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Functional Synthesis of Manufacturing Systems Using Co-Platforming to Minimize Cost of Machines and System Changes

[+] Author and Article Information
Mohamed Abbas

Intelligent Manufacturing Systems (IMS) center, Industrial and Manufacturing Systems Engineering, University of Windsor 401 Sunset Ave., Windsor, Ontario N9B 3P4, Canada
abbasl@uwindsor.ca

Hoda ElMaraghy

Intelligent Manufacturing Systems (IMS) center, Industrial and Manufacturing Systems Engineering, University of Windsor 401 Sunset Ave., Windsor, Ontario N9B 3P4, Canada
hae@uwindsor.ca

1Corresponding author.

ASME doi:10.1115/1.4038069 History: Received September 02, 2016; Revised September 11, 2017

Abstract

Manufacturers need to design manufacturing systems to cope with product variety and frequent changes in the product requirements. Switching from one product family to another in different production periods often requires reconfiguration of the manufacturing system with associated additional cost and financial burden. A mixed integer linear programming model is proposed in this paper to synthesize manufacturing systems based on the co-platforming methodology taking into consideration machine level changes including addition or removing machining axes and changing setup, and system level changes such as addition or removal of machines. The objective is to minimize the cost of change to transition between product families and production periods The proposed model is applied on a numerical example for verification and an industrial case study from Tier I automotive supplier. Finally, the effect of maintaining a common core of machines in the manufacturing system on the total investment cost is investigated. It has been demonstrated that synthesizing manufacturing systems using co-platforming strategy leads to a reduction in total investment cost including initial cost of machines and cost of reconfiguration compared to synthesizing manufacturing systems without system platform.

Copyright (c) 2017 by ASME
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