Predicting the effects of cycle time variability on the efficiency of electronics assembly mixed-model, zero-buffer flow processing lines.
ABSTRACT The research literature emphasises the need to use flow processing lines to undertake processing and assembly within low demand volume, high product variety electronics manufacturing environments that have significant levels of product, process and demand variability to contend with. Currently, the presence of such high levels of product, process and demand variability prevents the design of efficient flow processing lines by significantly disrupting the synchronisation of materials movement between work stations, resulting in under-utilisation of manufacturing resources, long lead times and poor delivery reliability.In order to ensure efficient flow processing under such conditions, a range of methods has been developed for both reducing levels of variability and for managing the effects of variability. However, ensuring the effective use of each of these methods requires detailed knowledge of the effects this variability has on the resource requirements of individual workstations.The current research is concerned with the development of predictive models that can quantitatively estimate the amounts of blocking and waiting, on individual workstations along a flow line, arising from differences in cycle times between these workstations. Information derived from such models are able to enable more precise and effective use of the methods used to off-set the effects of cycle time variability.
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ABSTRACT: Mixed-model assembly lines are of great practical relevance and are widely used in a range of industries, such as the final assembly of the automotive and electronics industries. Prior research mainly selected and discussed isolated problems rather than considering the whole planning process. In this article mixed-model production planning is decomposed into five steps: initial configuration of the line, master scheduling, reconfiguration planning, sequencing and resequencing. The paper reviews and discusses all relevant planning steps and proposes general planning instruments as well as formalized decision models for those steps, which have not been thoroughly investigated in the literature thus far.05/2007;
- McGraw-Hill., ISBN: 0-256-24795-1
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ABSTRACT: This paper describes the development of a survey instrument to assess the implementation of lean practices within an organization. Results of a literature review, which was used to identify lean manufacturing practices and existing lean assessment tools, are presented. The findings of this review were synthesized to develop an instrument to assess both the number and the level of implementation of a broad range of lean practices in an organization. As part of a larger research project, an exploratory study was completed using the survey. A cross section of electronic manufacturers in the Pacific Northwest was used for the exploratory study. Analysis of the survey results from the exploratory study are summarized in this paper to illustrate how the survey can be used to understand what factors might contribute to the implementation of lean practices. In the exploratory study completed, for example, it was found that while electronic manufacturers have implemented a broad range of lean practices, the level of implementation does vary and may be related to economic, operational, or organizational factors.Journal of Operations Management. 01/2005; 24.