Using the Collective System Design Approach to Facilitate a Sustainable Manufacturing System
Abstract
Reviewing the literature verifies that manufacturing industries fall short of the required sustainable criteria in the system design. One of the leading reasons behind such a failure refers to the lack of an effective system design knowledge toward the selected solutions by benchmarking. 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. 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. 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. The segregation of the tools and objectives of the system re-design in a path-dependent fashion is guided by the design principles. 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. This collaboration was built up by defining the customer-supplier connection inside the plant. 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. The after system redesign MSDD questionnaire analysis at these industries have shown that the industries successfully satisfied their system needs in a sustainable manner. 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. As the original MSDD lacked the requirements and solutions for the safety component, an updated version of the MSDD has been proposed to incorporate the safety branch to the MSDD. 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.
Degree
M.Sc.
Advisors
Cochran, Purdue University.
Subject Area
Design|Industrial engineering|Sustainability|Transportation
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