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First published in 1999, this book explores pint points, compares and dates the development of product differentiation and variety. This book also analyses’ how firms have embraced a variety of ways of efficiently managing this verity though production, the design of the product as well as in the relations with the suppliers and distributors.
In the last decade, the production of mechanical components to be assembled in final products produced in high volumes (e.g. cars, mopeds, industrial vehicles, etc.) has undergone deep changes due to the overall modifications in the way companies compete. Companies must consider competitive factors such as short lead times, tight product tolerances, frequent market changes and cost reduction. Anyway, companies often have to define production objectives as trade-offs among these critical factors since it can be difficult to improve all of them. Even if system flexibility is often considered a fundamental requirement for firms, it is not always a desirable characteristic of a system because it requires relevant investment cost which can jeopardize the profitability of the firm. Dedicated systems are not able to adapt to changes of the product characteristics while flexible systems offer more flexibility than what is needed, thus increasing investment and operative costs. Production contexts characterized by mid to high demand volume of well identified families of products in continuous evolution do not require the highest level of flexibility; therefore, manufacturing system flexibility must be rationalized and it is necessary to find out the best trade-off between productivity and flexibility by designing manufacturing systems endowed with the right level of flexibility required by the production problem. This new class of production systems can be named Focused Flexibility Manufacturing Systems-FFMSs. The flexibility degree in FFMSs is related to their ability to cope with volume, mix and technological changes, and it must take into account both present and future changes. The required level of system flexibility impacts on the architecture of the system and the explicit design of flexibility often leads to hybrid systems, i.e. automated integrated systems in which parts can be processed by both general purpose and dedicated machines. This is a key issue of FFMSs and results from the matching of flexibility and productivity that respectively characterize FMSs and Dedicated Manufacturing Systems (DMSs). The market share of the EU in the machine tool sector is 44%; the introduction of focused flexibility would be particularly important for machine tool builders whose competitive advantage is based on the ability of customizing their systems on the basis of needs of their customers. In fact, even if current production contexts frequently present situations which would fit well with the FFMS approach, tradition and know-how of machine tool builders play a crucial role. Firms often agree with the focused flexibility vision, nevertheless they decide not to pay the risk and efforts related to the design of this new system architecture. This is due also to the lack of well-structured design approaches which can help machine tool builders to configure innovative systems. Therefore, the FFMS topic is studied through the book chapters following a shared mission: "To define methodologies and tools to design production systems with a minimum level of flexibility needed to face, during their lifecycle, the product and process evolution both in the technological and demand aspects. The goal is to find out the optimal trade-off between flexibility and productivity". The book framework follows the architecture which has been developed to address the FFMS Design problem. This architecture is both broad and detailed, since it pays attention to all the relevant levels in a firm hierarchy which are involved in the system design. Moreover, the architecture is innovative because it models both the point of view of the machine tool builder and the point of view of the system user. The architecture starts analyzing Manufacturing Strategy issues and generating the possible demand scenario to be faced. Technological aspects play a key role while solving process plan problems for the products in the part family. Strategic and technological data becomes input when a machine tool builder performs system configuration. The resulting system configurations are possible solutions that a system user considers when planning its system capacity. All the steps of the architecture are deeply studied, developing methods and tools to address each subproblem. Particular attention is paid to the methodologies adopted to face the different subproblems: mathematical programming, stochastic programming, simulation techniques and inverse kinematics have been used. The whole architecture provides a general approach to implement the right degree of flexibility and it allows to study how different aspects and decisions taken in a firm impact on each other. The work presented in the book is innovative because it gives links among different research fields, such as Manufacturing Strategy, Process Plan, System Design, Capacity Planning and Performance Evaluation; moreover, it helps to formalize and rationalize a critical area such as manufacturing system flexibility. The addressed problem is relevant at an academic level but, also, at an industrial level. A great deal of industrial sectors need to address the problem of designing systems with the right degree of flexibility; for instance, automotive, white goods, electrical and electronic goods industries, etc. Attention to industrial issues is confirmed by empirical studies and real case analyses which are presented within the book chapters.
Flexible assembly systems offer quick and simple change-over between different products or tasks. They allow profitable investment to be made in automation, as well as providing opportunities for dynamic production development.
Driven by rising environmental and geopolitical concerns, regulations have been put in place over the last decade to compel car makers to lower the CO2 emissions of their cars. Due to these increasingly stringent vehicle efficiency standards, considerable effort has been expended to reduce vehicle fuel consumption. Since the mass of the vehicle dominates all of these efforts, it can be argued that future emission requirements will be impossible to achieve with steel vehicle structures. A transition to lightweight, non-steel materials seems inevitable. However, non-steel materials in most cases require dedicated manufacturing systems due to specific manufacturing requirements. Thus, lightweight vehicle systems will require a distinct divergence between today's manufacturing environment and the potential future manufacturing system. While many studies have assessed greenfield production costs for conventional vehicles and the lightweight alternative, this research recognizes an important reality of the automobile marketplace: any future lightweight vehicle will be implemented out of a steel-based manufacturing environment. Carmakers will have to adapt existing plant infrastructure to the particular requirements of the non-ferrous material. This research develops a conceptual framework and a transition cost model to quantify change penalties of transition processes imposed on vehicle assembly systems. This transition model is applied to a case study provided by Ford Motor Company in order to better understand implications of different manufacturing strategies on the system's capability of switching materials. The research identifies three different manufacturing change penalties which have to be paid when switching the base material in vehicle assembly systems. Taking these penalties into account, case studies suggest when, to what extent, and how materials transitions can be realized most cost-effectively. Partial component-wise transitions are presented as an attractive alternative to full material transitions. Finally, strategies are proposed how to increase the material flexibility of automotive manufacturing systems.
The book familiarizes the reader with the flexible assembly systems planning and scheduling issues and various operations research modelling and solution approaches. Some of the many topic highlights presented are the overall structure and components of a flexible assembly system, bi-objective integer programming models and algorithms for machine loading, assembly routing, and assembly plan selection, and fast combinatorial heuristics for scheduling flexible assembly lines with limited intermediate buffers. Also the book deals with just-in-time scheduling of flexible assembly lines, and dynamic dispatching algorithms for simultaneous scheduling of assembly stations and automated guided vehicles.
This handbook is a compilation of the current practical knowledge of flexible manufacturing systems (FMS). FMS allow manufacturing plants of all sizes to reduce their inventory while increasing their ability to meet consumer demands. By controlling automatic guided vehicles, robots, and machine tools with one central computer, products can now be produced in a variety of styles and models all at the same time. FMS are designed to adapt quickly and economically to changes in requirements and to unpredictable events. This guide explains how to effectively employ these useful new systems. - Includes specifications for software to implement simulation modeling - Surveys practical applications in the workplace - Presents materials in a step-by-step workbook style
The evolution and execution of automotive manufacturing are explored in this fundamental manual. It is an excellent reference for entry level manufacturing engineers and also serves as a training guide for nonmanufacturing professionals. The book covers the major areas of vehicle assembly manufacturing and addresses common approaches and procedures of the development process. Having held positions as both a University Professor and as a Lead Engineering Specialist in industry, the author draws on his experience in both theory and application to fill the gap between academic research and industrial practices. This concisely written, comprehensive review discusses the sophisticated principles and concepts of automotive manufacturing from development to applications and includes: 250 illustrations and 90 tables. End-of-chapter review questions. Research topics for in-depth case studies, literature reviews, and/or course projects. Analytical problems for additional practice. Directly extracted and summarized from automotive manufacturing practices, this book serves as an essential manual. The subject is complemented by the author’s first book, Automotive Vehicle Assembly Processes and Operations Management, which provides even greater depth to the complex endeavor of modern automotive manufacturing.