concerned, it is obvious that Industry 4.0 should be applied to lean processes. In this context, this paper attempts to emphasize the interaction between lean production and Industry 4.0 and proposes a methodology that provides guidance for Industry 4.0 in a lean production environment. Moreover, Industry 4.0 technologies and automation-oriented lean production applications are also included.