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Analysis of the manufacturing flexibility parameters with effective performance metrics: a new interactive approach based on modified TOPSIS-Taguchi method

Authors:
Yusuf Tansel Ic at Başkent University
Yusuf Tansel Ic
Turgut Şaşmaz
Turgut Şaşmaz
Turgut Şaşmaz
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Mustafa Yurdakul at Gazi University
Mustafa Yurdakul
Berna Dengiz at Başkent University
Berna Dengiz
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Abstract and Figures

Flexibility is one of the most important strategy parameters to achieve a long-term successful performance for a manufacturing company. Studies in the literature aim to operate a manufacturing system at optimum levels of flexibility parameters under its own manufacturing environment. This study aims to present an interactive analysis framework based on TOPSIS and Taguchi parameter design principles for investigating the effects of different levels of flexibility parameters on the performance of a flexible manufacturing cell (FMC). The main performance metric used in this study is manufacturing lead time. Other important metrics to evaluate quality control and inspection policies are also investigated in this study. To conclude, a combined model of an interactive approach based on TOPSIS and Taguchi methods are used to assess the effectiveness of the flexibility parameters for a FMC.
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International Journal on Interactive Design and Manufacturing (IJIDeM) (2022) 16:197–225
https://doi.org/10.1007/s12008-021-00799-5
ORIGINAL PAPER
Analysis of the manufacturing flexibility parameters with effective
performance metrics: a new interactive approach based on modified
TOPSIS-Taguchi method
Yusuf Tansel ˙
Iç1·Turgut ¸Sa¸smaz2·Mustafa Yurdakul3·Berna Dengiz1
Received: 9 November 2020 / Accepted: 6 November 2021 / Published online: 24 January 2022
© The Author(s), under exclusive licence to Springer-Verlag France SAS, part of Springer Nature 2021
Abstract
Flexibility is one of the most important strategy parameters to achieve a long-term successful performance for a manufacturing
company. Studies in the literature aim to operate a manufacturing system at optimum levels of flexibility parameters under its
own manufacturing environment. This study aims to present an interactive analysis framework based on TOPSIS and Taguchi
parameter design principles for investigating the effects of different levels of flexibility parameters on the performance of
a flexible manufacturing cell (FMC). The main performance metric used in this study is manufacturing lead time. Other
important metrics to evaluate quality control and inspection policies are also investigated in this study. To conclude, a
combined model of an interactive approach based on TOPSIS and Taguchi methods are used to assess the effectiveness of
the flexibility parameters for a FMC.
Keywords Product quality ·Taguchi method ·Interactive approach ·Experimental design ·Milling ·TOPSIS ·Flexible
manufacturing cell ·Flexibility
1 Introduction
Performance measurement has a critical importance to make
the right decisions for companies in today’s competitive
environment [1]. With effective and timely evaluation of per-
formance information, companies will be well ahead of their
competitors. In today’s competitive marketing conditions,
rapid response to customer demands without sacrificing qual-
ity is also very important. Otherwise, the loss of customers
and markets and decline in sales revenue are expected to
occur. In order to meet desired delivery dependability without
compromising the quality of products, a modern manufactur-
ing philosophy “flexible manufacturing” must be considered.
A Flexible Manufacturing Cell (FMC) is an integrated sys-
BYusuf Tansel ˙
Iç
yustanic@baskent.edu.tr
1Department of Industrial Engineering, Faculty of Engineering,
Baskent University, 06790 Etimesgut, Ankara, Turkey
2NUROL Machinery Co., Organize Sanayi Bölgesi, Avrupa
Hun Cad. No: 6, 06935 Etimesgut, Ankara, Turkey
3Department of Mechanical Engineering, Faculty of
Engineering, Gazi University, 06570 Etimesgut, Ankara,
Turkey
tem, which includes computer numerical controlled (CNC)
machine tools, automatic material handling systems and
quality control and inspection stations simultaneously.
Many studies in the literature have been published about
flexible manufacturing system. A number of researchers
proposed studies that use multi-attribute decision-making
techniques to conduct an assessment of different flexible
routes. In the literature, Knopp et al. [2] analyzed planning of
flexible manufacturing system with expanded routes in semi-
conductor manufacturing. They focused on reducing cyle
times to complete production. In another study, Goncalves
[3] worked on a CNC reinforced flexible manufacturing cell
and they highlighted importance of a robot-assisted inter-
face. Cutkosky et al. [4] described sensitive cells in flexible
manufacturing systems. Leitao et al. [5] studied development
of CNC machines in flexible manufacturing cells and they
investigated performance effects of a network established
between basic external equipments and flexible manufactur-
ing cells. Chan [6] examined examined impacts of different
levels of flexibility in routing of workparts among flexible
production systems by using an integrated application of
Taguchi and simulation approaches. Chan used a Taguchi
L25 orthogonal array in his study. “Routing Flexibility”,
“Number of Pallets”, “Routes” and “Sequencing Rules”
123
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