Abstract
A highly flexible manufacturing capability is central to the paradigm of mass customisation. In turn the role of rapid, high quality changeovers is crucial to this capability, whereby production can be switched with minimal penalty across a full (and expanding) range of product offerings. Many companies will seek better changeovers principally by refining the way that personnel complete assigned tasks. Further improvement opportunity can be sought by amending the design of process equipment. By means of focused design improvement an inherently more flexible manufacturing system can become available, on which simpler, more repeatable and faster changeovers can routinely take place.
Access this chapter
Tax calculation will be finalised at checkout
Purchases are for personal use only
Preview
Unable to display preview. Download preview PDF.
References
Bicheno J (2003) The New Lean Toolbox – Towards Fast, Flexible Flow. PICSIE Books, Buckingham
Booth R (1996) Agile manufacturing. Engineering Management J 6(2)105–112
Boyles R (1991) The Taguchi Capability Index. J of Quality Technology 23(1):17–26
Cakmakci M (2009) Process improvement: performance analysis of the setup time reduction-SMED in the automobile industry. The International J of Advanced Manufacturing Technology 41(2)168–179
Christopher M, Lowson CM, Peck H (2004) Creating agile supply chains in the fashion industry. International J of Retail and Distribution Management 32(8):367–376
Coronado AE, Lyons AC, Kehoe DF, Coleman J (2004) Enabling mass customization: extending build-to-order concepts to supply chains. Production Planning and Control 15(4):398–411
De Toni A, Tonchia S (1998) Manufacturing flexibility: a literature review. International J of Production Research 36:1587–1617
Feld WM (2000) Lean Manufacturing: Tools, Techniques, and how to Use Them. CRC Press, Boca Raton, FL, ISBN9781574442977
Goldhar JD, Jelinek M (1985) Computer integrated flexible manufacturing: Organizational, economic and strategic implication. Interfaces 15:94–105
Gould P (1997) What is Agility? Manufacturing Engineering 76(1):28–31
Gunasekaran A (1998) Agile manufacturing: Enablers and an implementation framework. International J of Production Research 36(5):1223–1247
Hall R (1983) Zero Inventories. Dow Jones–Irwin, Homewood, CA
Hirotec Corporation (2009) http://www.hirotec.co.jp/hirotec/us-htc/p_press.htm. Accessed August 2009
Kaplan AM, Haenlein M (2006) Toward a parsimonious definition of traditional and electronic mass customization. J of Product Innovation Management 23(2):168–182
Kidd PT (1995) Agile Manufacturing, Forging New Frontiers. Addison-Wesley, London
McCarthy I (2004) Special issue on ‘Mass customization’. Production Plannig and Control 15(4)
Matson J, McFarlane D (1998) Tools for assessing the responsiveness of manufacturing systems. Proc of the IEE Workshop, Responsiveness in Manufacturing, London
McIntosh RI (1998) The impact of innovative design on fast tool change methodologies. University of Bath, Bath
McIntosh RI, Culley SJ, Mileham AR, Owen GW (2000) A critical evaluation of Shingo’s ‘SMED’ (single minute exchange of die) methodology. International J of Production Research 38(11):2377–2395
McIntosh RI, Culley SJ, Mileham AR, Owen GW (2001) Improving Changeover Performance. Butterworth–Heinemann, Oxford
McIntosh RI, Matthews J, Mullineux G, Medland AJ (2010) Mass customisation: issues of application for the food industry. International J of Production Research 48(6):1557–1574. doi:10.1080/00207540802577938.
Mehrabi MG, Ulsoy AG, Koren Y (2000) Reconfigurable manufacturing systems: key to future manufacturing. J of Intelligent Manufacturing 11(4):403–419
Mileham AR, Culley SJ, McIntosh RI, Owen GW (1999) Rapid changeover a pre-requisite for responsive manufacture. International J of Operations and Production Management 19(8):785–796
Montreuil B, Poulin M (2005) Demand and supply network design scope for personalized manufacturing. Production Plannning and Control 16:454–469
Neuhausen J (2001) In Methodik zur Gestaltung modularer Produktionssysteme für Unternehmen der Serienproduktion. RWTH Aachen, Aachen
Nyhuis P, Kolakowski M, Heger C (2006) Evaluation of factory transformability – a systematic approach. Annals of the German Acadamic Society for Production Engineering 1:147–152
Owen GW, Culley SJ, Reik M, McIntosh RI, Mileham AR (2007) Using differing classification methodologies to identify a full compliment of potential changeover improvement opportunities. In: Loureiro G, Curran R (eds) Complex Systems Concurrent Engineering, pp 337–344. Springer, Berlin
Pine BJ (1992) Mass Customization: The New Frontier in Business Competition. Harvard Business School Press
Reik MP, Culley SJ, Mileham AR, Owen GW, McIntosh RI (2005) Design for changeover (DFC): enabling the design of highly flexible, highly responsive manufacturing processes. International Conference on Changeable, Agile, Reconfigurable and Virtual Production, Munich. Springer, Berlin
Reik MP, McIntosh RI, Owen GW, Mileham AR, Culley SJ (2006a) Design for changeover (DFC): enabling the design of highly flexible, highly responsive manufacturing processes. In: Blecker T, Friedrich G (eds) Mass Customization: Challenges and Solutions, pp 111–136. Springer, Berlin
Reik MP, McIntosh RI, Owen GW, Culley SJ, Mileham AR (2006b) A formal design for changeover (DFC) methodology: part 1 – theory and background. J of Engineering Manufacture 220(8):1225–1236
Reik MP, McIntosh RI, Owen GW, Culley SJ, Mileham AR (2006c) A formal design for changeover (DFC) methodology: part 2 – methodology and case study. The J of Engineering Manufacture 220(8):1237–1248
Salvador F, Rungtusanatham M, Forza C (2004) Supply-chain configurations for mass customization. Production Planning & Control 15(4): 381–397
Schonberger, RJ (1982) Japanese Manufacturing Techniques: Nine Hidden Lessons in Simplicity. The Free Press, New York.ISBN: 978-0029291009
Schuh G, Harre J, Gottschalk S, Kampker A (2004) WT. Werkstattstechnik 94:100–106
Sekine K, Arai A (1992) Kaizen for Quick Changeover: Going Beyond SMED. Productivity Press, Cambridge
Sethi AK, Sethi SP (1990) Flexibility in manufacturing: a survey. International J of Flexible Manufacturing Systems 2(4):289–328
Shingo S (1985) A Revolution in Manufacturing, the SMED System. Productivity Press, Cambridge
Slack N (1990) Strategic flexibility. In Voss, CA (ed.) Manufacturing Strategy? Theory and Practice, Proc of the 5th International Conference of the Operations Management Association, Warwick
Smith DA (2004) Quick Die Change. SME, Dearborn, MI
Tseng MM, Jiao J (2001) Mass customization. In: Handbook of Industrial Engineering, Technology and Operation Management, 3rd edn, Wiley, New York. ISBN 0-471-33057-4
Urbani A, Molinar-Tosatti L, Bosani R, Pierpaoli F (2003) Advances in mass customization and personalization. In: Tseng MM, Piller FT (eds) The Customer Centric Enterprise: Part IV. Springer, Berlin
Van Goubergen D, Van Landeghem H (2002) Rules for integrating fast changeover capabilities into new equipment design. Robotics and Computer-Integrated Manufacturing 18(4):205–214
Wiendahl HP, Heger CL (2003) Justifying changeability – a methodical approach to achieving cost effectiveness. Proc of the 2nd International Conference on Reconfigurable Manufacturing, Ann Arbor, MI
Womack JP, Jones DT, Ross D (1990) The Machine That Changed the World. Rawson Associates, New York
Zhao J, Cheung WM, Young RIM (1999) A consistent manufacturing data model to support virtual enterprises. International J of Agile Management Systems 1:150–158
Author information
Authors and Affiliations
Editor information
Editors and Affiliations
Rights and permissions
Copyright information
© 2011 Springer-Verlag London Limited
About this chapter
Cite this chapter
Owen, G., Matthews, J., McIntosh, R., Culley, S. (2011). Design for Changeover (DFC): Enabling Flexible and Highly Responsive Manufacturing. In: Fogliatto, F., da Silveira, G. (eds) Mass Customization. Springer Series in Advanced Manufacturing. Springer, London. https://doi.org/10.1007/978-1-84996-489-0_12
Download citation
DOI: https://doi.org/10.1007/978-1-84996-489-0_12
Publisher Name: Springer, London
Print ISBN: 978-1-84996-488-3
Online ISBN: 978-1-84996-489-0
eBook Packages: EngineeringEngineering (R0)