Research Article
BibTex RIS Cite

Kitting-Based Design of the In-plant Logistics Processes

Year 2018, Volume: 23 Issue: 4, 83 - 98, 31.12.2018
https://doi.org/10.17482/uumfd.456038

Abstract

Lean logistics aims
elimination of the non-value adding material handling and storage processes
both within the plants and among the supplier and customer companies, based on
lean thinking. In this context, the required parts must be delivered
effectively and systematically to the assembly stations, as much as required
and just-in time. However, due to the increase in the uncommon parts variety,
and erratic product demands, some new approaches of parts distribution to the
assembly lines is strongly required. Kitting or kit-delivery is one of these
new approaches. In this study, it is aimed to develop a parts delivery
methodology based on kitting and hence to plan and manage in-plant parts
distribution processes, effectively. In addition, based on a real case study,
the proposed methodology is explained. The unique aspect of this study is that
an integrated methodology that considers all stages of parts delivery based on
kitting is proposed, and the developed methodology can be applied to many
industrial sectors. 

References

  • Baudin, M. (2005) Lean logistics: the nuts and bolts of delivering materials and goods, CRC Press.
  • Bedworth, D. D., Bailey, J. (1987). Integrated production control systems, analysis, design. John Wiley & Sons, 370–374.
  • Boudella, M. E. A., Sahin, E., Dallery, Y. (2018). Kitting optimisation in Just-in-Time mixed-model assembly lines: assigning parts to pickrs in a hybrid robot–operator kitting system, International Journal of Production Research, 56(16), 5475-5494. doi:10.1080/00207543.2017.1418988
  • Boysen, N., Emde, S., Hoeck, M., Kauderer, M. (2015) Part logistics in the automotive industry: Decision problems, literature review and research agenda, European Journal of Operational Research, 242(1), 107-120. doi:10.1016/j.ejor.2014.09.065
  • Bozer, Y. A., McGinnis, L.F. (1992) Kitting versus line stocking: A conceptual framework and a descriptive model, International Journal of Production Economics, 28, 1-19. doi:10.1016/0925-5273(92)90109-K
  • Caputo, A.C., Pelagagge, P.M., Salini, P. (2016) Selection of assembly lines feeding policies based on parts features, IFAC-PapersOnLine, 49(12), 185-190. doi:10.1016/j.ifacol.2016.07.593
  • Caputo, A. C., Pelagagge, P. M., Salini, P. (2018) Selection of assembly lines feeding policies based on parts features and scenario conditions, International Journal of Production Research, 56(3), 1208-1232. doi:10.1080/00207543.2017.1407882.
  • Carlson, J.G., Yao, A.C., Girouard, W.F. (1994) The role of master kits in assembly operations, International Journal of Production Economics, 35, 253-258. doi:10.1016/0925-5273(94)90089-2
  • Carlson, O., Hensvold, B, (2008) Kitting in a high variation assembly line. A case study at Caterpillar BCP-E, Master Thesis. Lulea University of Technology.
  • Choobineh, F., Mohebbi, E. (2004) Material planning for production kits under uncertainty, Production Planning and Control, 13(1), 63-70. doi:10.1080/09537280310001659164
  • Çorakçı, M.A. (2008) An evaluation of kitting systems in lean production. Yüksek Lisans Tezi, University of Boras, School of Engineering, Boras.
  • Faccio, M. (2014) The impact of production mix variations and models varieties on the parts-feeding policy selection in a JIT assembly system, International Journal of Advanced Manufacturing Technology, 72, 543-560. doi:10.1007/s00170-014-5675-0
  • Gecü, B. (2008), İç lojistik sistemlerinin yalın üretim bakış açısıyla yeniden tasarlanması ve otomotiv sektöründe örnek bir uygulama, Istanbul Teknik Üniversitesi, Yüksek Lisans Tezi.
  • Günther, H.O., Gronalt, M., and Piller, F. (1996) Component kitting in semi-automated printed circuit board assembly, International Journal of Production Economics, 43, 213-226. doi:10.1016/0925-5273(96)00044-8
  • Hanson, R., Brolin, A. (2013) A comparison of kitting and continuous supply in in-plant materials supply, International Journal of Production Research, 51(4), 979-992. doi:10.1080/00207543.2012.657806.
  • Hua, S.Y., Johnson, D. (2010) Research issues on factors influencing the choice of kitting versus line stocking, International Journal of Production Research, 48(3), 779-800. doi:10.1080/00207540802456802
  • Hua, W., Zhou, C. (2008) Clusters and filling-curve-based storage assignment in a circuit board assembly kitting area, IIE Transactions, 40(6), 569-585. doi:10.1080/07408170701503462
  • Karadayı, S., Öksuz, M.K., Durmuşoğlu, M.B. (2017) Design methodology for a hybrid part feeding system in lean-based assembly lines, Assembly Automation, 37(1), 84-102. doi:10.1108/AA-09-2016-114
  • Kılıç, H.S., Durmuşoğlu, M.B. (2012) Design of kitting system in lean‐based assembly lines, Assembly Automation, 32(3), 226-234. doi:10.1108/01445151211244357
  • Limère, V., Van Landeghem, H., Goetschalckx, M. (2015) A decision model for kitting and line stocking with variable operator walking distances, Assembly Automation, 35(1), 47-56. doi:10.1108/AA-05-2014-043
  • Loveland, L.J., Monkman, S.K., and Morrice, D.J. (2007) Dell uses a new production-scheduling algorithm to accommodate increased product variety, Interfaces, 37(3), 209-219. doi:10.1287/inte.1060.0264
  • Medbo, L. (2003) Assembly work execution and materials kit functionality in parallel flow assembly systems, International Journal of Industrial Ergonomics, 31, 263-281. doi:10.1016/S0169-8141(02)00220-2
  • Ramachandran, S., Delen, D. (2005) Performance analysis of a kitting process in stochastic assembly systems, Computers & Operations Research, 32(4), 449-463. doi:10.1016/S0169-8141(02)00220-2
  • Ramakrishnan, R., Krishnamurthy, A., (2008) Analytical approximations for kitting systems with multiple inputs, Asia-Pacific Journal of Operations Research, 25(2), 187-216. doi:10.1142/S0217595908001742
  • Sali, M., Şahin, E., Patchong, A. (2015) An empirical assessment of the performances of three line feeding modes used in the automotive sector: line stocking vs. kitting vs. sequencing, International Journal of Production Research, 53(5), 1439-1459. doi:10.1080/00207543.2014.944630
  • Satoğlu, Ş. I., Şahin, I. E. (2013) Design of a just-in-time periodic material supply system for the assembly lines and an application in electronics industry, International Journal of Advanced Manufacturing Technology, 65(1-4), 319-332. doi:10.1007/s00170-012-4171-7
  • Satoğlu, Ş. I., Uçan, K. (2015, Mart). Redesigning the material supply system of the automotive suppliers based on lean principles and an application. In Industrial Engineering and Operations Management (IEOM), 2015, International Conference on (1-6). IEEE. doi:10.1109/IEOM.2015.7093860
  • Sellers, C.J., Nof, Y., (1989) Performance analysis of robotic kitting systems, Robotics and Computer-Integrated Manufacturing, 6(1),15-24. doi:10.1016/0736-5845(89)90081-1
  • Sol, E. (2010), Set Şeklinde Teslimat İle Hat Kenarı Besleme Sisteminin Karşılaştırılması, Yalın Lojistik Bakış Açısıyla İç Lojistik Faaliyetlerin Tasarlanması Ve Örnek Bir Uygulama, Istanbul Teknik Üniversitesi, Yüksek Lisans Tezi.

FABRİKA İÇİ LOJİSTİK SÜREÇLERİNİN SET YAPMA ESASLI TASARIMI VE BİR UYGULAMA

Year 2018, Volume: 23 Issue: 4, 83 - 98, 31.12.2018
https://doi.org/10.17482/uumfd.456038

Abstract

Yalın lojistik, yalın düşünce çerçevesinde, gerek fabrika
içi, gerekse müşteri-tedarikçi firmalar arası katma değeri olmayan malzeme
taşıma ve depolama süreçlerinin ortadan kaldırılmasını amaçlar. Bu kapsamda, üretim
içinde montaj istasyonlarına gerekli olan parçaların ihtiyaç duyulan miktarda,
tam zamanında, sistematik ve etkin bir biçimde beslenmesi gerekmektedir. Ancak
ürünlerin farklı modellerinde ortak olmayan parça çeşitliliğinin artması, ürün
taleplerinin değişken hale gelmesi gibi nedenlerle montaj hatlarına malzeme
besleme konusunda yenilikçi yaklaşımlar izlenmesine ihtiyaç duyulmuştur. Set
halinde teslimat bu tür yenilikçi bir fabrika içi malzeme besleme yaklaşımıdır.
Bu çalışmada, montaj hatlarına set yapma esaslı malzeme beslemeye yönelik bir
metodoloji geliştirilmesi ve böylece fabrika içi lojistik süreçlerinin etkin
bir şekilde planlanmasını ve yönetilmesini sağlamak amaçlanmıştır. Ayrıca
gerçek bir uygulama örneği ile önerilen metodoloji açıklanmıştır. Makalenin
özgün yönü, set yapma temelli malzeme beslemeye yönelik tüm aşamaları içeren,
bütünsel bir yaklaşım geliştirilmesi ve metodolojinin birçok endüstri dalında
uygulanabilecek nitelikte olmasıdır. 

References

  • Baudin, M. (2005) Lean logistics: the nuts and bolts of delivering materials and goods, CRC Press.
  • Bedworth, D. D., Bailey, J. (1987). Integrated production control systems, analysis, design. John Wiley & Sons, 370–374.
  • Boudella, M. E. A., Sahin, E., Dallery, Y. (2018). Kitting optimisation in Just-in-Time mixed-model assembly lines: assigning parts to pickrs in a hybrid robot–operator kitting system, International Journal of Production Research, 56(16), 5475-5494. doi:10.1080/00207543.2017.1418988
  • Boysen, N., Emde, S., Hoeck, M., Kauderer, M. (2015) Part logistics in the automotive industry: Decision problems, literature review and research agenda, European Journal of Operational Research, 242(1), 107-120. doi:10.1016/j.ejor.2014.09.065
  • Bozer, Y. A., McGinnis, L.F. (1992) Kitting versus line stocking: A conceptual framework and a descriptive model, International Journal of Production Economics, 28, 1-19. doi:10.1016/0925-5273(92)90109-K
  • Caputo, A.C., Pelagagge, P.M., Salini, P. (2016) Selection of assembly lines feeding policies based on parts features, IFAC-PapersOnLine, 49(12), 185-190. doi:10.1016/j.ifacol.2016.07.593
  • Caputo, A. C., Pelagagge, P. M., Salini, P. (2018) Selection of assembly lines feeding policies based on parts features and scenario conditions, International Journal of Production Research, 56(3), 1208-1232. doi:10.1080/00207543.2017.1407882.
  • Carlson, J.G., Yao, A.C., Girouard, W.F. (1994) The role of master kits in assembly operations, International Journal of Production Economics, 35, 253-258. doi:10.1016/0925-5273(94)90089-2
  • Carlson, O., Hensvold, B, (2008) Kitting in a high variation assembly line. A case study at Caterpillar BCP-E, Master Thesis. Lulea University of Technology.
  • Choobineh, F., Mohebbi, E. (2004) Material planning for production kits under uncertainty, Production Planning and Control, 13(1), 63-70. doi:10.1080/09537280310001659164
  • Çorakçı, M.A. (2008) An evaluation of kitting systems in lean production. Yüksek Lisans Tezi, University of Boras, School of Engineering, Boras.
  • Faccio, M. (2014) The impact of production mix variations and models varieties on the parts-feeding policy selection in a JIT assembly system, International Journal of Advanced Manufacturing Technology, 72, 543-560. doi:10.1007/s00170-014-5675-0
  • Gecü, B. (2008), İç lojistik sistemlerinin yalın üretim bakış açısıyla yeniden tasarlanması ve otomotiv sektöründe örnek bir uygulama, Istanbul Teknik Üniversitesi, Yüksek Lisans Tezi.
  • Günther, H.O., Gronalt, M., and Piller, F. (1996) Component kitting in semi-automated printed circuit board assembly, International Journal of Production Economics, 43, 213-226. doi:10.1016/0925-5273(96)00044-8
  • Hanson, R., Brolin, A. (2013) A comparison of kitting and continuous supply in in-plant materials supply, International Journal of Production Research, 51(4), 979-992. doi:10.1080/00207543.2012.657806.
  • Hua, S.Y., Johnson, D. (2010) Research issues on factors influencing the choice of kitting versus line stocking, International Journal of Production Research, 48(3), 779-800. doi:10.1080/00207540802456802
  • Hua, W., Zhou, C. (2008) Clusters and filling-curve-based storage assignment in a circuit board assembly kitting area, IIE Transactions, 40(6), 569-585. doi:10.1080/07408170701503462
  • Karadayı, S., Öksuz, M.K., Durmuşoğlu, M.B. (2017) Design methodology for a hybrid part feeding system in lean-based assembly lines, Assembly Automation, 37(1), 84-102. doi:10.1108/AA-09-2016-114
  • Kılıç, H.S., Durmuşoğlu, M.B. (2012) Design of kitting system in lean‐based assembly lines, Assembly Automation, 32(3), 226-234. doi:10.1108/01445151211244357
  • Limère, V., Van Landeghem, H., Goetschalckx, M. (2015) A decision model for kitting and line stocking with variable operator walking distances, Assembly Automation, 35(1), 47-56. doi:10.1108/AA-05-2014-043
  • Loveland, L.J., Monkman, S.K., and Morrice, D.J. (2007) Dell uses a new production-scheduling algorithm to accommodate increased product variety, Interfaces, 37(3), 209-219. doi:10.1287/inte.1060.0264
  • Medbo, L. (2003) Assembly work execution and materials kit functionality in parallel flow assembly systems, International Journal of Industrial Ergonomics, 31, 263-281. doi:10.1016/S0169-8141(02)00220-2
  • Ramachandran, S., Delen, D. (2005) Performance analysis of a kitting process in stochastic assembly systems, Computers & Operations Research, 32(4), 449-463. doi:10.1016/S0169-8141(02)00220-2
  • Ramakrishnan, R., Krishnamurthy, A., (2008) Analytical approximations for kitting systems with multiple inputs, Asia-Pacific Journal of Operations Research, 25(2), 187-216. doi:10.1142/S0217595908001742
  • Sali, M., Şahin, E., Patchong, A. (2015) An empirical assessment of the performances of three line feeding modes used in the automotive sector: line stocking vs. kitting vs. sequencing, International Journal of Production Research, 53(5), 1439-1459. doi:10.1080/00207543.2014.944630
  • Satoğlu, Ş. I., Şahin, I. E. (2013) Design of a just-in-time periodic material supply system for the assembly lines and an application in electronics industry, International Journal of Advanced Manufacturing Technology, 65(1-4), 319-332. doi:10.1007/s00170-012-4171-7
  • Satoğlu, Ş. I., Uçan, K. (2015, Mart). Redesigning the material supply system of the automotive suppliers based on lean principles and an application. In Industrial Engineering and Operations Management (IEOM), 2015, International Conference on (1-6). IEEE. doi:10.1109/IEOM.2015.7093860
  • Sellers, C.J., Nof, Y., (1989) Performance analysis of robotic kitting systems, Robotics and Computer-Integrated Manufacturing, 6(1),15-24. doi:10.1016/0736-5845(89)90081-1
  • Sol, E. (2010), Set Şeklinde Teslimat İle Hat Kenarı Besleme Sisteminin Karşılaştırılması, Yalın Lojistik Bakış Açısıyla İç Lojistik Faaliyetlerin Tasarlanması Ve Örnek Bir Uygulama, Istanbul Teknik Üniversitesi, Yüksek Lisans Tezi.
There are 29 citations in total.

Details

Primary Language Turkish
Subjects Engineering
Journal Section Research Articles
Authors

Mehmet Bülent Durmuşoğlu

Eda Sol This is me

Emre Çevikcan

Şule İtır Satoğlu

Publication Date December 31, 2018
Submission Date August 30, 2018
Acceptance Date December 10, 2018
Published in Issue Year 2018 Volume: 23 Issue: 4

Cite

APA Durmuşoğlu, M. B., Sol, E., Çevikcan, E., Satoğlu, Ş. İ. (2018). FABRİKA İÇİ LOJİSTİK SÜREÇLERİNİN SET YAPMA ESASLI TASARIMI VE BİR UYGULAMA. Uludağ Üniversitesi Mühendislik Fakültesi Dergisi, 23(4), 83-98. https://doi.org/10.17482/uumfd.456038
AMA Durmuşoğlu MB, Sol E, Çevikcan E, Satoğlu Şİ. FABRİKA İÇİ LOJİSTİK SÜREÇLERİNİN SET YAPMA ESASLI TASARIMI VE BİR UYGULAMA. UUJFE. December 2018;23(4):83-98. doi:10.17482/uumfd.456038
Chicago Durmuşoğlu, Mehmet Bülent, Eda Sol, Emre Çevikcan, and Şule İtır Satoğlu. “FABRİKA İÇİ LOJİSTİK SÜREÇLERİNİN SET YAPMA ESASLI TASARIMI VE BİR UYGULAMA”. Uludağ Üniversitesi Mühendislik Fakültesi Dergisi 23, no. 4 (December 2018): 83-98. https://doi.org/10.17482/uumfd.456038.
EndNote Durmuşoğlu MB, Sol E, Çevikcan E, Satoğlu Şİ (December 1, 2018) FABRİKA İÇİ LOJİSTİK SÜREÇLERİNİN SET YAPMA ESASLI TASARIMI VE BİR UYGULAMA. Uludağ Üniversitesi Mühendislik Fakültesi Dergisi 23 4 83–98.
IEEE M. B. Durmuşoğlu, E. Sol, E. Çevikcan, and Ş. İ. Satoğlu, “FABRİKA İÇİ LOJİSTİK SÜREÇLERİNİN SET YAPMA ESASLI TASARIMI VE BİR UYGULAMA”, UUJFE, vol. 23, no. 4, pp. 83–98, 2018, doi: 10.17482/uumfd.456038.
ISNAD Durmuşoğlu, Mehmet Bülent et al. “FABRİKA İÇİ LOJİSTİK SÜREÇLERİNİN SET YAPMA ESASLI TASARIMI VE BİR UYGULAMA”. Uludağ Üniversitesi Mühendislik Fakültesi Dergisi 23/4 (December 2018), 83-98. https://doi.org/10.17482/uumfd.456038.
JAMA Durmuşoğlu MB, Sol E, Çevikcan E, Satoğlu Şİ. FABRİKA İÇİ LOJİSTİK SÜREÇLERİNİN SET YAPMA ESASLI TASARIMI VE BİR UYGULAMA. UUJFE. 2018;23:83–98.
MLA Durmuşoğlu, Mehmet Bülent et al. “FABRİKA İÇİ LOJİSTİK SÜREÇLERİNİN SET YAPMA ESASLI TASARIMI VE BİR UYGULAMA”. Uludağ Üniversitesi Mühendislik Fakültesi Dergisi, vol. 23, no. 4, 2018, pp. 83-98, doi:10.17482/uumfd.456038.
Vancouver Durmuşoğlu MB, Sol E, Çevikcan E, Satoğlu Şİ. FABRİKA İÇİ LOJİSTİK SÜREÇLERİNİN SET YAPMA ESASLI TASARIMI VE BİR UYGULAMA. UUJFE. 2018;23(4):83-98.

Announcements:

30.03.2021-Beginning with our April 2021 (26/1) issue, in accordance with the new criteria of TR-Dizin, the Declaration of Conflict of Interest and the Declaration of Author Contribution forms fulfilled and signed by all authors are required as well as the Copyright form during the initial submission of the manuscript. Furthermore two new sections, i.e. ‘Conflict of Interest’ and ‘Author Contribution’, should be added to the manuscript. Links of those forms that should be submitted with the initial manuscript can be found in our 'Author Guidelines' and 'Submission Procedure' pages. The manuscript template is also updated. For articles reviewed and accepted for publication in our 2021 and ongoing issues and for articles currently under review process, those forms should also be fulfilled, signed and uploaded to the system by authors.