The Impact of Routing and Operation Flexibility on the Performance of Matrix Production Compared to a Production Line

Abstract

An increasing number of product variants and a decrease in demand certainty challenge manufacturing companies. Lean, flow-oriented production lines are best-practice to assure efficient production in a predictable environment. However, with the increase in complexity and uncertainty, more flexible production systems such as matrix production currently receive much attention. Having neither a common takt time nor a rigid linkage, they offer new degrees of freedom regarding process order and machine choice. This paper contributes to answering the question under which conditions a matrix production is favourable compared to a production line. To answer this question, the effects of MTTF and MTTR as driving factor to choose a matrix production over a production line are analysed. Regarding the material flow in the matrix, the benefits of routing flexibility and operation flexibility concerning throughput time, tardiness and output of the matrix production are evaluated. The results show that a rule based approach has its limits especially regarding the exploitation of operation flexibility. For low levels of routing flexibility, the rule based approach tends to generate sup-optimal solutions due to a lack of coordination between the agents.