Ürün çeşitliliğinin tasarım, tedarik ve üretim süreçlerine etkisinin sistem dinamiği yaklaşımı ile incelenmesi

Yıl 2021, , 1185 - 1198, 24.05.2021

Zafer Doğruyol Samet Güner

https://doi.org/10.17341/gazimmfd.731788

Öz

Otomotiv üreticileri, pazarda rekabetçi kalabilmek için müşterilerinin giderek artan ürün kişiselleştirme taleplerine yanıt vermeye çalışmaktadır. Ancak ürün kişiselleştirmeye bağlı olarak ürün çeşitliliğinde yaşanan artış, hemen hemen tüm süreçlerde karmaşıklığa neden olurken üretim süreçlerinde de bazı problemlerin ortaya çıkmasına zemin hazırlamaktadır. Bu çalışma, ürün çeşitliliğindeki artışın diğer süreçlere etkilerini incelemek amacıyla yapılmıştır. Bir otobüs üretim tesisi üzerinde yapılan bu çalışmada ürün çeşitliliğindeki artışın tasarım, tedarik ve üretim süreçlerine etkisini analiz edebilen bir sistem dinamiği modeli geliştirilmiştir. Sistem dinamiği modelinin geliştirilmesi sürecinde mülakatlar yoluyla uzman görüşleri alınmıştır. Araştırma sonuçları, tasarım yükündeki artışın belirli bir seviyeye kadar verimlilik ve kalite üzerinde olumlu bir etkiye sahip olduğunu, ancak belirli bir aşamadan sonra artan karmaşıklığa bağlı olarak çeşitliliği yönetmenin zorlaştığını ve süreçlerin olumsuz etkilendiğini ortaya koymuştur. Geliştirilen model kullanılarak incelenen işletme için uygun bir tasarım yükü belirlenmeye çalışılmıştır. Böylece bu çalışmanın ürün çeşitliliğindeki artışın diğer süreçlere olan muhtemel etkilerini izleme ve uygun ürün çeşitliliği seviyesine karar verme noktasında yöneticilere yardımcı olması beklenmektedir.

Anahtar Kelimeler

Ürün çeşitliliği, sistem dinamiği yaklaşımı, simülasyon, karmaşıklık

Kaynakça

• [1] Magee, C.L., de Weck, O.L., An Attempt at Complex System Classification, Massachusetts Institute of Technology, 2002.
• [2] Kersten, W., Grussenmeyer R., Lammers T., Complexity management in distribution networks- reviewing current approaches, Research in Logistics & Production, 2(1), 55-68, 2012.
• [3] Efthymiou, K., Mourtzis, D., Pagoropoulos, A., Papakostas, N., Chryssolouris, G., Manufacturing systems complexity analysis methods review, International Journal of Computer Integrated Manufacturing, 29(9), 1025-1044, 2016.
• [4] Kohr, D., Budde, L., Friedli, T., Identifying Complexity Drivers in Discrete Manufacturing and Process Industry, The 50th CIRP Conference on Manufacturing Systems, 2017.
• [5] Stalk, G. The Next Source of Competitive Advantage, Harvard Business Review, Temmuz 1988.
• [6] MacDuffie, J.P., Sethuraman, K., Fisher, M.L., Product Variety and Manufacturing Performance: Evidence from the International Automotive Assembly Plant Study, Management Science, 42(3), 307-474, 1996.
• [7] Guimaraes, T., Martensson, N., Stahre, J., Igbaria, M., Empirically testing the impact of manufacturing system complexity on performance, International Journal of Operations & Production Management, 19(12), 1254-1269, 1999.
• [8] Randall, T.R., Terwiesch, C., Ulrich, K. User Design of Customized Products, Marketing Science, 26(2), 268-280, 2007.
• [9] Aggeri, F., Segrestin, B., Innovation and project development: an impossible equation? Lessons from an innovative automobile project development, R&D Management, 37(1), 37-47, 2007.
• [10] Webbink, R.F., Hu, S.J., Automated generation of assembly system-design solutions, IEEE Transactions on Automation Science and Engineering, 2(1), 32-39, 2005.
• [11] Marcora, S.M., Staiano. W., Manning. V., Mental fatigue impairs physical performance in humans, Journal of Applied Physiology, 106, 857-864, 2009.
• [12] Trattner, A.L., Hvam, L., Herbert-Hansen, Z.N.L., Raben, C., Product variety, product complexity and manufacturing operational performance: A systematic literature review, 24th International Annual EurOMA Conference, Edinburgh, United Kingdom, 2017.
• [13] Forrester, J.W., System dynamics—the next fifty years, System Dynamics Review, 23(2-3), 359-370, 2007.
• [14] Lane, D.C., The power of the bond between cause and effect: Jay Wright Forrester and the field of system dynamics, System Dynamics Review, 23(2-3), 95-118, 2007.
• [15] Fisher, M., Jain, A., MacDuffie, J.P., Strategies for Product Variety: Lessons from the Auto Industry, içinde Redesigning the Firm, (ed) Bowman, E.H., Kogut, B.M., Oxford University Press, 1995.
• [16] Ramdas, K., Managing Product Variety: An Integrative Review and Research Directions, Production and Operations Management, 12(1), 79-101, 2003.
• [17] Scavarda, L.P., Schaffer, J., Scavarda, A.J., Reis, A.C., Schleich, H., Product variety: an auto industry analysis and a benchmarking study, Benchmarking An International Journal 16(3):387-400, 2009.
• [18] Sanderson, S., Uzumeri, M., The innovation imperative: strategies for manufacturing product models and families. Irwin Professional Publisher, Illinois, 1997.
• [19] Cooper, R.G., The drivers of success in new-product development, Industrial Marketing Management, 76, 36-47, 2019.
• [20] Mason, R.B., Dobbelstein, T., The Influence of the Level of Environmental Complexity and Turbulence on the Choice of Marketing Tactics, Journal of Economics and Behavioral Studies, 8(2), 40-55, 2016.
• [21] Ramdas, K., Sawhney, M., A Cross-Functional Approach to Evaluating Multiple Line Extensions for Assembled Products, Management Science, 47(1), 22-36, 2000.
• [22] Schleich, H., Schaffer, J., Scavarda, L.F., Managing Complexity in Automotive Production, 19th International Conference on Production Research, 2005
• [23] Jacobs, M.A., Swink, M., Product portfolio architectural complexity and operational performance: Incorporating the roles of learning and fixed assets, Journal of Operations Management, 29(7–8), 677-691, 2011.
• [24] Baldwin, C.Y., Clark, K., Design rules: The power of modularity, The MIT Press, 2000.
• [25] Vogel, W., Lasch, R. Complexity drivers in manufacturing companies: a literature review, Logistics Research, 9, 1-66, 2016.
• [26] Fisher, M.L., Ittner, C.D., The Impact of Product Variety on Automobile Assembly Operations: Empirical Evidence and Simulation Analysis, Management Science, 45(6), 1999.
• [27] Cooper, W.W., Sinha, K.K., Sullivan, R.S., Measuring Complexity in High-Technology Manufacturing: Indexes for Evaluation, Interfaces, 22(4), 38-48, 1992.
• [28] Nafisia, R.M., Wiktorssonb, M., Rösiöb, C., Manufacturing Involvement in New Product Development: An Explorative Case Study in Heavy Automotive Component Assembly, ru26th CIRP Design Conference, Procedia CIRP, 50, 65-69, 2016.
• [29] Weisera, A.K., Baasnerb, B., Hoschb, M., Schlueterb, M., Ovtcharovaave, J., Complexity Assessment of Modular Product Families, ru26th CIRP Design Conference, Procedia CIRP, 50, 595-600, 2016.
• [30] Fujimoto, H., Ahmed, A., Iida, Y., Hanai, M., Assembly Process Design for Managing Manufacturing Complexities Because of Product Varieties, International Journal of Flexible Manufacturing Systems, 15, 283-307, 2003.
• [31] Bozarth, C.C., Warsinga, D.P., Flynn, B.B., Flynn, E.J., The impact of supply chain complexity on manufacturing plant performance, Journal of Operations Management, 27, 78-93, 2009.
• [32] ElMaraghy, H., Schuh, G., ElMaraghy, W., Piller, F., Schönsleben, P., Tseng, M., Bernard, A., Product variety management, CIRP Annals, 62(2), 629-652, 2013.
• [33] Amabile, T.M., Mueller, J.S., Simpson, W.B., Hadley, C.N., Kramer, S.J., Fleming, L., Patterson, C., Time Pressure and Creativity in Organizations: A Longitudinal Field Study, Harvard Business School Working Paper, No. 02-073, 2002.
• [34] Karayazı, F., Cedimoğlu, İ.H., Ürün varyant konfigürasyon yönetiminin ürün ağacı ve hataları üzerindeki etkilerinin incelenmesi, Sakarya Üniversitesi Fen Bilimleri Enstitüsü Dergisi, 19(2), 187-196, 2015.
• [35] Koren, Y., Shpitalni, M., Gu, P., Hu, S.J., Product Design for Mass-Individualization, CIRP 25th Design Conference Innovative Product Creation, Procedia CIRP, 36, 64-71, 2015.
• [36] Stäblein, T., Holweg, M., Miemczyk, J., Theoretical versus actual product variety: how much customisation do customers really demand?, International Journal of Operations & Production Management, 31(3), 350-370, 2011.
• [37] Cupek, R., Ziebinski, A., Huczala, L., Erdogan, H., Agent-Based Manufacturing Execution Systems for Short-Series Production Scheduling, Computers in Industry, 82, 245-258, 2016.
• [38] Federal Transit Administration, Asset Inventory Module Report, 2017.
• [39] Zeltzer, L.L.D.L.G., Analysing and Levelling Manufacturing Complexity in Mixed-Model Assembly Lines, Basılmamış Doktora Tezi, Universiteit Gent, 2016.
• [40] Wochner, S., Grunow, M., Stäblein, T., Stolletz, R., Planning for ramp-ups and new product introductions in the automotive industry: Extending sales and operations planning, International Journal of Production Economics, 182, 372-383, 2016.
• [41] Buergin, J., Blaettchen, P., Qu, C., Lanza, G., Assignment of Customer Specific Orders to Plants with Mixed-Model Assembly Lines in Global Production Networks, Procedia CIRP, 50, 330-335, 2016.
• [42] Chatras, C., Giard, V., Sali, M., High variety impacts on Master Production Schedule: a case study from the automotive industry, IFAC-PapersOnLine, 48(3), 1073-1078, 2015.
• [43] Bednar, S., Salanci, V., Product Variety Induced Complexıty and its Measurement, Acta Tecnología - International Scientific Journal about Technologies, 2(2), 5-9, 2016.
• [44] Seha, S., Zamberi J., Fairul, A.J., design and simulation of integration system between automated material handling system and manufacturing layout in the automotive assembly line, 4th International Conference on Mechanical Engineering Research (ICMER2017), 1-10, 2017.
• [45] Martin, M.V., Ishi, K., Design for variety: Development of complexity indices and design charts, Proceedings of ASME Design Engineering Technical Conferences, (DETC’97), 1997.
• [46] Schuh, G., Rebentisch, E., Riesener, M., Mattern, C., Fey, P. Method for the evaluation and adaptation of new product development project complexity, Procedia CIRP, 60, 338-343, 2017.
• [47] Coyle, G., System Dynamics Review: Qualitative and quantitative modelling in system dynamics: some research questions, System Dynamics Review, 16(3), 225-244, 2000.
• [48] Duggan, J., System Dynamics Modeling with R, Springer International Publishing, 2016.
• [49] Çil, İ., Karaduman, E., Özçetin, K.N., İpek, M., Bir tekstil firmasında satış tahminleri üzerinden emniyet stoğu gün sayısının system dinamiği yaklaşımıyla belirlenmesi, Sakarya Üniversitesi Fen Bilimleri Enstitüsü Dergisi, 22 (2), 826-837, 2018.