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INTELLIGENT DECISION SUPPORT SYSTEM FOR SELECTION OF QUALITY TOOLS AND TECHNIQUES VIA CATEGORIZATION INPUT FUNCTION OUTPUT DEFINITION MODEL
No full textVast numbers of Quality Tools and Techniques (QTT) for problem-solving and improvement activities give a significant challenge to determine the suitable QTT. The chosen QTT affect the effectiveness of improvement activity and misused of QTT can slow down the improvement process and flawed the conclusion. Hence, the use of QTT is found as one of the critical success factors in the quality improvement. The overall purpose of this study was to develop the web-based intelligent decision support system for selection of quality tools and techniques (QTT) based on the CIFOD model. This study presents a CIFOD model that was developed from the attributes of QTT's characteristic. In this study, 97 attributes of QTT's characteristic were classified into 5 main groups and 16 sub-groups. CIFOD is the acronym of those 5 main groups namely Categorization, Input, Function, Output dan Definition. Interdependence multivariate analysis was adopted to analyze the attributes and the CF A through AMOS shows the classification of the attributes into CIFOD model was fit to the data sample. 45 common QTTs were selected to map with the attributes that obtained from expert opinion and the study found that the QTT were able to define through the attributes. The web-based IDSS namely eCIFOD was produced by translating the QTT mapping into the SQL Union and SQL Inner Join. PHP scripts were developed to run the system and uploaded to online after the Black Box Testing show good result. A single case with a single unit of the case study research strategy was used to conduct the UAT. The result shows the eCIFOD able to list out 11 QTis that needed by the improvement team and the level of user acceptance level for the eCIFOD exhibit the positive feedback. Finally, the finding of this study provided contributions to the theoretical implication and the managerial implication. In the theoretical implication, the findings contribute to the literature of QTT's body of knowledge in term of various viewpoints on the attributes of QTT's characteristic to define the QTT and the development of QTT classification namely CIFOD model. For the managerial implication, the findings contribute to the decision support of QTT selection for practical application of problemsolving and quality improvement activities
DEVELOPMENT OF PART REPLENISHMENT APPROACH TO IMPROVE PRODUCTION EFFICIENCY IN LOW VOLUME AUTOMOTIVE ASSEMBLY COMPANY
No full textThe part replenishment system (PRS) has long been studied in the manufacturing field where the study has been mostly carried out in internal replenishment (warehouse and inventory), and the external replenishment (distribution and logistics). However, it was found that there was a lack of PRS work in the in-house replenishment (production floor) consisting of material management between warehouse and production floor. Since the material replenishment activities are usually carried-out by warehouse personnel, the material management issues might be overlooked during preparation of production system. Most studies carried out on material replenishment in the production floor were based on trial and error, which only solved the issue if occurred during production process. Consequently, the difficulties arise in deciding which direction or guide should be taken for part replenishment improvements. Thus, in this thesis, systematic approach of PRS for strengthening the material management between warehouse and production floor was developed to improve the efficiency and effectiveness of the production floor. The developed approach consisted of three main phases, which were manufacturing system identification, Part Replenishment (PR) strategies and techniques, and the verification and validation of the approach. Three techniques of the PRS were identified based on the chronology of the manufacturing perspective in the pull and push system, namely self-service, adhoc and dedicated. The PR strategies were then developed with an interaction of different number of trolleys and different number of shelves or modes, where the trolley consisted of single and dual, while maximum number of three shelves was employed. Each strategy or mode based on combination number of trolley and shelves was examined in terms of waiting time by using queuing analysis theory and analyzed by using WITNESS simulation software. The result showed the dual system with three shelves (Mode 5) was identified as the optimum strategy that increased the production output and provided a smoothness production flow which consequently optimized the production lead time and avoiding part shortage, part missing and part mixing. The developed PRS approach was then verified, validated and implemented in a selected case study industry where the dedicated dual system with three shelves (Mode 5) had drastically increased the target output from 5 units to 16 units per day. In overall, the developed PRS approach has ensured that the materials are replaced at the right time, with the right quantity and at the right place by eliminating the waste of waiting time and avoiding production idling
