Evaluation of Resetting Performance in Cellular Manufacturing Systems - A Structured Approach to Sustainable Improvement of Resetting Performance

Doktorsavhandling, 2002

This thesis deals with the question of how to achieve responsiveness in cellular manufacturing systems, with special emphasis given to the rapid resetting between product runs. Findings from action research in cellular manufacturing systems are presented, along with a comprehensive methodology for resetting improvements based on performance evaluation. Summing up, it is argued that long resetting times mainly originate from drawbacks in the manufacturing organisation and not from the manufacturing technology in use. Manufacturing technology for fast and adjustment-free resetting is available today. Short and stable resetting times, however, are strongly dependent on the manufacturing organisation´s ability of continuously maintaining a high level of method utilization, competence development, and system utilisation. Short resetting times are only sustained, if all related work tasks are performed consistently with timeliness and quality. To reach these objectives, an improvement methodology - the RPE framework - is outlined in this thesis. This improvement methodology is derived from considerations of a scientific base for resetting processes. The scientific base and its implications are discussed in the thesis. The framework for resetting performance evaluation - RPE framework - proposed here offers a comprehensive improvement methodology for resetting processes. A detailed procedure on how to evaluate resetting performance on method-, organization-, and profitability levels is provided. The results from performance evaluation hence will guide the improvement work irrespective of the improvement methodology chosen. Further, the use of modern computer tools supporting resetting evaluation and improvement is suggested. Resetting improvement is a constant interplay between work methods, workforce performance, and system utilisation. The scientific evaluation of resetting performance, as proposed in this thesis, builds the base for successful and sustainable improvement of resetting time and responsiveness in cellular manufacturing systems.