Seru üretim sisteminde hat-seru dönüşümü ve çizelgeleme problemi için matematiksel model önerisi

Year 2022, Volume: 37 Issue: 3, 1213 - 1224, 28.02.2022

Ahad Furugi , Melis Haliloğlu

https://doi.org/10.17341/gazimmfd.884293

Cited By: 1

Abstract

Günümüz rekabet ortamında işletmeler rekabet gücünü artırmak için müşterilerin çeşitli ve kişiye özel taleplerine hızlı ve yüksek verimlilik ile yanıt vermeleri gerekmektedir. Üretim sistemlerinde verimliliği ve esnekliği artırmak amacıyla Amerikan Ford şirketi tarafından ortaya çıkan seri üretim (montaj hattı), Japonya’daki Toyota firması tarafından geliştirilen Toyota Üretim Sistemi (TÜS) ve grup teknolojisine dayalı Hücresel Üretim Sistemi (HÜS) gibi farklı üretim sistemleri geliştirilmiştir. Ancak, dinamik talepler, ürünlerin kısa yaşam döngüsü ve yüksek çeşitlilik nedeniyle montaj hattı ve TÜS’de verimlilik düşmektedir. Sony ve Canon gibi Japon şirketleri, pazar taleplerini karşılamak için bir Japon hücresel üretim sistemi geliştirmişlerdir ve geleneksel HÜS'den ayırmak için bu üretim sistemine seru üretim sistemi adı vermişlerdir. Literatürde seru üretim sistemi ile ilgili az sayıda çalışma yapılmıştır. Özellikle Türkçe literatürde, seru üretim sistemlerini inceleyen sadece iki çalışmaya rastlanmıştır. Bu yönüyle çalışmanın literatürdeki bu boşluğu doldurması hedeflenmektedir. Bu çalışmada seru üretim sistemi ele alınarak bu konuda kapsamlı literatür taramasının yanı sıra montaj hattının seru üretim sistemine dönüştürme (hat-seru dönüşümü) ve siparişlerin toplam gecikmelerini minimize eden çizelgeleme problemleri aynı anda matematiksel bir model olarak önerilmiştir. Modelin çözümü için GAMS paket programı kullanılmıştır ve sonuçlar analiz edilmiştir.

Keywords

Seru üretim sistemi, hat-seru dönüşümü problemi, çizelgeleme, matematiksel programlama

A mathematical model for line-seru conversion and scheduling problem in seru production system

Abstract

In today's competitive environment, businesses need to respond quickly and with high efficiency to the diverse and personal demands of customers in order to increase their competitiveness. In order to increase efficiency and flexibility in production systems, different production systems such as mass production (assembly line) produced by the American Ford company, Toyota Production System (TPS) developed by Toyota in Japan and cellular production system (CM) based on group technology (GT) have been developed. However, productivity is dropped in the assembly line and Toyota production system due to dynamic demands, short life cycle of products and high diversity. Japanese companies such as Sony and Canon have developed a Japanese cellular manufacturing system to meet market demands and to distinguish it from the traditional CM, they have called this production system a seru production system. There have been few studies in the literature on the seru production system. Especially in the Turkish literature, there are only two studies that considered seru production systems. With this aspect, this study is aimed to fill this gap in the literature. In this study, a comprehensive literature review has been conducted. In addition, a mathematical model is proposed for the conversion of the assembly line to the seru production system (line-seru conversion) and scheduling problems that minimize total tardiness. The GAMS package program is used to solve the model and the results are analyzed.

Keywords

seru production system, line-seru conversion problem, scheduling, mathematical programming

References

• 1. Yu, Y. ve J. Tang, Review of seru production. Frontiers of Engineering Management. 6(2): p. 183-192, 2019
• 2. Singh, S. A study on seru production system. in 3rd International Conference on Emerging Technologies in Engineeri ng, Biomedical, Management and Science. of Conference.
• 3. Lian, J., vd., A multi-skilled worker assignment problem in seru production systems considering the worker heterogeneity. Computers & Industrial Engineering. 118: p. 366-382, 2018
• 4. Yu, Y., vd., Seru system balancing: Definition, formulation, and exact solution. Computers & Industrial Engineering. 122: p. 318-325, 2018
• 5. Yu, Y., vd., Mathematical analysis and solutions for multi-objective line-cell conversion problem. European Journal of Operational Research. 236(2): p. 774-786, 2014
• 6. Ying, K.-C. ve Y.-J. Tsai, Minimising total cost for training and assigning multiskilled workers in seru production systems. International Journal of Production Research. 55(10): p. 2978-2989, 2017
• 7. Johnson*, D.J., Converting assembly lines to assembly cells at sheet metal products: Insights on performance improvements. International journal of production research. 43(7): p. 1483-1509, 2005
• 8. Kaku, I., vd., A mathematical model for converting conveyor assembly line to cellular manufacturing. Industrial Engineering & Management Systems. 7(2): p. 160-170, 2008
• 9. Kaku, I., vd., Modeling and numerical analysis of line-cell conversion problems. International Journal of Production Research. 47(8): p. 2055-2078, 2009
• 10. Stecke, K.E., vd., Seru production: an extension of just-in-time approach for volatile business environments, in Analytical Approaches to Strategic Decision-Making: Interdisciplinary Considerations. 2014, IGI Global. p. 45-58.
• 11. Stecke, K.E., vd., Seru: the organizational extension of JIT for a super-talent factory. International Journal of Strategic Decision Sciences (IJSDS). 3(1): p. 106-119, 2012
• 12. Yin, Y., vd., The evolution of seru production systems throughout Canon. Operations Management Education Review. 2, 2008
• 13. Zwierzyński, P. ve H. Ahmad, Seru production as an alternative to a traditional assembly line. Engineering Management in Production and Services. 10(3): p. 62-69, 2018
• 14. Kaku, I., Is seru a sustainable manufacturing system? Procedia Manufacturing. 8: p. 723-730, 2017
• 15. Akino, S., Internationalization of Japanese Company and Change of Production System (III). Rikkyo Economic Review. 51(1): p. 29-55, 1997
• 16. Schmenner, R.W. ve M.L. Swink, On theory in operations management. Journal of operations management. 17(1): p. 97-113, 1998
• 17. Molleman, E. ve J. Slomp, Functional flexibility and team performance. International Journal of Production Research. 37(8): p. 1837-1858, 1999
• 18. Iwamuro, H., An easy book about seru production. Nikkan Kogyo Shimbun, Tokyo, 2004
• 19. Ertay, T. ve D. Ruan, Data envelopment analysis based decision model for optimal operator allocation in CMS. European journal of operational research. 164(3): p. 800-810, 2005
• 20. Sakazume, Y., Is Japanese Cell Manufacturing a New System?: A Comparative Study between Japanese Cell Manufacturing and Cellular Manufacturing (< Special English Issue> Production and Logistics). Journal of Japan Industrial Management Association. 55(6): p. 341-349, 2005
• 21. Miyake, D.I., The shift from belt conveyor line to work-cell based assembly systems to cope with increasing demand variation in Japanese industries. International Journal of Automotive Technology and Management. 6(4): p. 419-439, 2006
• 22. Yu, Y., vd., How to carry out assembly line–cell conversion? A discussion based on factor analysis of system performance improvements. International Journal of Production Research. 50(18): p. 5259-5280, 2012
• 23. Liu, C., vd., Reconfiguration of assembly systems: From conveyor assembly line to serus. Journal of Manufacturing Systems. 31(3): p. 312-325, 2012
• 24. Liu, C., vd., Training and assignment of multi-skilled workers for implementing seru production systems. The International Journal of Advanced Manufacturing Technology. 69(5): p. 937-959, 2013
• 25. Yu, Y., vd., Reducing worker(s) by converting assembly line into a pure cell system. International Journal of Production Economics. 145(2): p. 799-806, 2013
• 26. Liu, C., vd., Production planning of multi-stage multi-option seru production systems with sustainable measures. Journal of Cleaner Production. 105: p. 285-299, 2015
• 27. Yu, Y., vd., Complexity of line-seru conversion for different scheduling rules and two improved exact algorithms for the multi-objective optimization. SpringerPlus. 5(1): p. 1-26, 2016
• 28. Sun, W., vd., Formulations, features of solution space, and algorithms for line-pure seru system conversion. 2016, 2016
• 29. Luo, L., vd. Seru loading with worker-operation assignment in single period. in 2016 IEEE International Conference on Industrial Engineering and Engineering Management (IEEM). of Conference.: IEEE, Year
• 30. Shao, L., vd., A bi-objective combination optimisation model for line-seru conversion based on queuing theory. International Journal of Manufacturing Research. 11(4): p. 322-338, 2016
• 31. Shao, L., vd. Production system performance improvement by assembly line-seru conversion. in Proceedings of the Tenth International Conference on Management Science and Engineering Management. of Conference.: Springer, Year
• 32. Yu, Y., vd., Line-seru conversion towards reducing worker (s) without increasing makespan: models, exact and meta-heuristic solutions. International Journal of Production Research. 55(10): p. 2990-3007, 2017
• 33. Wang, Y. ve J. Tang, Cost and service-level-based model for a seru production system formation problem with uncertain demand. Journal of Systems Science and Systems Engineering. 27(4): p. 519-537, 2018
• 34. Wu, L., vd., Cross-trained worker assignment and comparative analysis on throughput of divisional and rotating seru. Industrial Management & Data Systems, 2018
• 35. Lian, J., vd., A multi-skilled worker assignment problem in seru production systems considering the worker heterogeneity. 118: p. 366-382, 2018
• 36. Sun, W., vd., A cooperative coevolution algorithm for the seru production with minimizing makespan. IEEE Access. 7: p. 5662-5670, 2019
• 37. Sun, W., vd., Reducing the total tardiness by Seru production: model, exact and cooperative coevolution solutions. International Journal of Production Research: p. 1-12, 2019
• 38. Yılmaz, Ö.F., Operational strategies for seru production system: a bi-objective optimisation model and solution methods. International Journal of Production Research. 58(11): p. 3195-3219, 2020
• 39. Sarı, E.B., Seru Üretim Sistemi - Japon Hücresel Imalat Sistemi. 2020: Nobel Bilimsel Eserler. 92.
• 40. Tüzemen, A., Yeni bir üretim sistemi: Seru. Cumhuriyet Üniversitesi İktisadi ve İdari Bilimler Dergisi. 21(2): p. 334-351,
• 41. Williams, M., Back to the past: some plants tear out long assembly lines, switch to craft work. The Wall Street Journal, 1994
• 42. Yin, Y. The direction of Samsung style next generation production methods. in A Speech given at the Samsung Production Methods Innovation Forum, October. of Conference., Year
• 43. Cao, S., Production reform: Seru cases in Japan and China. Unpublished Master Thesis. Yamagata University, Japan, 2008
• 44. Yin, Y., vd., Improving productivity, flexibility, and efficiency using seru, a flexible manufacturing organization. Working paper, Yamagata University, 2011