No description available.

No description available.

No description available.

No description available.

No description available.

<div>Reviewing the literature verifies that manufacturing industries fall short of the required sustainable criteria in the system design.</div><div>One of the leading reasons behind such a failure refers to the lack of an effective system design's knowledge toward the selected solutions by benchmarking.</div><div>The Collective System Design (CSD) approach provides a countermeasure for this shortcoming by starting the design approach with a collective agreement upon the external and internal customer needs and then choosing the solutions for the system design to achieve those needs. </div><div>The general requirements and solutions to a manufacturing system are covered in the Manufacturing System Design Decomposition (MSDD) in a linear and path-dependent fashion, which is a core derivative of the CSD.</div><div><br></div><div>The CSD application in industrial case studies has been provided in this thesis to elaborate on how the CSD approach assists industries to re-design their systems in a sustainable manner.</div><div>The segregation of the tools and objectives of the system re-design in a path-dependent fashion is guided by the design principles.</div><div>The case studies described how to achieve the external customer needs of product quality, quantity, variety, and on-time delivery with a collaborative work inside the plant. </div><div>This collaboration was built up by defining the customer-supplier connection inside the plant.</div><div>Cell re-design and balancing of operations with a well-defined standard work is also elaborated in this research to help produce what is needed to be shipped today with the least amount of waste in the system.</div><div>The after system redesign MSDD questionnaire analysis at these industries have shown that the industries successfully satisfied their system needs in a sustainable manner. </div><div><br></div><div>In those case studies, an internal customer need for a safe working environment was also brought to light and the CSD approach was introduced and applied to achieve the associated requirements of safety. </div><div>As the original MSDD lacked the requirements and solutions for the safety component, an updated version of the MSDD has been proposed to incorporate </div><div>the safety branch to the MSDD.</div><div>In addition, some enhancements to the current version of the MSDD have been made for a clearer and more thorough understanding of the system design.</div>

Made available in DSpace on 2016-06-02T19:50:27Z (GMT). No. of bitstreams: 1 TeseCRNS.pdf: 1772351 bytes, checksum: 17b2dc82dae0e985204bfa2fd68f873b (MD5) Previous issue date: 2005-04-29 / Universidade Federal de Minas Gerais / The management of manufacturing systems have become more complex, once that new products are arising, product demands are uncertain, life cycles get shorter, and a wide variety of products compete for common resources. This thesis deals with the design and planning of discrete manufacturing systems, based on open queueing network models to support the decision making of capacity allocation. As manufacturing systems may be represented by generalized queueing networks, and there are no exact solution methods, here is employed the decomposition approximate method to evaluate the performance of systems under different configurations. It is shown in the thesis how these approximations are suitable and effective to estimate the work-in-process (WIP) and the production leadtime of an actual metallurgical industry queueing network. It is also shown that discrete capacity allocation models, based on the approximations, are effective to evaluate and optimize the performance of the case study under different configurations. Trade-off curves between capacity investment and WIP are generated and are useful not only to support a manager to estimate how much capacity he/she should allocate, but also to decide where it should be allocated in the queueing network. These curves also support the decision making in terms of capacity, if the variability of the external arrivals, the product mix and/or the throughput for the network change. Besides adding capacity, partitioning the facility is another alternative to reduce the system complexity. This thesis also approaches the focused factory design problem, involving the partition of the facility into smaller shops and the capacity allocation in each shop. Again, the decomposition approximations were employed to evaluate the system performance. Despite its importance, this problem has rarely been reported in the literature. In this thesis, the goal is to reduce the system complexity either from the product management point of view or from the workstation management point of view. From the product management point of view, a model whose complexity constraint is na upper limit on the production leadtime variance of the products passing through the network was studied. From the workstation management point of view, the complexity constraint of the model keeps constant the expected waiting time of a product at a workstation, once it waits for being served. It is shown through these models for some instances that the partition of the facility into smaller shops decreases the complexity system without necessary capacity additional investments. Futhermore, sometimes it is possible to keep the network performance (or even to improve it), partitioning the network into smaller shops which need less capacity than the original configuration with a single shop. / A gestão de sistemas de manufatura tem se tornado mais complexa na medida em que novos produtos estão surgindo, a demanda de produtos é incerta, os ciclos de vida são mais curtos e uma grande variedade de produtos competem pelos mesmos recursos. Esta tese trata o projeto e planejamento de sistemas discretos de manufatura, baseados em modelos de redes de filas abertas, para auxiliar no processo de tomada de decisões. Porque sistemas de manufatura podem ser representados por redes de filas genéricas, e não existem métodos exatos de solução, aqui é empregado o método aproximado de decomposição para avaliar o desempenho dos sistemas em diferentes configurações. Mostra-se nesta tese que estas aproximações são adequadas e efetivas para estimar os estoques em processo (WIP) e o leadtime de produção de uma rede de manufatura real de uma indústria metal-mecânica. Mostra-se ainda que os modelos de alocação de capacidade discreta, baseados nestas aproximações, também são efetivos para avaliar e otimizar o desempenho da rede do estudo de caso em diferentes configurações. Curvas de trade-off entre investimento em capacidade e WIP são geradas e são úteis não somente para auxiliar um gerente a estimar quanto alocar de capacidade, mas também para decidir onde alocá-la na rede de filas. As curvas também auxiliam a tomada de decisões em termos de capacidade, se a variabilidade das chegadas externas, o mix de produtos e/ou a taxa de produção da rede mudam. Além de adicionar capacidade, a partição da instalação é outra alternativa para reduzir a complexidade do sistema. Esta tese também aborda o problema de projeto de fábrica focalizada, envolvendo a partição da instalação em subplantas e a alocação de capacidade em cada estação das subplantas. Novamente, as aproximações por decomposição foram utilizadas para avaliar e otimizar o desempenho do sistema. Apesar de sua importância, este problema tem sido muito pouco reportado em literatura. Nesta tese, o objetivo é reduzir a complexidade do sistema do ponto de vista da gestão do produto, ou do ponto de vista da gestão da estação. Do ponto de vista da gestão do produto, é apresentado um modelo cuja restrição de complexidade é um limitante superior para a variância do leadtime dos produtos na rede. Do ponto de vista da gestão da estação, a restrição de complexidade do modelo fixa o tempo médio de espera de um produto na estação, quando há espera. Mostra-se, por meio destes modelos para alguns casos que, a partição da instalação em subplantas reduz a complexidade do sistema, sem necessidade de investimentos adicionais em capacidade. Além disso, algumas vezes, é possível manter (ou até melhorar) o desempenho da rede, particionando-a em subplantas que necessitam de menos capacidade do que a configuração original com uma planta única.