Implementation of process modeling and simulation using IDEF0 in Malaysian automotive industry /
The rapid development in the automotive sector and competition across the globe demands efficient manufacturing processes and systems, quality tools, process modeling techniques, etc. Process modeling and simulation (PMS) is one of the most important tasks which is commonly outsourced by the majorit...
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| Main Author: | |
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| Format: | Thesis |
| Language: | English |
| Published: |
Kuala Lumpur :
Kulliyyah of Engineering, International Islamic University Malaysia,
2011
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| Subjects: | |
| Online Access: | http://studentrepo.iium.edu.my/handle/123456789/4877 |
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| Summary: | The rapid development in the automotive sector and competition across the globe demands efficient manufacturing processes and systems, quality tools, process modeling techniques, etc. Process modeling and simulation (PMS) is one of the most important tasks which is commonly outsourced by the majority of Malaysian automotive supplier industries. The PMS services rendered by the external companies have several drawbacks such as poor conceptualization of the manufacturing process, miscommunication, high costs, etc. This research attempts to propose an efficient and uncomplicated PMS technique which can be used in-house. One of the main objectives of the research is to model and simulate manufacturing process in an automotive industry and analyze the system performance based on the new technique. A new approach has been adapted with the use of IDEF0 in iGrafx® Process for Six Sigma which includes an integrated feature, RapidDOE with MiniTab. Two major automotive industries in Malaysia (Case study A and Case study B) have been demonstrated successfully. The data from industries has been collected and translated into AS-IS static and dynamic models in iGrafx® Process for Six Sigma. The IDEF0 represent the AS-IS static model while the simulation model represent AS-IS dynamic model. By this the 'AS-IS' model was achieved without becoming too complex to a good degree of similarity at a discrepancy level of 2.8% for the case A and 0% to case study B. The interpretation of the generated statistical results has been used to improve the model using RapiDOE. The result from the statistical analysis provided a basis for the recommendation of the 'TO-BE' model. This scenario has been verified and recommended as a process modeling and simulation (PMS) template for the plant managers of the respective case studies as it has been proven to identify process system characteristic. It appears that this realistic investigation is the first in Malaysian automotive industries. As such, PMS techniques cannot be implemented due to several barriers in-house. Therefore current research has developed a novel framework to facilitate the implementation of PMS technique in Malaysian automotive industries. The framework is segmented into four major stages and the role in each stage has been simplified with recommendation of various methods and suggestions. The critical factors that govern the implementation PMS technique in Malaysian automotive industries were identified and analyzed using IDEF0 technique. |
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| Item Description: | Abstract in English and Arabic. "A thesis submitted in fulfilment of the requirement for the degree of Doctor of Philosophy (Engineering)."--On t.p. |
| Physical Description: | xvii, 203 leaves : ill. charts; 30cm. |
| Bibliography: | Includes bibliographical references (leaves 166-176). |