Investigations into Flexible Operational Paradigms to Mitigate Variability.

Abstract

The work of this dissertation is concerned with the study of the effectiveness of paradigms of production flexibility to either improve system performance or mitigate system risk. A brief introduction to the concept of operational flexibility is provided in Chapter I. In Chapter II, we consider a cross-trained workforce on a serial production line, and we introduce a new strategy of worker cross training called a “fixed task zone chain” (FTZC) as a special type of zone based cross training. This new approach seeks to maximize the performance of a production line, in the same fashion as a standard two skill chain, but with a significant reduction in the number of skills that must be cross trained. This allows a firm to maintain nearly the same levels of throughput, but at a fraction of the cross-training and implementation costs. Chapter III targets our study of operational flexibility on the field of supply chain management. A flexible supply chain design is useful to mitigate the effect of stochastic supplier disruptions on operations and, especially, financial cash flows. The work of this chapter develops mitigation strategies for a firm to use in sourcing from flexible suppliers and demonstrates the conditions under which flexibility in the firm’s supply chain is necessary. Finally, to assist with the understanding of the flexibility paradigms, we have designed an instrument to promote the understanding of flexibility with respect to cross-training as well as to assist in its implementation. That is, we develop a hands on, active learning experience placing participants “on the job” in a serial production line of cross-trained workers where participants can: 1) learn basic concepts of operations management, production control, and workforce agility; 2) understand system responsiveness and what can be done to improve it; 3) generate creative thinking and discussion on the value of flexibility; and 4) experience first-hand foundational factory physics concepts like cycle time, throughput, and Work In Process (WIP).