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Analysis of the manufacturing flexibility parameters with effective performance metrics: a new interactive approach based on modified TOPSIS-Taguchi method

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Abstract

Flexibility is one of the most important strategy parameters to achieve a long-term successful performance for a manufacturing company. Studies in the literature aim to operate a manufacturing system at optimum levels of flexibility parameters under its own manufacturing environment. This study aims to present an interactive analysis framework based on TOPSIS and Taguchi parameter design principles for investigating the effects of different levels of flexibility parameters on the performance of a flexible manufacturing cell (FMC). The main performance metric used in this study is manufacturing lead time. Other important metrics to evaluate quality control and inspection policies are also investigated in this study. To conclude, a combined model of an interactive approach based on TOPSIS and Taguchi methods are used to assess the effectiveness of the flexibility parameters for a FMC.

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Funding

This research was supported by Baskent University, Ankara, Turkey, under the Contract No. BA/FM-15.

Author information

Authors and Affiliations

  1. Department of Industrial Engineering, Faculty of Engineering, Baskent University, 06790, Etimesgut, Ankara, Turkey

    Yusuf Tansel İç & Berna Dengiz

  2. NUROL Machinery Co., Organize Sanayi Bölgesi, Avrupa Hun Cad. No: 6, 06935, Etimesgut, Ankara, Turkey

    Turgut Şaşmaz

  3. Department of Mechanical Engineering, Faculty of Engineering, Gazi University, 06570, Etimesgut, Ankara, Turkey

    Mustafa Yurdakul

Authors
  1. Yusuf Tansel İç
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  2. Turgut Şaşmaz
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  3. Mustafa Yurdakul
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Correspondence to Yusuf Tansel İç.

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Appendices

Appendix A: Cutting tool information

In this study three different end mill cutters were used with respect to standard DIN 844/BN HSS-E Form B which are alloyed as 303/20, HSS-E 8 Co%.

  • d = 3 mm, 4-necked, y = 30° helix angle with finger HSS cutter 

  • d = 4 mm, 4-necked, y = 30° helix angle with finger HSS cutter 

  • d = 5 mm, 4-necked, y = 30° helix angle with finger HSS cutter 

See Fig. 

Fig. 6
figure 6

End mill HSS cutter

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6.

Appendix B: Experimental set-up

The components are as follows:

  1. 1.

    Flexible manufacturing system control computer

  2. 2.

    CNC control computer (GE Fanuc Series 21)

  3. 3.

    Robot Arm (Festo RV-2AJ-SI3)

  4. 4.

    CNC vertical machining center (EMCO PC MiI 55)

  5. 5.

    Control station

  6. 6.

    Material handling conveyor (FESTO)

See Figs.

Fig. 7
figure 7

The experimental set-up

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7 and

Fig. 8
figure 8

Mahr-Marsurf PS1

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8.

Appendix C: Conducting to experiment

Various assumptions are made as follows in this study [5]:

  • The system is fully automated.

  • All machines are 100% reliable.

  • There is no scrap produced by machines.

  • Setup times of the machines are not included in the processing time.

  • Once the process starts in the machime, it is not allowed to cancel the operation.

  • The machine can handle only one part of the cycle.

  • Pallet capacity is three.

  • Pallets are not allowed to enter the processing area if the part is not ready.

  • All pallets are 100% reliable.

  • Operation ends when all the parts’ processes are completed.

See Fig. 

Fig. 9
figure 9

Performing of the experiments

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9.

Appendix D: ANOVA tables

See Tables

Table 30 Two-way analysis of variance for MLT
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30,

Table 31 4-parameter analysis of variance for MLT
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31,

Table 32 Two way variance analysis for surface roughness
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32 and

Table 33 4-parameters analysis of variance for surface roughness values
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33.

Appendix E: Taguchi results via graphical illustrations

See Figs.

Fig. 10
figure 10

Taguchi results for MLT (S/N ratios)

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10,

Fig. 11
figure 11

Taguchi results for MLT (means)

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11,

Fig. 12
figure 12

Taguchi results for surface roughness (S/N ratios)

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12 and

Fig. 13
figure 13

Taguchi results for surface roughness (means)

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13.

Appendix F: Taguchi results via graphical illustrations (continue)

See Figs.

Fig. 14
figure 14

TOPSIS-Taguchi method’s result (S/N ratios)

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14,

Fig. 15
figure 15

TOPSIS-Taguchi method’s result (means)

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15,

Fig. 16
figure 16

Taguchi analysis result for scenario 2 (S/N ratios)

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16,

Fig. 17
figure 17

Taguchi analysis result for scenario 2 (means)

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17,

Fig. 18
figure 18

Taguchi analysis result for scenario 3

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18 and

Fig. 19
figure 19

Taguchi analysis result for scenario 3

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19.

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İç, Y.T., Şaşmaz, T., Yurdakul, M. et al. Analysis of the manufacturing flexibility parameters with effective performance metrics: a new interactive approach based on modified TOPSIS-Taguchi method. Int J Interact Des Manuf 16, 197–225 (2022). https://doi.org/10.1007/s12008-021-00799-5

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