Developing an integrated model between QFD and AHP for assembly line : case study at an electronic company
The lean assembly line refers to a solution or a suggestion that is able to minimise cycle time for a daily basis working period. There is no specific method; it will take a look at the production lines from first till the end of line to observe where the problems are. Despite the broad efforts that...
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| Format: | Thesis |
| Language: | English |
| Published: |
2020
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| Online Access: | http://umpir.ump.edu.my/id/eprint/30321/ http://umpir.ump.edu.my/id/eprint/30321/1/Developing%20an%20integrated%20model%20between%20QFD%20and%20AHP%20for%20assembly%20line.wm.pdf |
| Summary: | The lean assembly line refers to a solution or a suggestion that is able to minimise cycle time for a daily basis working period. There is no specific method; it will take a look at the production lines from first till the end of line to observe where the problems are. Despite the broad efforts that have been made to make the lean production system more reasonable, however, the status of the current achievement of lean practices and lean continuous improvement strategies by Malaysian industry has not been analysed extensively. Thus, the objectives of the present research are to investigate which lean practices and lean continuous improvement strategies are important to the Malaysian manufacturing industry and how significant the difference between priority and current achievement. Moreover, the research was carried out to develop a lean hierarchical function deployment model for assembly line performance improvement and to propose lean assembly line model best practices for production operation system using simulation analysis. Survey and case study approaches were chosen in this research. In investigating the level achieved and factors of the lean practices (LP) and lean improvement strategies (LS), a set of questionnaire has been developed based on the parameters from the literature. The Lean Hierarchical Function Deployment (LHFD) model is based on Analytic Hierarchy Process (AHP) and Quality Function Deployment (QFD); where AHP was originally developed for making the decision making for the complex problem; while QFD was developed for the design of process and development. This LHFD methodology was focused and elaborated more on the extended AHP and QFD used for finding the relationship between lean assembly line and lean continuous improvement strategies. In this research, the survey data from 61 manufacturing firms in Malaysia were used to confirm the status of lean implementation among manufacturing firms and the significant relationship between all parameters in general. Meanwhile, a case study was performed in an electrical product assembly firm to reconfirm the lean assembly essential parameter using LHFD model. The findings showed that there are four main criteria can be categorised for lean practices which is shortening process time (SPT), man and machine use (MMU), inventory and storage control (ISC) and workspace optimisation (WO). Besides, method of improvement, improve workstation layout and production time saving tricks are three main lean continuous improvement strategies that most potential effect on the four categorised of above mentioned lean practices in the assembly line performance improvement. The modelling and simulation analysis found that different types of strategies had contributed different end result. The method of improvement requires specific knowledge and working experience in the workstation meanwhile, using about the time saving tricks need creativity of a line supervisor to alter or re-arrange the job specification and working time. To improve workstation layout, it focuses on the workspace reduction through minimising of work on progress product transportation time. These findings have significant implication, theoretically and practically for translating the strategy and policies on preparing the deployment approach as a sub activity in the LHFD model, especially to absorb any changes or uncertainty in productivity issues. The other researchers, industrial practitioners, government and local authority can refer the proposed framework to understand the diverse effects of the integration of lean practice and the strategies, as well as to identify the strength and weaknesses in setting the policies to achieve the basis of performance improvement implementation for lean assembly line. |
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