Efficacy of lean metrics in evaluating the performance of manufacturing system

This research objective is to develop a quantitative analysis framework and a simulation methodology to evaluate the efficacy of lean metrics in a production system. A re-configurable system is developed to improve the assembly line system's performance and an optimal design of the production line under the combination of product mix and production volume. The performance of the production line under different scenario is analyzed to identify an optimal combination of product mix to meet future customer demands. Flexibility is added to the existing line to become re-configurable. The simulation-modeling tool is used to evaluate alternative designs in a dynamic uncertain manufacturing environment. An optimal buffer size and production requirements are identified for the production line. The validation has been done in terms of throughput and cycle time to show the model providing significant improvement with real life application.;Lean metrics are integrated with computer simulation to facilitate rapid analysis of equipment and manufacturing system productivity, and the investigation of productivity improvement opportunities. The results of this research make possible the representation effectiveness of these metrics and the use of lean metrics for quantitative benchmarking and comparison of the productivity of various factories. A real-world manufacturing case study is reported to demonstrate how to employ these techniques to improve manufacturing productivity. (Abstract shortened by UMI.)...