Evaluating the Ranking of Performance Variables in Flexible Manufacturing System through the Best-Worst Method
Abstract
:1. Introduction
2. Review of Literature
2.1. Literature Review on FMS Performance, Accompanied by a Bibliometric Overview
2.2. Review of Multi-Criteria-Decision-Making (MCDM) Approaches
2.3. Gap Analysis
- Lack of Consistent Labeling: While numerous researchers have defined the weights of performance variables in various studies pertaining to Flexible Manufacturing Systems (FMSs), only a few have classified them into dimensions based on “Quality (Q)”, “Productivity (P)”, and “Flexibility (F)”, which would encompass the manufacturing system and technological methods [30]. This research introduces a novel classification system based on these dimensions, conveying a structured framework to assess FMS performance.
- Limited Deployment of a Novel MCDM Approach: Although FMS performance variables have been considered in studies using various approaches, such as ISM, SEM, Exploratory Factor Analysis (EFA), Confirmatory Factor Analysis (CFA), and others, no single study has employed a novel Multi-Criteria Decision Making (MCDM) approach comparable to BWM for assessing the significance (weight) of these variables. BWM offers enhanced consistency, minimal violation, total deviation, and conformity.
- Inclusion of More Variables [14]: This research has incorporated 34 key performance variables and three factors extracted from the manufacturing industry, encompassing a larger number of variables compared to other studies, indicating a more comprehensive approach.
- Empirical Validation: There is a need for more empirical studies that validate the findings from conceptual frameworks and propose practical solutions for enhancing FMS performance [2]. This study bridges this gap by presenting a comprehensive empirical analysis based on a broad literature review, consultations with industry experts, and the BWM approach.
- Exploring Technological Advancements: Additionally, there is limited research on the implication of technological advancements, such as Industry 4.0, on FMS performance, indicating a potential research gap in this area [4,30]. This study acknowledges this gap and, through the BWM methodology, explores the implications of these advancements on FMS performance.
- Scarcity of Case Studies in Europe and the USA Context: There is a lack of case studies on FMS implementation not only in India [37] but also in German manufacturing firms, which hinders a precise understanding of the outcomes and implications of performance variables in the German context. This research draws attention to this gap and, by providing a case study, offers valuable insights into FMS performance in distinct geographical contexts.
2.4. Contributions of the Study
3. Research Methodology
3.1. Overview of BWM Approach
3.1.1. Phases of the BWM Process
- Phase 1: Determine the performance variables of the FMS.
- Phase 2: Determining the Best and Worst FMS Components.
- Phase 3: Expert Panels’ Pairwise Comparison.
- Phase 4: Expert Panels’ Pairwise Comparison of the Worst Parameter.
- Phase 5: Estimation of Weights for the Optimal FMS Components.
- Minimizing Maximum Discrepancies: The core objective is to minimize the maximum absolute discrepancy between two expressions for each variable ‘j’. The first expression is |WB/Wj − aBj|, which measures the extent to which the assigned weight WB deviates from the normalized weight aBj. The second expression is |Wj/Ww − ajW|, assessing the extent to which Wj differs from the variable’s weight relative to the normalized.
- Balancing Variables: The linear programming framework aims to balance these variables and minimize their discrepancies. The objective is to find an optimal solution where the differences between the assigned weights (Wj) and the benchmark-based weights (aBj and ajW) are as small as possible.
- Accounting for Constraints: The framework considers specific constraints to ensure a feasible solution. These constraints include:
- ∘
- Non-negativity constraints: ensuring that all weights (Wj) are non-negative (Wj ≥ 0 for every ‘j’).
- ∘
- Weight sum condition: maintaining the sum of all weights equal to 1, indicating that the weights encompass all evaluated components (∑j Wj = 1).
3.1.2. Consistency Ratio and Interpretation
3.2. Case Explanation
3.2.1. Introduction to the Subject Company
3.2.2. Motivation for BWM Implementation
3.3. Analysis of Weight Ranking
3.3.1. The Expert Panel
3.3.2. Calculating Average Weights
3.3.3. Ensuring Consistency
3.3.4. Determining Global Weights
3.3.5. Final Ranking of FMS Performance Variables
- Quality (Q): This factor carries a weight of 0.5544, indicating its paramount role in the FMS performance assessment.
- Productivity (P): With a weight of 0.1715, productivity is a notable, although secondary, factor in the assessment.
- Flexibility (F): Flexibility is assigned a weight of 0.2208, signifying its essential yet less influential role in the assessment process.
3.4. Findings and Discussion
4. The Implications of this Study
- Strategic Prioritization: Manufacturing professionals can employ the insights to strategically prioritize FMS elements. By recognizing the essential role of quality, they can focus on enhancing quality management practices and minimizing rejection rates.
- Operational Improvements: The findings on productivity and automation suggest opportunities for operational enhancement. Implementing automation and optimizing cycle times could lead to cost reductions and increased efficiency.
- Flexibility Enhancements: Manufacturing experts can leverage the interpretation of flexibility dynamics to boost their production agility in real time. Strategies such as routing flexibility and redundancy can improve overall efficiency and responsiveness in the context of Industry 4.0.
- Research and Innovation: Researchers in the field could build on this study’s findings to explore related topics further. Future research might delve into specific strategies for implementing prioritized factors in real manufacturing settings.
4.1. Theoretical Contributions
4.2. Practical Implications
5. Discussion and Conclusions
6. Limitations and Future Research
Author Contributions
Funding
Data Availability Statement
Conflicts of Interest
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No | Author | Publication | Methodology | Performance Variable |
---|---|---|---|---|
1 | [2] | 2011 | Simulation modelling, Fuzzy logic |
|
2 | [4] | 2018 | Exploratory Factor Analysis (EFA), Confirmatory Factor Analysis (CFA), Absolute Fit Indices, Incremental Fit Indices |
|
3 | [6] | 2014 | ISM, SEM, GTMA |
|
4 | [25] | 2016 | Effectiveness Index, ISM |
|
5 | [19] | 2018 | Interpretive Structural Modelling (ISM), Structural Equation Modelling (SEM), Graph Theory, Matrix Approach (GTMA) |
|
6 | [26] | 2016 | Total Interpretive Structural Modelling (TISM) |
|
7 | [21] | 1991 | Identification of flexibilities, Fishbone diagram |
|
8 | [27] | 2018 | MOORA Approach, Ratio System Approach |
|
9 | [19] | 2018 | MOORA Approach, Ratio System Approach |
|
10 | [28] | 2019 | TISM, Fuzzy logic |
|
11 | [29] | 2012 | COPRAS approach |
|
1. | Introduction of an innovative approach based on BWM for evaluating FMS performance. |
2. | Incorporation of insights gained from an extensive literature review and consultation with industry professionals. |
3. | Comprehensive overview and analysis of 272 scientific publications. |
4. | Identification of research gaps in the literature. |
5. | Development of a novel classification for FMS performance variables based on “(Q)”, “(P)”, and “(F)” dimensions. |
6. | Enhancement of consistency, minimal violation, total deviation, and conformity compared to other existing approaches such as AHP. |
7. | Identification of the need for further empirical studies. |
8. | Highlighting the limited research on the implications of technological advancements, such as Industry 4.0, on FMS performance. |
9. | Integration with other smart production system components. |
10. | Consideration of sustainability. |
11. | Generalizability to other industries. |
Expert | Designation | Education | Exp. (in Years) |
---|---|---|---|
Expert 1 | Academician | Ph.D. Supply Chain Management | 13 |
Expert 2 | Production Manager | M. Tech Production Engineering | 9 |
Expert 3 | Production Manager | M. Tech Industrial Engineering | 13 |
Expert 4 | Manufacturing Manager | B. E. Mechanical | 9 |
Expert 5 | Plant Manager | M. Industrial Management | 14 |
Expert 6 | Operations Manager | M. Tech Mechanical | 13 |
Expert 7 | Operation Management | Ph.D. Operational Management | 4 |
Expert 8 | Manufacturing Manager | Ph.D. Operational Management | 10 |
Expert 9 | Production Engineer | M. Industrial Management | 7 |
Expert 10 | Quality Engineer | M. Industrial Management | 8 |
Expert 11 | Production Management | M. Operational Management | 10 |
Expert 12 | Operation Management | Ph.D. Operational Management | 9 |
Expert 13 | Manufacturing Manager | Ph.D. Operational Management | 13 |
Major Factor | Sub-Factor | References |
---|---|---|
Quality (Q) | Defect rate (Q1) | [37] |
Automation (Q2) * | [37,38] | |
Scrap rate (Q3) | [4,38,39] | |
Process capability (Q4) | [37,40,41] | |
Conformance to specification (Q5) | [42] | |
Effect of tool life (Q6) | [43] | |
Rework percentage (Q7) | [4,43] | |
First-pass yield (FPY) (Q8) | [44] | |
Customer satisfaction (Q9) | [26,45] | |
Rejection percentage (Q10) | [4,46] | |
Takt time (Q11) | [47] | |
Productivity (P) | Machine utilization (P1) | [48] |
Unit labor cost (P2) | [4,49,50] | |
Unit manufacturing cost (P3) | [4,43] | |
Production rate (P4) | [45] | |
Manufacturing lead time (P5) | [43,51] | |
Work-in-progress (WIP) inventory (P6) | [4] | |
Setup time (P7) | [45,48] | |
OEE (Overall Equipment Effectiveness) (P8) | [52,53] | |
Throughput time (P9) | [4,43] | |
Labor productivity (P10) | [54] | |
Setup cost (P11) | [4,48] | |
Cycle time (P12) | [55] | |
Flexibility (F) | Changeover time (F1) | [56] |
Equipment utilization (F2) | [4,57] | |
Volume flexibility (F3) | [28] | |
Routing flexibility (F4) | [48] | |
Product mix (F5) | [4] | |
Use of automated material handling device (F6) | [25,58] | |
Reduced work in process inventory (F7) | [4,43] | |
Redundancy (F8) | [58] | |
Use of reconfigurable machine tool (F9) | [38] | |
Flexible fixturing (F10) | [59,60,61] | |
Machine reconfiguration time (F11) | [53] |
Expert | Best | Q | P | F |
---|---|---|---|---|
Expert 1 | Q | 1 | 3 | 5 |
Expert 2 | Q | 1 | 8 | 6 |
Expert 3 | P | 2 | 1 | 3 |
Expert 4 | Q | 1 | 8 | 7 |
Expert 5 | Q | 1 | 2 | 3 |
Expert 6 | Q | 1 | 3 | 2 |
Expert 7 | F | 7 | 8 | 1 |
Expert 8 | F | 4 | 3 | 1 |
Expert 9 | Q | 1 | 6 | 4 |
Expert 10 | P | 2 | 1 | 7 |
Expert 11 | Q | 1 | 4 | 7 |
Expert 12 | Q | 1 | 4 | 7 |
Expert 13 | Q | 1 | 7 | 6 |
Expert | Worst | Q | P | F |
---|---|---|---|---|
Expert 1 | P | 8 | 1 | 4 |
Expert 2 | F | 4 | 6 | 1 |
Expert 3 | F | 8 | 9 | 1 |
Expert 4 | P | 9 | 1 | 7 |
Expert 5 | F | 8 | 7 | 1 |
Expert 6 | F | 3 | 5 | 1 |
Expert 7 | P | 3 | 1 | 2 |
Expert 8 | P | 5 | 1 | 6 |
Expert 9 | F | 2 | 4 | 1 |
Expert 10 | Q | 1 | 3 | 4 |
Expert 11 | F | 7 | 4 | 1 |
Expert 12 | F | 7 | 4 | 1 |
Expert 13 | P | 9 | 1 | 6 |
Expert | Q | P | F | Ksi* |
---|---|---|---|---|
Expert 1 | 0.6790 | 0.1234 | 0.1975 | 0.3086 |
Expert 2 | 0.7636 | 0.1454 | 0.0909 | 0.4000 |
Expert 3 | 0.3958 | 0.5208 | 0.0833 | 0.2708 |
Expert 4 | 0.8000 | 0.0555 | 0.1444 | 0.3555 |
Expert 5 | 0.5750 | 0.3000 | 0.1250 | 0.3250 |
Expert 6 | 0.5278 | 0.3611 | 0.1111 | 0.1944 |
Expert 7 | 0.6786 | 0.1786 | 0.1429 | 0.3929 |
Expert 8 | 0.1667 | 0.6852 | 0.1481 | 0.3519 |
Expert 9 | 0.7083 | 0.2083 | 0.0833 | 0.1250 |
Expert 10 | 0.1750 | 0.1000 | 0.7250 | 0.3250 |
Expert 11 | 0.7589 | 0.0714 | 0.1696 | 0.2589 |
Expert 12 | 0.6607 | 0.2143 | 0.1250 | 0.4107 |
Expert 13 | 0.7083 | 0.2083 | 0.0833 | 0.1250 |
Final weight | 0.5844 | 0.2240 | 0.1715 | 0.2956 |
Major Factor | Major Weight | Sub-Factor Element | Local Weighting | Global Weighting | Ultimate Rank |
---|---|---|---|---|---|
Quality (Q) | 0.5544 | Q1 | 0.0942 | 0.0522 | 4 |
Q2 | 0.0969 | 0.0537 | 3 | ||
Q3 | 0.0815 | 0.0452 | 10 | ||
Q4 | 0.0724 | 0.0401 | 11 | ||
Q5 | 0.0933 | 0.0517 | 5 | ||
Q6 | 0.0889 | 0.0493 | 7 | ||
Q7 | 0.0933 | 0.0517 | 5 | ||
Q8 | 0.0981 | 0.0544 | 2 | ||
Q9 | 0.0863 | 0.0478 | 8 | ||
Q10 | 0.1093 | 0.0606 | 1 | ||
Q11 | 0.0858 | 0.0476 | 9 | ||
Productivity (P) | 0.2240 | P1 | 0.0792 | 0.0177 | 20 |
P2 | 0.0902 | 0.0202 | 15 | ||
P3 | 0.0844 | 0.0189 | 18 | ||
P4 | 0.0889 | 0.0199 | 16 | ||
P5 | 0.0728 | 0.0163 | 27 | ||
P6 | 0.0658 | 0.0147 | 31 | ||
P7 | 0.0959 | 0.0215 | 12 | ||
P8 | 0.0764 | 0.0171 | 22 | ||
P9 | 0.0922 | 0.0207 | 14 | ||
P10 | 0.0759 | 0.0170 | 24 | ||
P11 | 0.0857 | 0.0192 | 17 | ||
P12 | 0.0926 | 0.0207 | 13 | ||
Flexibility (F) | 0.1715 | F1 | 0.0790 | 0.0135 | 32 |
F2 | 0.0912 | 0.0156 | 29 | ||
F3 | 0.0975 | 0.0167 | 25 | ||
F4 | 0.1069 | 0.0183 | 19 | ||
F5 | 0.0892 | 0.0153 | 30 | ||
F6 | 0.0924 | 0.0158 | 28 | ||
F7 | 0.0750 | 0.0129 | 33 | ||
F8 | 0.1005 | 0.0172 | 21 | ||
F9 | 0.0958 | 0.0164 | 26 | ||
F10 | 0.0733 | 0.0126 | 34 | ||
F11 | 0.0992 | 0.0170 | 23 |
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Bagherian, A.; Chauhan, G.; Srivastav, A.L.; Kumar Sharma, R. Evaluating the Ranking of Performance Variables in Flexible Manufacturing System through the Best-Worst Method. Designs 2024, 8, 12. https://doi.org/10.3390/designs8010012
Bagherian A, Chauhan G, Srivastav AL, Kumar Sharma R. Evaluating the Ranking of Performance Variables in Flexible Manufacturing System through the Best-Worst Method. Designs. 2024; 8(1):12. https://doi.org/10.3390/designs8010012
Chicago/Turabian StyleBagherian, Anthony, Gulshan Chauhan, Arun Lal Srivastav, and Rajiv Kumar Sharma. 2024. "Evaluating the Ranking of Performance Variables in Flexible Manufacturing System through the Best-Worst Method" Designs 8, no. 1: 12. https://doi.org/10.3390/designs8010012
APA StyleBagherian, A., Chauhan, G., Srivastav, A. L., & Kumar Sharma, R. (2024). Evaluating the Ranking of Performance Variables in Flexible Manufacturing System through the Best-Worst Method. Designs, 8(1), 12. https://doi.org/10.3390/designs8010012