FLEXIBILITY ASSESSMENT TO MITIGATE COMPLEXITY: TRUCKS PRODUCTION ANALYSIS
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Published
May 10, 2017
Jorge Muniz Jr
Luis Oliveira Nascimento Henrique Rocha Martins Luis Alberto Duncan Rangel
http://orcid.org/0000-0003-3496-0256
Luis Oliveira Nascimento Henrique Rocha Martins Luis Alberto Duncan Rangel
Abstract
New products are continuously developed in order to support customized demands. Flexibility supports customized demands, low costs, and agility, but it remains a challenge with regards to high-volume and high-diversity complexity as observed in trucks production. This research aims to discuss an assessment approach based on AHP application to rank flexibility projects. It is a multi-criteria decision method based on the Analytic Hierarchy Process (AHP). Decision-makers (88 managers) from different truck plant areas (production, logistics, quality, sales and finance) were interviewed and asked to consider lean thinking, mass customization, and agility to rank flexibility improvement projects that aim to reduce time-to-market and increase company competitiveness increase.
How to Cite
Muniz Jr, J., Nascimento, L. O., Martins, H. R., & Rangel, L. A. D. (2017). FLEXIBILITY ASSESSMENT TO MITIGATE COMPLEXITY: TRUCKS PRODUCTION ANALYSIS. International Journal of the Analytic Hierarchy Process, 9(1). https://doi.org/10.13033/ijahp.v9i1.404
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Keywords
flexibility, lean, agility, complexity, trucks
References
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Baykasoglu, A., & Ozbakir, L. (2008). Analysing the effect of flexibility on manufacturing systems performance. Journal of Manufacturing Technology Management. 19(2), 172-193. Doi:
http://dx.doi.org/10.1108/17410380810847909
Bertrand, J. W. M. and Fransoo, J. C. (2002). Operations management research methodologies using quantitative modeling, International Journal of Operations & Production Management, 22(2), 241-264 Doi:
http://dx.doi.org/10.1108/01443570210414338
Boyle, T. A. (2006) Towards best management practices for implementing manufacturing flexibility. Journal of Manufacturing Technology Management. 17(1), 6-21. Doi:
http://dx.doi.org/10.1108/17410380610639470
Boyton, A.C., Victor, B., & Pine II, B. J. (1993). New competitive strategies: Challenges to organizations and information technology. IBM Systems Journal, 32(1), 40-64. Doi: 10.1147/sj.321.0040
Bozókia, S., Fülöpa, J., &Rónyaib, L. (2007). On optimal completion of incomplete pairwise comparison matrices. Mathematical and Computer Modelling, 52(1-2), 318-333. Doi: http://dx.doi.org/10.1016/j.mcm.2010.02.047
Cachon, G. Olivares, M. (2010). Drivers of finished goods inventory in the U.S. automobile industry. Management Science, 56(1), 202-216. Doi: http://dx.doi.org/10.1287/mnsc.1090.1095
Chang, S., Lin, R., Chang, F., Chen, R. (2007). Achieving manufacturing flexibility through entrepreneurial orientation. Industrial Management & Data Systems, 107(7), 997-1017.Doi: http://dx.doi.org/10.1108/02635570710816711
Chen, I.J., Paulraj, A., Lado, A.A. (2004). Strategic purchasing, supply management and firm performance. Journal of Operations Management, 22, 505-523. Doi: http://dx.doi.org/10.1016/j.jom.2004.06.002
Emiliani, M.L, Stec, D.J. (2004). Using value stream mapping to improve leadership. Leadership & Organization Development Journal, 25, 622-645. Doi:
http://dx.doi.org/10.1108/01437730410564979
Fedrizzia, M. &Gioveb, S. (2007). Incomplete pairwise comparison and consistency optimization. European Journal of Operational Research, 183(1), 303-313. Doi: http://dx.doi.org/10.1016/j.ejor.2006.09.065
Forman, E. & Peniwati, K. (1998). Aggregating individual judgments and priorities with the analytic hierarchy process. European Journal of Operational Research, 108(1), 165-169. Doi: 10.1016/S0377-2217(97)00244-0
Guo, Y.; Xu, Z. A. (2007). Model of lean supplier management based on the lean production. International Federation for Information Processing, 254(1), 717-726. Doi: 10.1007/978-0-387-75902-9_81
Gupta, D. and Buzacott, J. A. (1989). A framework for understanding flexibility of manufacturing systems. Journal of Manufacturing Systems, 8(2), 89-96. Doi: https://doi.org/10.1016/0278-6125(89)90028-9
Hallgren, M., Olhager, J. (2009). Lean and agile manufacturing: External and internal drivers and performance outcomes. International Journal of Operations & Production Management, 29(10), 976-999. Doi:
http://dx.doi.org/10.1108/01443570910993456
Harker, I.J. (1987). Incomplete pairwise comparison in the Analytic Hierarchy Process. Mathematical Modelling, 9(11), 837-848. Doi: https://doi.org/10.1016/0270-0255(87)90503-3
Hayes, R. H., Wheelwright, S. C. (1979). Link manufacturing process and product life cycles. Harvard Business Review, 133-140. Doi: 10.1002/9780470618813.app3
Holweg, M. (2006). The genealogy of lean production. Journal of Operation Management, 25(2), 420-437. Doi: http://dx.doi.org/10.1016/j.jom.2006.04.001
Hu, S. J., Ko, J., Weyand, L. Elmaraghy, H. A. Lien, T. K. Koren, Y., Bley, H., Chryssolouris, G., Nasr, N., Shpitalni, M. (2011). Assembly system design and operations for product variety. CIRP Annals - Manufacturing Technology, 60(2), 715–733. Doi: http://dx.doi.org/10.1016/j.cirp.2011.05.004
Jeyaraman, K., Kee Leo, L. (2010). A conceptual framework for critical success factors of lean six sigma. International Journal of Lean Six Sigma. 1, 191-215. Doi:
http://dx.doi.org/10.1108/20401461011075008
Kara, S., & Kayis, B. (2004). Manufacturing flexibility and variability: An overview. Journal of Manufacturing Technology Management, 15(6), 466-478. Doi:
http://dx.doi.org/10.1108/17410380410547870
Kerbache, L., Van Delft, C. (2014). Efficient purchaser incentive when dealing with suppliers implementing continuous improvements plans. International Transactions in Operations Research, 21, 673-701. Doi: 10.1111/itor.12059
Kwiesielewicz, M., van Uden, E. (2003). Ranking decision variants by subjective paired comparisons in cases with incomplete data. In: V. Kumar (Ed.), et al., Computational Science and Its Applications–ICCSA 2003, Lecture Notes in Computer Science, 2669, Springer-Verlag, Berlin/Heidelberg, 208–215. Doi: 10.1007/3-540-44842-X_22
Leeuw, S., Holweg, M., Williams, G. (2011). The impact of descentralized control on firm-level inventory. International Journal of Physical Distribution & Logistics Management, 41(5), 435-456. Doi:
http://dx.doi.org/10.1108/09600031111138817
MacCormack, A., Verganti, R., &Iansiti, M. (2001). Developing products on “Internet timeâ€: The anatomy of a flexible development process. Management Science, 47(1), 133-152. Doi: http://dx.doi.org/10.1287/mnsc.47.1.133.10663
Modrak, V., Marton, D., &Bednar, S. (2015). The influence of mass customization strategy on configuration complexity of assembly systems. Conference of Intelligent Computation on Manufacturing Engineering (CIRP), 33, 538-543. Doi: https://doi.org/10.1016/j.procir.2015.06.071
Naga, V. & Kodali, J.M. (2016). An empirical study for implementation of lean principles in Indian manufacturing industry. Benchmarking: An International Journal, 23(1),183-207.Doi: http://dx.doi.org/10.1108/BIJ-11-2013-0101
Powell, D. (2013). ERP Systems in lean production: New Insights from a review of lean and ERP literature. International Journal of Operations & Production Management, 33(11/13), 1490-1510. Doi: http://dx.doi.org/10.1108/IJOPM-07-2010-0195
Riesenbeck, H., Herrmann, A., Heitmann, M., Algesheimer, R. (2006). An approach to profit-maximizing product design on the basis of the platform concept. International Journal of Quality & Reliability Management, 23(7), 788-806. Doi:
http://dx.doi.org/10.1108/02656710610679815
Saaty, T.L. (1980). The Analytic Hierarchy Process. New York, NY: McGraw-Hill. Doi: http://dx.doi.org/10.1080/00137918308956077
Salgado, E. G., Salomon, V. A. P., Carlos H. P. Mello, C. H. P. (2012). Analytic Hierarchy prioritization of new product development activities for electronics manufacturing. International Journal of Production Research, 50(17), 4860-4866. Doi: http://dx.doi.org/10.1080/00207543.2012.657972
Slack, N. (2005). The flexibility of manufacturing systems. International Journal of Operations & Production Management, 25(12), 1190-1200.
Smith, S., Smith, G.C., Jiao, R., & Chu, C. (2013). Mass customization in the product life cycle. Journal of Intelligent Manufacturing, 24(5), 877-885. Doi:10.1007/s10845-012-0691-0
Swink, M., Melnyk, S. A., Cooper, M. B., & Hartley, J. L (2013). Managing operations across the supply chain 2nd. ed., McGraw Hill.
Wahab, M.I. M., Wu, D. & Lee, C. (2008). A generic approach to measuring the machine flexibility of manufacturing systems. European Journal of Operational Research, 186, 137–149. Doi: http://dx.doi.org/10.1016/j.ejor.2007.01.052
Wang, R., Zhang, T., Ying, S. (2007). Analysis of supply chain contract on supplier flexibility. International Conference on Management Science & Engineering. Doi: 10.1109/ICMSE.2007.4421915 Doi: 10.1109/ICMSE.2007.4421915
Wedley. W.C. (1993). Consistency prediction for incomplete AHP matrices. Mathematical and Computer Modelling, 17(4–5), 151-161. Doi: https://doi.org/10.1016/0895-7177(93)90183-Y
Wee, H.M., We, S. (2009). Lean supply chain and its effect on product cost and quality: a case study on Ford Motor Company. Supply Chain Management: an International Journal,14/15, 335-341. Doi: http://dx.doi.org/10.1108/13598540910980242
Witell, L., Gustafsson, A., Johnson, M. (2014). The effect of customer information during new product development on profits from goods and services. European Journal of Marketing, 48(9), 1709-1730.
Doi: http://dx.doi.org/10.1108/EJM-03-2011-0119
Baines, T., Lightfoot, H., Williams, G.M., & Greenough, R. (2006). State-of-the-art in lean design engineering: A literature review on white collar lean. Proceedings of the Institution of Mechanical Engineers Part B-Journal of Engineering Manufacture, 220(9), 1539-1547.
Baykasoglu, A., & Ozbakir, L. (2008). Analysing the effect of flexibility on manufacturing systems performance. Journal of Manufacturing Technology Management. 19(2), 172-193. Doi:
http://dx.doi.org/10.1108/17410380810847909
Bertrand, J. W. M. and Fransoo, J. C. (2002). Operations management research methodologies using quantitative modeling, International Journal of Operations & Production Management, 22(2), 241-264 Doi:
http://dx.doi.org/10.1108/01443570210414338
Boyle, T. A. (2006) Towards best management practices for implementing manufacturing flexibility. Journal of Manufacturing Technology Management. 17(1), 6-21. Doi:
http://dx.doi.org/10.1108/17410380610639470
Boyton, A.C., Victor, B., & Pine II, B. J. (1993). New competitive strategies: Challenges to organizations and information technology. IBM Systems Journal, 32(1), 40-64. Doi: 10.1147/sj.321.0040
Bozókia, S., Fülöpa, J., &Rónyaib, L. (2007). On optimal completion of incomplete pairwise comparison matrices. Mathematical and Computer Modelling, 52(1-2), 318-333. Doi: http://dx.doi.org/10.1016/j.mcm.2010.02.047
Cachon, G. Olivares, M. (2010). Drivers of finished goods inventory in the U.S. automobile industry. Management Science, 56(1), 202-216. Doi: http://dx.doi.org/10.1287/mnsc.1090.1095
Chang, S., Lin, R., Chang, F., Chen, R. (2007). Achieving manufacturing flexibility through entrepreneurial orientation. Industrial Management & Data Systems, 107(7), 997-1017.Doi: http://dx.doi.org/10.1108/02635570710816711
Chen, I.J., Paulraj, A., Lado, A.A. (2004). Strategic purchasing, supply management and firm performance. Journal of Operations Management, 22, 505-523. Doi: http://dx.doi.org/10.1016/j.jom.2004.06.002
Emiliani, M.L, Stec, D.J. (2004). Using value stream mapping to improve leadership. Leadership & Organization Development Journal, 25, 622-645. Doi:
http://dx.doi.org/10.1108/01437730410564979
Fedrizzia, M. &Gioveb, S. (2007). Incomplete pairwise comparison and consistency optimization. European Journal of Operational Research, 183(1), 303-313. Doi: http://dx.doi.org/10.1016/j.ejor.2006.09.065
Forman, E. & Peniwati, K. (1998). Aggregating individual judgments and priorities with the analytic hierarchy process. European Journal of Operational Research, 108(1), 165-169. Doi: 10.1016/S0377-2217(97)00244-0
Guo, Y.; Xu, Z. A. (2007). Model of lean supplier management based on the lean production. International Federation for Information Processing, 254(1), 717-726. Doi: 10.1007/978-0-387-75902-9_81
Gupta, D. and Buzacott, J. A. (1989). A framework for understanding flexibility of manufacturing systems. Journal of Manufacturing Systems, 8(2), 89-96. Doi: https://doi.org/10.1016/0278-6125(89)90028-9
Hallgren, M., Olhager, J. (2009). Lean and agile manufacturing: External and internal drivers and performance outcomes. International Journal of Operations & Production Management, 29(10), 976-999. Doi:
http://dx.doi.org/10.1108/01443570910993456
Harker, I.J. (1987). Incomplete pairwise comparison in the Analytic Hierarchy Process. Mathematical Modelling, 9(11), 837-848. Doi: https://doi.org/10.1016/0270-0255(87)90503-3
Hayes, R. H., Wheelwright, S. C. (1979). Link manufacturing process and product life cycles. Harvard Business Review, 133-140. Doi: 10.1002/9780470618813.app3
Holweg, M. (2006). The genealogy of lean production. Journal of Operation Management, 25(2), 420-437. Doi: http://dx.doi.org/10.1016/j.jom.2006.04.001
Hu, S. J., Ko, J., Weyand, L. Elmaraghy, H. A. Lien, T. K. Koren, Y., Bley, H., Chryssolouris, G., Nasr, N., Shpitalni, M. (2011). Assembly system design and operations for product variety. CIRP Annals - Manufacturing Technology, 60(2), 715–733. Doi: http://dx.doi.org/10.1016/j.cirp.2011.05.004
Jeyaraman, K., Kee Leo, L. (2010). A conceptual framework for critical success factors of lean six sigma. International Journal of Lean Six Sigma. 1, 191-215. Doi:
http://dx.doi.org/10.1108/20401461011075008
Kara, S., & Kayis, B. (2004). Manufacturing flexibility and variability: An overview. Journal of Manufacturing Technology Management, 15(6), 466-478. Doi:
http://dx.doi.org/10.1108/17410380410547870
Kerbache, L., Van Delft, C. (2014). Efficient purchaser incentive when dealing with suppliers implementing continuous improvements plans. International Transactions in Operations Research, 21, 673-701. Doi: 10.1111/itor.12059
Kwiesielewicz, M., van Uden, E. (2003). Ranking decision variants by subjective paired comparisons in cases with incomplete data. In: V. Kumar (Ed.), et al., Computational Science and Its Applications–ICCSA 2003, Lecture Notes in Computer Science, 2669, Springer-Verlag, Berlin/Heidelberg, 208–215. Doi: 10.1007/3-540-44842-X_22
Leeuw, S., Holweg, M., Williams, G. (2011). The impact of descentralized control on firm-level inventory. International Journal of Physical Distribution & Logistics Management, 41(5), 435-456. Doi:
http://dx.doi.org/10.1108/09600031111138817
MacCormack, A., Verganti, R., &Iansiti, M. (2001). Developing products on “Internet timeâ€: The anatomy of a flexible development process. Management Science, 47(1), 133-152. Doi: http://dx.doi.org/10.1287/mnsc.47.1.133.10663
Modrak, V., Marton, D., &Bednar, S. (2015). The influence of mass customization strategy on configuration complexity of assembly systems. Conference of Intelligent Computation on Manufacturing Engineering (CIRP), 33, 538-543. Doi: https://doi.org/10.1016/j.procir.2015.06.071
Naga, V. & Kodali, J.M. (2016). An empirical study for implementation of lean principles in Indian manufacturing industry. Benchmarking: An International Journal, 23(1),183-207.Doi: http://dx.doi.org/10.1108/BIJ-11-2013-0101
Powell, D. (2013). ERP Systems in lean production: New Insights from a review of lean and ERP literature. International Journal of Operations & Production Management, 33(11/13), 1490-1510. Doi: http://dx.doi.org/10.1108/IJOPM-07-2010-0195
Riesenbeck, H., Herrmann, A., Heitmann, M., Algesheimer, R. (2006). An approach to profit-maximizing product design on the basis of the platform concept. International Journal of Quality & Reliability Management, 23(7), 788-806. Doi:
http://dx.doi.org/10.1108/02656710610679815
Saaty, T.L. (1980). The Analytic Hierarchy Process. New York, NY: McGraw-Hill. Doi: http://dx.doi.org/10.1080/00137918308956077
Salgado, E. G., Salomon, V. A. P., Carlos H. P. Mello, C. H. P. (2012). Analytic Hierarchy prioritization of new product development activities for electronics manufacturing. International Journal of Production Research, 50(17), 4860-4866. Doi: http://dx.doi.org/10.1080/00207543.2012.657972
Slack, N. (2005). The flexibility of manufacturing systems. International Journal of Operations & Production Management, 25(12), 1190-1200.
Smith, S., Smith, G.C., Jiao, R., & Chu, C. (2013). Mass customization in the product life cycle. Journal of Intelligent Manufacturing, 24(5), 877-885. Doi:10.1007/s10845-012-0691-0
Swink, M., Melnyk, S. A., Cooper, M. B., & Hartley, J. L (2013). Managing operations across the supply chain 2nd. ed., McGraw Hill.
Wahab, M.I. M., Wu, D. & Lee, C. (2008). A generic approach to measuring the machine flexibility of manufacturing systems. European Journal of Operational Research, 186, 137–149. Doi: http://dx.doi.org/10.1016/j.ejor.2007.01.052
Wang, R., Zhang, T., Ying, S. (2007). Analysis of supply chain contract on supplier flexibility. International Conference on Management Science & Engineering. Doi: 10.1109/ICMSE.2007.4421915 Doi: 10.1109/ICMSE.2007.4421915
Wedley. W.C. (1993). Consistency prediction for incomplete AHP matrices. Mathematical and Computer Modelling, 17(4–5), 151-161. Doi: https://doi.org/10.1016/0895-7177(93)90183-Y
Wee, H.M., We, S. (2009). Lean supply chain and its effect on product cost and quality: a case study on Ford Motor Company. Supply Chain Management: an International Journal,14/15, 335-341. Doi: http://dx.doi.org/10.1108/13598540910980242
Witell, L., Gustafsson, A., Johnson, M. (2014). The effect of customer information during new product development on profits from goods and services. European Journal of Marketing, 48(9), 1709-1730.
Doi: http://dx.doi.org/10.1108/EJM-03-2011-0119
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