Enhanced integrated modelling approach to reconfiguring manufacturing enterprises

Dynamism and uncertainty are real challenges for present day manufacturing enterprises (MEs). Reasons include: an increasing demand for customisation, reduced time to market, shortened product life cycles and globalisation. MEs can reduce competitive pressure by becoming reconfigurable and change-capable. However, modern manufacturing philosophies, including agile and lean, must complement the application of reconfigurable manufacturing paradigms. Choosing and applying the best philosophies and techniques is very difficult as most MEs deploy complex and unique configurations of processes and resource systems, and seek economies of scope and scale in respect of changing and distinctive product flows. It follows that systematic methods of achieving model driven reconfiguration and interoperation of component based manufacturing systems are required to design, engineer and change future MEs. This thesis, titled Enhanced Integrated Modelling Approach to Reconfiguring Manufacturing Enterprises , introduces the development and prototyping a model-driven environment for the design, engineering, optimisation and control of the reconfiguration of MEs with an embedded capability to handle various types of change. The thesis describes a novel systematic approach, namely enhanced integrated modelling approach (EIMA), in which coherent sets of integrated models are created that facilitates the engineering of MEs especially their production planning and control (PPC) systems. The developed environment supports the engineering of common types of strategic, tactical and operational processes found in many MEs. The EIMA is centred on the ISO standardised CIMOSA process modelling approach. Early study led to the development of simulation models during which various CIMOSA shortcomings were observed, especially in its support for aspects of ME dynamism. A need was raised to structure and create semantically enriched models hence forming an enhanced integrated modelling environment. The thesis also presents three industrial case examples: (1) Ford Motor Company; (2) Bradgate Furniture Manufacturing Company; and (3) ACM Bearings Company. In order to understand the system prior to realisation of any PPC strategy, multiple process segments of any target organisation need to be modelled. Coherent multi-perspective case study models are presented that have facilitated process reengineering and associated resource system configuration. Such models have a capability to enable PPC decision making processes in support of the reconfiguration of MEs. During these case studies, capabilities of a number of software tools were exploited such as Arena®, Simul8®, Plant Simulation®, MS Visio®, and MS Excel®. Case study results demonstrated effectiveness of the concepts related to the EIMA. The research has resulted in new contributions to knowledge in terms of new understandings, concepts and methods in following ways: (1) a structured model driven integrated approach to the design, optimisation and control of future reconfiguration of MEs. The EIMA is an enriched and generic process modelling approach with capability to represent both static and dynamic aspects of an ME; and (2) example application cases showing benefits in terms of reduction in lead time, cost and resource load and in terms of improved responsiveness of processes and resource systems with a special focus on PPC; (3) identification and industrial application of a new key performance indicator (KPI) known as P3C the measuring and monitoring of which can aid in enhancing reconfigurability and responsiveness of MEs; and (4) an enriched modelling concept framework (E-MUNE) to capture requirements of static and dynamic aspects of MEs where the conceptual framework has the capability to be extended and modified according to the requirements. The thesis outlines key areas outlining a need for future research into integrated modelling approaches, interoperation and updating mechanisms of partial models in support of the reconfiguration of MEs

Integrated modelling approach in support of change-capable PPC strategy realisation

The increasing demand for customization, reduced time to market and globalization are the real challenges for today’s manufacturing enterprises (MEs). Therefore MEs can reduce these competitive pressures by becoming more and more change-capable. The agile and lean manufacturing philosophies must complement the application of reconfiguration techniques. However, choosing and applying the best philosophies and techniques are far from being well understood and well structured processes because most MEs deploy complex and unique configurations of processes and resource systems, and seek economies of scope and scale in respect of a number of distinctive product flows. It follows that systematic methods of achieving model driven reconfiguration and interoperation of component based manufacturing systems are required to design, engineer and change next generation MEs. This paper discusses research aimed at developing and prototyping a model-driven environment for the design, optimization and control of enterprises with an embedded capability to handle various types of change in an example of a production planning and control (PPC) scenario. The developed environment supports the engineering of common types of strategic, tactical and operational process found in many MEs. Also reported are initial findings of manufacturing case study work in which coherent multi-perspective models of a specific ME have facilitated process reengineering and associated resource system configuration and interoperation. In order to understand the system prior to realisation of any PPC strategy, multiple process segments of organisations need to be modelled. The paper considers key PPC strategies and describes a novel systematic approach to create coherent sets of unified models that facilitate the engineering of PPC strategies. Case study models are presented with capability to enable PPC decision making processes in support of complex organisation design and change (OD&C). The paper outlines key areas for future research including the need for research into unified modelling approaches and interoperation of partial models in support of complex OD&C

An integrated model driven approach in support of next generation

Shortened product life cycles and globalization have induced dynamism and uncertainty into world markets. Hence manufacturing enterprises (MEs) can gain competitive advantage from being reconfigurable. But appropriate application of agile and lean Manufacturing philosophies must complement the application of reconfiguration techniques. However, choosing and applying the best philosophies and techniques are far from being well understood and well structured processes because most MEs deploy complex and unique configurations of processes and resource systems, and seek economies of scope and scale in respect of a number of distinctive product flows. It follows that systematic methods of achieving model driven configuration of component based manufacturing systems are required to design, engineer and change next generation MEs. This paper discusses research aimed at developing and prototyping a model-driven environment for the design, optimization and control of reconfigurable manufacturing enterprises with an embedded capability to handle various types of change. The developed environment supports the engineering of common types of strategic, tactical and operational process found in many MEs. Also reported are initial findings of manufacturing case study work in which coherent multi-perspective models of a specific ME have facilitated process reengineering and associated resource system configuration. The paper outlines key areas for future research including the need for research into unified modelling approaches and interoperation of partial models in support of complex organisation design and change (OD&C)

A computer integrated unified modelling approach to responsive manufacturing

Computer modelling approaches have significant potential to enable decision-making about various aspects of responsive manufacturing. In order to understand the system prior to the selection of any responsiveness strategy, multiple process segments of organisations need to be modelled. The article presents a novel systematic approach for creating coherent sets of unified enterprise, simulation and other supporting models that collectively facilitate responsiveness. In this approach, enterprise models are used to explicitly define relatively enduring relationships between (i) production planning and control (PPC) processes, that implement a particular strategy and (ii) process-oriented elements of production systems, that are work loaded by the PPC processes. Coherent simulation models, can in part be derived from the enterprise models, so that they computer execute production system behaviours. In this way, time-based performance outcomes can be simulated; so that the impacts of alternative PPC strategies on the planning and controlling historical or forecasted patterns of workflow, through (current and possible future) production system models, can be analysed. The article describes the unified modelling approach conceived and its application in a furniture industry case study small and medium enterprise (SME)

Organizational design: need for a socio-technical inclusive system design approach to meet 21st century workforce challenges

Changes occurring in the business and socio-economic global environments increase the complexity of working systems. The global workforce is becoming more diverse where people from different social, cultural, geographical and technical backgrounds work together in spite of their existing differences. Existence of varying human responses caused due to variations in individual’s physical, physiological, psychological, social and cognitive responses to the organizational design becomes a real challenge for designers. Moreover, increase in the number of older workers, also requires the attention of designers, as they are different in many ways. These issues increase the complexity of organizational systems and have serious implications for human factors and ergonomics as this complexity challenges the way conventional organizational systems are designed and implemented. There is a great need to develop new strategies where human variations are rightly understood and then emphasized during organizational design process. A proposed Sociotechnical Inclusive System Design approach has been discussed for addressing social and technical issues of organizational design by integrating socio-technical principles with inclusive thinking so that these challenges might be addressed at the organizational and individual levels. This article briefly describes global workforce challenges like increase in diversity, ageing, and impact of individual level variations on workplace safety and task performance. Finally, it highlights the need to design organizational systems based on diversity and differences where social and technical inclusivity should be an integral part of any design decision so that organizations can effectively utilize their human capital. The suggested design approach can draw multiple benefits including employee satisfaction, workplace safety and well-being, high productivity and quality and retention of a skilled workforce for a longer time. All these benefits ultimately support the attainment of long term organizational sustainability

Manufacturer's perspective on inclusive design drivers and barriers - developing countries case

Inclusive Design aims to ensure that the design needs of the largest possible audience are addressed. Developing countries contribute about 41% of the global population and the percentage of older people and people with disabilities is increasing, which further highlights the need for an inclusive design approach. This discusses the demographics and the need to consider the design needs of this large segment of the world population. Exploration of drivers and barriers to inclusive design are identified so that strategies can be devised to promote drivers and remove barriers. This ongoing research will be based on a survey that will be used to collect manufacturer’s perspective on these issues. Data analysis will provide an opportunity to understand the manufacturer’s perspective and how understanding and awareness can be increased. This research will improve the lives of people in developing countries and will highlight business opportunities for local and international manufacturing companies

Product to process lifecycle management in assembly automation systems

Presently, the automotive industry is facing enormous pressure due to global competition and ever changing legislative, economic and customer demands. Product and process development in the automotive manufacturing industry is a challenging task for many reasons. Current product life cycle management (PLM) systems tend to be product-focussed. Though, information about processes and resources are there but mostly linked to the product. Process is an important aspect, especially in assembly automation systems that link products to their manufacturing resources. This paper presents a process-centric approach to improve PLM systems in large-scale manufacturing companies, especially in the powertrain sector of the automotive industry. The idea is to integrate the information related to key engineering chains i.e. products, processes and resources based upon PLM philosophy and shift the trend of product-focussed lifecycle management to process-focussed lifecycle management, the outcome of which is the Product, Process and Resource Lifecycle Management not PLM only

Enterprise modelling in support of methods based engineering: lean implementation in an SME

Popular ‘methods-based’ approaches to engineering enterprises include: BPR, Continuous Improvement, Kaizen, TQM, JIT, Lean and Agile Manufacturing. Generally the industrial application of such methods-based approaches leads to long lead-times, high costs, and poorly justified engineering projects that do not prepare the organization for future change. These outcomes are to be expected because (1) invariably Manufacturing Enterprises (MEs) constitute very complex and dynamic systems that naturally require complex design and change processes and (2) current methods-based approaches to organizational design and change are not analytically well founded. Therefore the authors argue that a framework and modelling toolset are required to facilitate ongoing and integrated application of methods-based engineering approaches, providing underlying modelling structures and concepts to ‘systemize’ and ‘quantify’ key aspects of organization design and change. Unless suitable decomposition, quantitative and qualitative modelling principles are used to underpin an approach such as a Lean Manufacturing, deficiencies will remain. Often, MEs adopt the “we need be lean” mindset without holistic understandings of causal and temporal impacts of such philosophies on ME processes, resource systems and current and possible future workflows. Enterprise Modelling (EM) partially addresses the aforementioned problems and can support the development of robust understandings about current enterprise processes and potential capabilities of systems. However in general, current EM techniques are geared best to capturing and organizing relatively enduring knowledge and data about any given organization but are themselves deficient in respect to replicating and predicting dynamic system behaviors. This paper presents a model driven approach to organization design and change in support of methods-based engineering, applying Lean Manufacturing principles, with a UK based bearing manufacturer. EM and various derivative Simulation Modelling (SM) views were generated to display system behaviors under changing scenarios

An integrated modelling approach in support of next generation reconfigurable manufacturing systems

Dynamism and uncertainty are real challenges for present day manufacturing enterprises (MEs). Choosing and applying the best philosophies and techniques is very difficult as most MEs deploy complex and unique configurations of processes and resource systems to cope with changing product flows. It follows that systematic methods of achieving model-driven reconfiguration and interoperation of component-based manufacturing systems are required to design, engineer and change next generation (NG) MEs. This paper describes a novel systematic approach, namely an integrated modelling approach (IMA), designed to support next generation reconfigurable manufacturing systems (NGRMS). The IMA is helpful in creating coherent sets of models that facilitate the engineering of production planning and control (PPC) strategies. Coherent multi-perspective industrial case study models are also presented that have facilitated process reengineering and associated resource system configuration. Those models have a capability to enable PPC decision making in support of complex organisation design and change (OD&C)

Unified modelling in support of organization design and change

The aim of this research is to provide a unified modelling-based method to help with the evaluation of organization design and change decisions. Relevant literature regarding model-driven organization design and change is described. This helps identify the requirements for a new modelling methodology. Such a methodology is developed and described. The three phases of the developed method include the following. First, the use of CIMOSA-based multi-perspective enterprise modelling to understand and capture the most enduring characteristics of process-oriented organizations and externalize various types of requirement knowledge about any target organization. Second, the use of causal loop diagrams to identify dynamic causal impacts and effects related to the issues and constraints on the organization under study. Third, the use of simulation modelling to quantify the effects of each issue in terms of organizational performance. The design and case study application of a unified modelling method based on CIMOSA (computer integrated manufacturing open systems architecture) enterprise modelling, causal loop diagrams, and simulation modelling, is explored to illustrate its potential to support systematic organization design and change. Further application of the proposed methodology in various company and industry sectors, especially in manufacturing sectors, would be helpful to illustrate complementary uses and relative benefits and drawbacks of the methodology in different types of organization. The proposed unified modelling-based method provides a systematic way of enabling key aspects of organization design and change. The case company, its relevant data, and developed models help to explore and validate the proposed method. The application of CIMOSA-based unified modelling method and integrated application of these three modelling techniques within a single solution space constitutes an advance on previous best practice. Also, the purpose and application domain of the proposed method offers an addition to knowledge