Cim - What Really Makes Factories Flexible?

Introduction:

In this literature, "What really makes factories flexible?" the writer brought out the topic for factory flexibility, which defines as a production facility organized to respond to customer orders quickly in order to provide a full and varied range of operations or services, across many product lines with very short changeover times and may introduce new products of similar range fairly easy. For example, most modern automobile plants are designed as flexible factories to build various models. Having acknowledged the importance of flexibility, how would manufacturing managers in a broad array of industries find pathways to improve the process? What are the difficulties of defining flexibility of a plant and how do they measure flexibility in terms of plant productivity? What measurements are needed to show improvement of the process? The author performed a research in a study of sixty-one factories in North America that manufacture fine paper to find out the answer.

Define the problem:

Unlike most other industries in which different plants make different products, the paper industry's products are more comparable across plants since paper are produced by very similar process. There are a few characteristics for the paper industries to be the right candidate. In paper industry, the qualities of products by grades are straightforward numbers which can be able to be measured by the author. These numbers enabled the author to develop both the range of paper a plant could produce and how much time it needed for a plant to switch from making one kind of paper to making another. By using these numbers the author was be able to define the operational flexibility for manufacturing plants needed to measure and find the ways to improve the processes. Defining the problem is the first thing needed by each manager. "What is flexibility?" Managers are having hard times to define as the term may mean very different for different people. At plant level, it is about the ability to change over or adapt new system, however, specifying and characterizing this ability is not an easy task. As one manager may talk about the flexibility to produce the types of production from up and down depending on what the market needs; another manager may talks about the flexibility to change over from making one type of paper to another with less time and money. In the author's point of view, flexibility should be emphasized in determining by its competitive environment. The measurement of flexibility can be based on a) product range in different things as a plant can have the ability to produce a small number of products that are very different from one another b) mobility for a plant to change over from making one product to another and c) uniformity of performance as a flexible plant can perform comparably well to make any product within a specified range. Once managers have defined the different kinds of flexibility they are trying to develop, another set of issues had come up as how to measure the flexibility and improvement of flexibility. Also it is often unclear in which general features of a plant must be changed in order to make its operations flexible. The depth and wisdom of experience managers have to be carefully assessing their strategies to define what kind of flexibility they are looking for before embarking on a flexibility program, or otherwise the results can be disastrous.

Implication and analysis to select best alternatives:

By collecting production data, the author was able to measure the breadth of paper grades that each plant was capable of producing and the changeover time that each plant required to switch between grades. There were additional measurements of flexibility such as workforce by length of service, the level of computer integration (CIM), the change and break frequency, etc. Each plant may emphasize in a whole range of factors from different quality and types of flexibility based on the managers, so end up there are large differences across plants. One major issue covered in this literature is that the degree of computer integration (CIM) does not really help on plant flexibility by increasing range of products produced or improving change over time even though large money was invested in it. Managers often have difficulty justifying CIM projects on the basis of cost savings or quality improvements therefore justify them on basis of improved flexibility CIM will provide. In this case, only the engineers or a few trained employees understand how the system works; most of the plant operators are not trained to operate which create problems. Operators instead decide to perform