Methodology to Develop Optimal Operational Flexibility in a Low Volume-High Variety Manufacturing Setup with a Suitable MES

This research work has two parts. The first part is to optimize the operational flexibility of a manufacturing setup and part two is to develop a manufacturing execution system (MES) for a manufacturing setup. Low Volume-High Variety manufacturing environment offers a great challenge for the manufacturer because of the customized orders. Typical manufacturing environment consists of Job Shop, batch type and mass production system. The Low Volume - High Variety exists in Job shop production systems. We have argued that there exists a potential of research in this environment due to more variety of tasks with very low volumes. The authors have looked into the issue of flexibility and try to measure the dimensions of flexibility with the implementation of a suitable MES. Using real data from the discrete parts manufacturing industry and making use of manufacturing simulation the limits are set from the operational view point for enhancing production rate. For this, the highest and lowest limits for the systems are used to measure the flexibility both in traditional and flexible systems. Tools like line balancing and more streamlining of the operations are used for more balanced line in both systems. The results of the traditional and manual systems are compared and concluded that flexible systems offers more flexibility for the set limits. The sensitivity analysis is carried out on the input variables that affect the output performance measures for more optimized production. Finally, implemented a MES to integrate the shop floor manufacturing activities with the Enterprise Resource Planning ERP.