Modeling Process Platforms based on An Object-Oriented Visual Diagrammatic Modeling Language Linda Zhang To cite this version: Linda Zhang. Modeling Process Platforms based on An Object-Oriented Visual Diagrammatic Modeling Language. International Journal of Production Research, Taylor & Francis, 2009, 47 (16), pp.4413-4435. <10.1080/00207540801950144>. <hal-00513029> HAL Id: hal-00513029 https://hal.archives-ouvertes.fr/hal-00513029 Submitted on 1 Sep 2010 HAL is a multi-disciplinary open access archive for the deposit and dissemination of scientific research documents, whether they are published or not. The documents may come from teaching and research institutions in France or abroad, or from public or private research centers. 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International Journal of Production Research ee rP Fo Modeling Process Platforms based on An Object-Oriented Visual Diagrammatic Modeling Language Manuscript ID: Date Submitted by the Author: Keywords (user): Original Manuscript 05-Jan-2008 Zhang, Linda; University of Groningen, Operations PRODUCTION MANAGEMENT, PRODUCTION MODELLING w Keywords: TPRS-2007-IJPR-0717.R1 ie Complete List of Authors: International Journal of Production Research ev Manuscript Type: rR Journal: Process platform, high variety production ly On http://mc.manuscriptcentral.com/tprs Email: ijpr@lboro.ac.uk Page 1 of 36 MODELING PROCESS PLATFORMS BASE ON AN OBJECT-ORIENTED VISUAL DIAGRAMMATIC MODELING LANGUAGE Lianfeng Zhang † †Department of Operations, University of Groningen, Landleven 5, 9747 AD Groningen, The Netherlands rP Fo ABSTRACT Process platforms have been recognized as a promising means of dealing with product variety while achieving a near mass production efficiency. To assist practitioners to better understand, implement and use process platforms, this study addresses the underlying ee logic of coping with the challenges in high variety production by adopting process platforms. Accordingly, this paper proposes to model process platforms with focus on the rR application processes. In view of the significance of dynamic modeling and visualization in shedding light on the logic of any processes, this study introduces a visual diagrammatic ev modeling language based on object-oriented (OO) techniques, named as OOVDML. With the graphical notations, uniquely shaped symbols, syntax and semantics, control iew mechanisms and arrangement rules, the OOVDML not only captures the logic of process platform’s application but also provides a visualization of their behaviors in a holistic view. Moreover, incorporating OO modeling allows readers to focus on their own interests. This On study approaches to modeling process platform’s application with respect to activities pertaining to customer order processing, engineering change control and production job ly 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 International Journal of Production Research planning. Also reported is an industrial example of electronics products. The results of the case study not only show the suitability of the OOVDML but also shed light on the dynamic behaviors of process platforms. Key Words: Process platform, high variety production, diagrammatic modeling, objectoriented methods, visualization. Corresponding author. Email: L.Zhang@rug.nl http://mc.manuscriptcentral.com/tprs Email: ijpr@lboro.ac.uk 1 International Journal of Production Research 1. INTRODUCTION Manufacturing environments nowadays are characterized by a high variety of customized products, often coupled with small quantities and short delivery lead-times. To survive the resulting intense global competition by pleasing their customers, manufacturing companies struggle to provide quickly high product variety at low costs. The key for companies to achieve efficiency in producing large numbers of customized products lies in an ability to rP Fo maintain the resulting high variety production to be as stable as possible (Schierholt, 2001; Williams et al., 2007; Zhang, 2007). In this respect, process configuration contributes to manufacturing stability by generating similar processes for part families (Schierholt, 2001). ee It is an alternative of computer-aided process planning per se. Similar as the process configuration thinking, a concept of process platforms has been rR recognized as a promising means for companies to achieve a near mass production efficiency by managing high variety production, wherein the complex products consisting ev of assemblies and parts are involved (Zhang, 2007). The rationale is to plan and utilize similar, yet optimal, production processes as these existing on shop floors to fulfill diverse iew customized products. Current research efforts have approached process platforms from several aspects (Zhang, 2007), including conceptual formulation (Jiao et al., 2007a), On structural representation (Zhang et al., 2007), construction (Jiao et al., 2007b) and identification of mapping relationships within a process platform (Jiao et al., 2008). ly 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 Page 2 of 36 Besides the insight provided by the above works, a good understanding of the underlying logic of coping with difficulties in high variety production by adopting process platforms is necessary for companies to design, develop and apply process platforms. With an attempt to assist practitioners to better understand, implement and use process platforms, this study addresses the underlying logic of process platform’s behaviors. In view of the significance of dynamic modeling and visualization in shedding light on the http://mc.manuscriptcentral.com/tprs Email: ijpr@lboro.ac.uk 2 Page 3 of 36 logic of any processes, this paper, accordingly, proposes to model process platforms with focus on the application processes, i.e., dynamic modeling. Along with the complexities in fulfilling high product variety, the resulting difficulties in modeling process platform’s application behaviors have been recognized, as elaborated below. 1.1. Difficulties in modeling process platforms Modeling process platforms intends to visualize their application behaviors in high rP Fo variety production in a holistic view. The diverse customized products along with the resulting large number of constituent items impose many complexities in production. For example, many personal, activities, data, information, etc. are involved in different phases of production. The same data may be manipulated by many different activities, which, in ee their turn, may manipulate other data as well. Personal may carry out different activities rR and activities may be carried out by different personal. Activities also have mutual dependencies. They may access the same data at the same time or they may be ordered in ev complex ways. In this regard, modeling process platforms is expected to capture the inherent complexities in one dimension rather than many dimensions, e.g., activities, iew processes, personal. Describing the different types of system elements in more than one dimension incurs difficulties in providing readers with an overall picture of process platform’s application in a holistic view. On Second, process platform modeling is to shed light on the underlying logic of coping ly 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 International Journal of Production Research with difficulties by adopting process platforms in high variety production. Incorporating process platforms when fulfilling various products has brought about many additional events, activities, information and data in production. Moreover, it is not uncommon that any processes involve a number of activities that are concurrent, dependent and parallel. Because of these activities/events and their complicated relationships, reasoning about process platform’s application behaviors is important for the interested readers to gain an http://mc.manuscriptcentral.com/tprs Email: ijpr@lboro.ac.uk 3 International Journal of Production Research insight in the logic. Therefore, the process platform models to be constructed must be able to reveal the underlying reasoning of process platform’s application. Third, in a company, people at different levels view the same thing from different aspects and have different focuses. This is also true for process platform’s application. For example, while management people may care about the functional areas involved and their relationships, production personal are more concerned with the activity details in his/her rP Fo own area. In accordance with the different views, the process platform models to be constructed should present the corresponding application processes at different levels of abstraction, which allows different readers to pay attention to their own interested areas. Furthermore, the ultimate goal of process platform modeling is to help practitioners ee better understand and grasp the essence of process platform’s application. Thus, it raises rR the importance in an unambiguous modeling. In other words, process platform models should be constructed to allow different readers to interpret the corresponding application ev uniquely and in an exactly same way. Besides, the models are expected to provide an easyunderstandability and readability. 1.2. Strategy for solution iew To cope with the modeling difficulties, this study puts forward an OOVDML (object- On oriented (OO) visual diagrammatic modeling language) by integrating the principles of a number of well-defined modeling techniques. ly 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 Page 4 of 36 Graphical notations and diagrams are incorporated in the OOVDML to provide a visualization of process platform’s application in a holistic view. Besides graphical representations, textual representations in the natural language are introduced. Textual representations are able to capture the complicated data, information, personal, activities and their relationships and further map them in one dimension. In the OOVDML, they are used to model the detailed activities, involved personal, inputs and outputs. They are also http://mc.manuscriptcentral.com/tprs Email: ijpr@lboro.ac.uk 4 Page 5 of 36 used to denote the names and attributes of graphical notations defined. To deal with the issues regarding different levels of abstractions, the class concept in OO modeling is incorporated. Both the class attributes and/or detailed class operations can be hidden, when necessary. As a result, the readers are able to focus on their own interests. Moreover, a number of arrangement rules and control mechanisms along with predicate formulas are defined in the OOVDML to capture and model the reasoning of process platform’s rP Fo application behaviors. Rather than all processes in high variety production, this study approaches process platform modeling with focus on activities pertaining to production job planning, engineering change control and customer order processing. The reason is that these ee processes are fundamental to efficient high variety production. rR The rest of the paper is structured as follows: The work regarding high variety production management and dynamic modeling languages is present in Section 2, ev following which the fundamentals of process platforms are introduced in Section 3. The OOVDML is detailed in Section 4. Section 5 reports an industrial example involving iew vibration motors for mobile phones. Section 6 concludes the paper by discussing advantages and disadvantages of the proposed OOVDML and by identifying future research. 2. RELATED WORK ly On 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 International Journal of Production Research In the past several decades, a large body of literature has been reported to assist companies to provide various customized products as expected by customers. Such research efforts have been made mainly in the areas of product platform development (Simpson, 2004), product family design (Sanderson and Uzumeri, 1995), outsourcing (Harland et al., 2005) and supply chain management (Min and Zhou, 2002). While the resulting methodologies/system prototypes/frameworks, to some degree, help companies http://mc.manuscriptcentral.com/tprs Email: ijpr@lboro.ac.uk 5 International Journal of Production Research achieve design efficiency and effectiveness and selection of proper supply chain partners, they lack an explicit consideration of issues regarding production of high product variety based on companies existing manufacturing resources (Lu and Botha, 2006). Schierholt (2001) introduces the concept of process configuration, which combines the principles of product configuration and process planning, to deal with manufacturing process generation. Williams et al. (2007) put forward process parameter platforms for developing rP Fo manufacturing processes by taking into account the non-uniform market demand. In essence, both process configuration and process parameter platforms address process development for parts. Zhang (2007) presents process platforms to assist companies to achieve a near mass production efficiency in high variety production. Unlike process ee configuration and process parameter platforms, process platforms intend to facilitate rR production process generation for complicated end-products, wherein both parts and assemblies are involved. ev The conceptual models of process platforms are formulated with respect to basic constructs, definitions, relationships and functionalities using set theory and OO iew techniques (Jiao et al., 2007a). Also discussed are process platform’s concept implications: generic variety representation, generic structures and generic planning. The large number On of different types of product items (including end-products) and the corresponding process elements involved in a process platform have been identified and described using unified ly 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 Page 6 of 36 modeling language (Zhang et al., 2007). To assist companies to benefit from the past production practice, Jiao et al. (2007b) put forward a data mining methodology to identify and form process families in relation to product families. Similarly, to facilitate configuration rule construction in process platforms, an approach based on association rule mining is discussed to obtain mapping relationships between product and process variety from large volumes of existing production data (Jiao et al., 2008). http://mc.manuscriptcentral.com/tprs Email: ijpr@lboro.ac.uk 6 Page 7 of 36 Dynamic modeling is to model the relevant processes involving objects being studied. As the core of process modeling, modeling techniques or languages have been investigated. There are two classes of process modeling languages using formal notations: visual diagrammatic process modeling languages and programming process modeling languages. Since the programming process modeling languages (Vernadat, 1993; Sutton et al., 1990) have strong limitations in readability and understandability, most process modeling has rP Fo employed diagrams. Diagrammatic representation that combines graphic notations and natural language-like strings as the formalism can facilitate readers’ understanding. The major diagrammatic process modeling languages can be summarized as simple process diagrams, advanced process diagrams and functional description diagrams. The ee simple process diagrams, such as traditional flow charts, material flow diagrams (Baudin, rR 1990) and acyclic networks (Hajdu, 1997), are simple, easy to use and understand. However, they are unable to express complicated execution relationships and have limited ev capacity in representing behavioral aspect of a process. With an attempt to include more information about processes, advanced process diagrams, e.g., process flow entity iew diagrams (Grabowski et al., 1996), event-driven process chains (Zukunft and Rump, 1996), IDEF3 (http://www.idef.com/Home.htm), event diagrams (Martin and Odell, 1992), Petri On nets (Peterson, 1981), role activity diagrams (Ould, 1995), have been developed. Compared with simple process diagrams, the advanced process diagrams can capture more ly 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 International Journal of Production Research information about processes from, e.g., organizational perspective, behavioral perspective. Nevertheless, most of such advanced process diagrams are unable to handle the exceptional and non-deterministic execution relationships. Furthermore, they lack the capability to represent processes from the informational and functional perspectives. While functional description diagrams, including IDEF0 (http://www.idef.com/Home.htm), object flow diagrams (Martin and Odell, 1992) and use case diagrams (Jacobson, 1992), http://mc.manuscriptcentral.com/tprs Email: ijpr@lboro.ac.uk 7 International Journal of Production Research are well-defined mechanisms to represent functional, informational and organizational perspectives of processes, they are unable to express the behavioral perspective. OO modeling notions and methods (Rumbaugh et al., 1991; Booch, 1994; Martin and Odell, 1996; Harmon, 1998) are powerful for dealing with modeling complexity in the real world and building a model in a comprehensive, expressive, understandable and structured formalism. The notions and technique are believed to provide an innovative and effective rP Fo way of modeling a variety of production activities in relation to diverse products as well. Recognizing the limitations of the diagrammatic process modeling languages and the power of OO notations and methods, Ma (1999) puts forward a language including a customer process flow diagram and an entity representation diagram to model service ee product design. With reference to his work, the OOVDML is devised in this study to rR model process platform’s application processes. 3. FUNDAMENTALS OF A PROCESS PLATFORM ev Current practice in design, be it product configuration or platform-based product family design, leads to the concept of product families. A product family consists of a set iew of customized, yet related, products which perform a same basic function. While customized products belonging to the same family assume a common product structure, On they differ with one another in optional features and functionalities. The design changes among family members impose necessary variations in converting abstract design ly 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 Page 8 of 36 concepts into physical products. On the other hand, the similarity and commonality inherent in product families, exhibited by similar and/or same raw materials, components, subassemblies and assemblies, makes it possible for companies to utilize similar production processes to fulfill product family members. Lu and Botha (2006) point out that unlike product development, process development has not received too much attention in today’s manufacturing environment because of the technical difficulties and managerial http://mc.manuscriptcentral.com/tprs Email: ijpr@lboro.ac.uk 8 Page 9 of 36 challenges to be considered. In response to the lack of research in process development, Zhang (2007) proposes process platforms to assist companies to plan similar, yet optimal, production processes for product families. The ultimate goal is to help companies achieve a near mass production efficiency in producing high product variety. A process platform entails a conceptual structure and overall logical organization of production processes to produce a product family. It provides a generic umbrella to rP Fo capture and utilize commonality, within which each new product fulfillment is instantiated and extended, and thereby anchoring process planning to a common structure. A process platform contains all data pertaining to the product family, e.g., items, quantity-per, parent-child relationships, and all production process data of the corresponding process ee family, e.g., operations types and precedence, work centers, machines, tools, standard rR cycle times, setup activities. With an attempt to include all product and process family data in a single structure without data redundancy, the concept of generic variety representation ev (van Veen, 1992) is adopted to organize data in process platforms. In a process platform, the specific data pertaining to individual products and iew production processes is organized as a generic product structure of the product family and as a generic process structure of the process family in relation to the product family, On respectively. As a result, the two generic structures are common to all members in product and process families. Further, they are integrated into a single structure, called generic ly 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 International Journal of Production Research product-process structure, which is fundamental to the process platform. The integration is achieved by adopting the mapping relationships between two sets of family data. Figures 1 and 2 show conceptually the generic product-process structure, the generic product structure and the corresponding generic process structure, respectively. As shown in the figures, each node in the generic structures is either a generic product item or a generic process in relation to a generic product item. While a generic product http://mc.manuscriptcentral.com/tprs Email: ijpr@lboro.ac.uk 9 International Journal of Production Research item represents a family of item variants (or individual items) of the same type, a generic process refers to the set of production processes to produce variants belonging to the corresponding item family. For example, A1 (in both figures) is a family of assemblies of type A1 and AP1 represents the set of assembly processes producing A1. A generic process is further decomposed into a set of ordered generic operations, as shown by the decomposition of, for example, AP4 in the Generic Process Structure in Figure 2. Each rP Fo generic operation, in turn, is described by generic process elements such as generic work centers (including tools, fixtures, jigs, etc.), cycle times and setups. Similarly, each such generic process element represents a family of process elements of the same type. <<<<<<<<<<<<<<<<<<<<<<Insert Figure 1 Here>>>>>>>>>>>>>>>>>>> ee <<<<<<<<<<<<<<<<<<<<<<Insert Figure 2 Here>>>>>>>>>>>>>>>>>>> The way of organizing product family data and process family data into a unified rR generic structure enables the simultaneous derivation of a bill of materials (BOM) and the corresponding bill of manufacturing resources and operations (BOMfrO) for a new design. ev While a BOM represents a product design and describes items level by level along the iew product hierarchy, a BOMfrO represents a production process and reveals operations, operations precedence and the set of manufacturing resources, e.g., machines, tools, fixtures, in accordance with items in the BOM. On With focus on the development of an appropriate language to model process platform’s application in high variety production, this study assumes the interested readers can get ly 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 Page 10 of 36 comprehensive and detailed information/knowledge about process platforms by referring to (Zhang, 2007). 4. THE OBJECT-ORIENTED VISUAL DIAGRAMMATIC MODELING LANGUAGE In most situations, a process flow consists of more than one activity. These activities interact with one another through a number of temporal and logical relationships. In line with activities and their relationships, execution transitions are defined as follows: http://mc.manuscriptcentral.com/tprs Email: ijpr@lboro.ac.uk 10 Page 11 of 36 Definition 1: An execution transition refers to a set of temporal and logical relationships among the executions of activities in a process flow. In the domain of production, the temporal and logical relationships can be classified into three basic types, including S(ai_aj): the temporal and logical relationship between activities ai and aj is sequential. It means that aj is performed only after the completion of ai. In other rP Fo words, the execution of one activity depends on the completion of another. P(ai_aj): the temporal and logical relationship between ai and aj is parallel. It means that ai and aj are executed either synchronously or asynchronously and there is no logical constraints on their execution. ee O(ai_aj): the temporal and logical relationship between ai and aj is optional. It rR means that either ai or aj rather than both can be executed under certain conditions. 4.1. Primary constructs, notations and semantics ev The OOVDML consists of 5 building blocks: StartPoint, AchievementPoint, ProductionActivityClass, ArrowLink and SequentialJunction. (1) ProductionActivityClass (PAC) iew It is common that similar production activities are always performed for some similar On objectives. From the OO point of view, the set of specific production activities can be generalized into a class. By incorporating OO concepts, a PAC is defined to represent a ly 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 International Journal of Production Research class of similar production activity instances. Such activity instances not only possess the similar structural properties but also are performed by the responsible functions or personal by following a common pattern. Figure 3 shows the notation of a PAC and an example. <<<<<<<<<<<<<<<<<<<<<<Insert Figure 3 Here>>>>>>>>>>>>>>>>>>> A PAC, drawn as a rectangle with 3 compartments, has a name, attributes and operations, as shown in Figure 3(a). Activity attributes describe the structural properties of http://mc.manuscriptcentral.com/tprs Email: ijpr@lboro.ac.uk 11 International Journal of Production Research a class of production activities. The activity attributes common to most production activity classes are identified as follows: • responsible functions: indicating the functions executing these activities; • processing time: showing the duration time of an activity; • frequency of occurrence: describing the frequency of an activity; and • constraints: concerning with the conditions that need to be met for an occurrence of rP Fo an activity to start, continue, or stop. Activity operations describe the behavioral property of a class of production activities, more specifically the processing steps. An activity starts when its operation is triggered; an activity terminates when its operation stops. ee The syntax of the production activity names, attributes and operations is defined as rR follows: ActivityName ዊ= Ipa: Gerund-phrase // Gerund-phrase: a gerund phrase string ev Ipa ዊ= PA IntegerNumber IntegerNumber ዊ= 1 | 2 | 3 | … iew ActivityAttribute ዊ= ActivityAttributeName = AttributeValue ActivityAttributeName ዊ= String // String: a string AttributeValue ዊ= STF // STF: a written representation in strings, tables, figures, or the combination of them On ActivityOperation ዊ= ActivityOperationName {ActivityScript} ActivityOperationName ዊ= Gerund-phrase ( ) | Verb-phrase ( ) ly 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 Page 12 of 36 ActivityScript ዊ= Script // Script: a script written in the natural language An Ipa is a code of a production activity instance of a class. A code is formed by a reserved word PA (production activity) and an integer number. A Gerund-phrase is a gerund phrase and is used as a part of a name string that can be understood literally. An ActivityAttributeName denotes the name of an activity attribute and an AttributeValue represents a value of an attribute. An ActivityOperationName and an ActivityScript define the name and specification of an activity operation, respectively. http://mc.manuscriptcentral.com/tprs Email: ijpr@lboro.ac.uk An 12 Page 13 of 36 ActivityOperationName can be either a Gerund-phrase or a Verb-phrase. An ActivityScript is written in the mode of a script in the natural language. A Script describes the prescriptive actions of the responsible function or personal, the critical conditions under which the actions happen and the involved inputs/outcomes. An example of a script of a PAC: Managing demand is as follows: After completing the calculation of the forecasted product demand, they submit the rP Fo result to the coordinator. The coordinator analyses all the received results to assure the completeness of demand information, e.g., the sources and quantity. Subsequently, he communicates the obtained final demand information to planners responsible for production planning and master production planning… (2) ArrowLink and SequentialJunction ee They are two building blocks representing precedence execution transitions in the rR process flow of production activities. Figure 4 shows an ArrowLink and a SequentialJunction. ev <<<<<<<<<<<<<<<<<<<<<<Insert Figure 4 Here>>>>>>>>>>>>>>>>>>> An ArrowLink indicates one-way traffic to “transmit” an execution control flow. It iew paves a section of road for execution transition from the completion of some activities to the starting of others. A SequentialJunction acts as a “transformer” and transforms its incoming execution control flows into its outgoing flows. While the incoming execution On control flows refer to the control flows on the ArrowLinks that connect to the SequentialJunction by their arrow ends, or head ends, the outgoing execution control flows ly 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 International Journal of Production Research are the flows on the ArrowLinks that connect to the SequentialJunction by their tail ends. A set of control conditions, under which the incoming execution control flows are transformed into outgoing flows, make up the control mechanism. An ArrowLink is represented by an adorned arrow line with an arrow end and a tail end. The adornment in the form of a string sits near the arrow line and identifies the ArrowLink. A SequentialJunction is represented by an adorned solid bar and a dashed-rectangle tag. http://mc.manuscriptcentral.com/tprs Email: ijpr@lboro.ac.uk 13 International Journal of Production Research Similarly, the adornment in the form of a string is placed near the solid bar and identifies the SequentialJunction. The strings on the tag describe the set of control conditions. When a SequentialJunction connects only two ArrowLinks, the tag is allowed to be omitted. In this case, the default control condition is when the incoming ArrowLink receives execution control flow, the outgoing ArrowLink does. The strings are written in predicate formulas. Such formulas are able to provide a convenient and flexible mode to define the control rP Fo conditions in concise propositions. The basic components of strings include two predicates, three connectives and related semantics conventions as follows: Predicates: (1) signal(x): ArrowLink x has an execution control flow; and ee (2) event(e): event e occurs. rR Connectives: (1) : (conjunction) means “and”; (2) : (disjunction) indicates “or”; and (3) ev : (conditional symbol) means “if… then…”. Related semantics conventions: n iew For ArrowLink x that connects to a PAC by the head end, when signal(x) becomes true, an activity defined by the connected PAC will eventually happen, i.e., start. n On When an activity defined by a PAC completes or terminates, signal(x) becomes true for ArrowLink x connecting to the PAC by its tail end. n ly 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 Page 14 of 36 When a StartPoint is initiated, signal(x) becomes true for ArrowLink x that connects to the StartPoint by its tail end. n For ArrowLink x that connects to an AchievementPoint, when signal(x) becomes true, a process of production activities ends. With the above definitions and semantics, the OOVDML is able to represent three types of activities bearing the three temporal and logical relationships: http://mc.manuscriptcentral.com/tprs Email: ijpr@lboro.ac.uk 14 Page 15 of 36 (1) the activities that will start after one or more activities complete, i.e., S(ai_aj); (2) the activities that are performed in parallel, i.e., P(ai_aj); and (3) the activities that are performed optionally, i.e., O(ai_aj). The following examples explain how strings on the tags model the precedence execution transitions. Example 1. Figure 5 gives a fragment of a simplified production process flow with three rP Fo production activities: PA1, PA2 and PA3. The control condition represented by the tag attached to J1 describes the execution transition as follows: After the completion of the activities preceding ArrowLink ar1, all three activities: PA1, PA2 and PA3 are performed eventually. The control condition represented by the tag attached to J2 models the ee following execution transition. The necessary condition, under which activities following rR ar8 will be carried out, is the completion of PA1 and PA2, or PA3. <<<<<<<<<<<<<<<<<<<<<<Insert Figure 5 Here>>>>>>>>>>>>>>>>>>> ev Along with the completion of activities some events may occur. Hence, such events are considered as the cause of triggering certain activities. In such cases, predicate event(e) iew can be used to define the relevant control condition. Example 2. The control condition represented by the tag attached to J2 in Figure 6 models the below execution transition. On <<<<<<<<<<<<<<<<<<<<<<Insert Figure 6 Here>>>>>>>>>>>>>>>>>>> After activity PA2 is finished, ly 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 International Journal of Production Research (1) if event e3i: option A specified by the customer happens, then PA3i will be performed; (2) if event e3j: option B specified by the customer happens, then PA3j will be performed; and (3) if event e3k: option C specified by the customer happens, then PA3k will be performed. http://mc.manuscriptcentral.com/tprs Email: ijpr@lboro.ac.uk 15 International Journal of Production Research In Figure 6, the tag attached to J1 is omitted and the default control condition is that when ar1 receives an execution control flow, ar2 obtains the execution control flow as well. (3) StartPoint and AchievementPoint: A StartPoint denotes a start point. It indicates the initiation of a process flow of production activities. A start point attribute can be used to represent the name of the process flow. An AchievementPoint denotes the ending point rP Fo of a process flow of production activities. When necessary, an achievement point attribute is used to indicate the noticeable “achievements”. Figure 7 shows the notation examples of a StartPoint and an AchievementPoint. A StartPoint is represented by a circle with strings in the centre indicating the start point attribute. An AchievementPoint is represented by a ee rounded rectangle. When necessary, strings can be put in the centre to denote its attribute. rR <<<<<<<<<<<<<<<<<<<<<<Insert Figure 7 Here>>>>>>>>>>>>>>>>>>> 4.2. Arrangement rules ev The following rules are defined to connect rationally the primary constructs, thus modeling process platform’s behaviors. R1. For a StartPoint, • there is only one ArrowLink that connects to the StartPoint by its tail end. On R2. For an AchievementPoint, • iew there is only one ArrowLink that connects to the AchievementPoint by its head end. R3. For a PAC, • there ly 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 Page 16 of 36 exist two different ArrowLinks. One connects to the PAC by its head end and the other by its tail end. R4. For an ArrowLink, any one of the following cases is valid. • Its tail end connects to a SequentialJunction and the head end connects to a PAC. • Its tail end connects to a PAC and the head end connects to a SequentialJunction. http://mc.manuscriptcentral.com/tprs Email: ijpr@lboro.ac.uk 16 Page 17 of 36 • Its tail end connects to a SequentialJunction and the head end connects to another SequentialJunction. R5. For a SequentialJunction, • there is one or more ArrowLinks that connect to the SequentialJunction by their respective head ends; and • there is one or more ArrowLinks that connect to the SequentialJunction by their rP Fo respective tail ends. R6. For two different SequentialJunctions, • there exists either only one or no ArrowLink that directly connects to the two SequentialJunctions by its two ends. ee 5. INDUSTRIAL EXAMPLE rR The industrial example adopted is the production of vibration motors for mobile phones in an electronics company. While vibration motors for mobile phones are not so ev complicated compared with others, the degree of their product complexity allows the modeling of process platform’s application by reflecting real world situations as more as iew possible. Due to the frequent design changes to mobile phones, motors must be customized to match the requirements of these diverse mobile phones. In spite of the fact On that such individual motors have certain items in common, they have their distinct design specifications, thus imposing different production requirements. Different from the mass ly 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 International Journal of Production Research production environment in the past, the current manufacturing environment in the company is characterized by diverse customized motors, low production volumes, short delivery lead-times and increasingly reduced costs. Together with the limited manufacturing resources, these characteristics complicate the company’s production from every aspect: planning, scheduling, execution, etc. Taking production process planning as an example, the production process for producing a standardized motor in the mass http://mc.manuscriptcentral.com/tprs Email: ijpr@lboro.ac.uk 17 International Journal of Production Research production environment may not be optimal when various motors are to be fulfilled using the same set of manufacturing resources within a same time period. For illustrative simplicity, modeling process platforms using the proposed OOVDML has been applied to a motor family. Figure 8 shows the common product structure of the motor family and, Figure 9 shows a simplified version of the generic product-process structure underpinning the process platform of the motor family. Furthermore, this case rP Fo study focuses on process platform modeling with respect to activities pertaining to production job planning, customer order processing and engineering change control. <<<<<<<<<<<<<<<<<<<<<<Insert Figure 8 Here>>>>>>>>>>>>>>>>>>> <<<<<<<<<<<<<<<<<<<<<<Insert Figure 9 Here>>>>>>>>>>>>>>>>>>> 5.1. ee Customer order processing While viewed from a broad viewpoint, customer order processing encompasses the rR entire process ranging from customer order entry, production, to the shipping of endproducts, it relates to activities pertaining to customer order entry in a narrow aspect. ev The company adopts various functional requirements to constitute product catalogues iew representing the motors that they can offer. Such product catalogues are expected to facilitate customer order entry since customers are more familiar with general functions fulfilled by motors rather than technical details. The company accommodates the On functional representation of individual motors through identifying specific items by variety parameters and the corresponding value instances. In this regard, functional requirements ly 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 Page 18 of 36 are associated with options, i.e., generic items, in their process platforms. Since functional requirements relate to generic items in a process platform, each functional requirement specified in a customer order can be described by an instance of a generic item with respect to specific parameter values, i.e., {FR} ~ {Generic item. Parameter = Parameter value}, that is, a specific item. Hence, variety parameters coherently link functional requirements in a customer order to the corresponding motors http://mc.manuscriptcentral.com/tprs Email: ijpr@lboro.ac.uk 18 Page 19 of 36 and constitute items. By incorporating production job planning (to be introduced below), the company derives both BOMs and BOMfrOs from the process platform and further generates the set of production job data. Therefore, the process platform performs as a well-structured mechanism that ties customer orders to the corresponding BOMs, BOMfrOs and production job data, and thus facilitate the management of customer orders in their production fulfillment. rP Fo In line with the fact that the company has applied various functional requirements at different levels to represent their motor offerings, Table 1 shows a customer order, represented by a list of functional requirements, with a lost size: 50 units. Figure 10 shows the process of processing the customer order. ee <<<<<<<<<<<<<<<<<<<<<<Insert Table 1 Here>>>>>>>>>>>>>>>>>>>> rR <<<<<<<<<<<<<<<<<<<<<Insert Figure 10 Here>>>>>>>>>>>>>>>>>>> 5.2. Engineering change control ev An engineering change (EC) refers to a change and/or a modification in material, dimension, form, fit or function of an item, be it a part, an assembly, or an end-product, iew after the design is released (Maull et al., 1992). It is common that each EC causes a series of down-stream changes along the product development process across a company where On multi-disciplines work together dealing with these induced changes. As a result, various functions across a company have to adjust their activities in order to deal with ECs and ly 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 International Journal of Production Research their impacts. Hence, for the purpose of production management, ECs must be made to relevant BOM files and be managed as a part of the engineering change control (ECC) process. This coincides with the observations from 1) Terwiesch and Loch (1999): ECs consume one third to one half of the total engineering capacity and represent 20-50% of total tool costs; and 2) McIntosh (1995): ECs occur frequently for continuous improvement and determine as much as 70 to 80% of the final cost of a product. As http://mc.manuscriptcentral.com/tprs Email: ijpr@lboro.ac.uk 19 International Journal of Production Research claimed by Tavcar and Duhovnik (2005), companies’ ability to manage engineering changes efficiently reflects their agility. Failure to control ECs and manage the corresponding ECC process inevitably leads to the production of low quality (sometimes even unwanted) products, higher production costs and delayed order deliveries. Since the company’s production involves a high variety of customized motors coupled with small quantities and short delivery lead times, ECs become more serious due to the rP Fo various design changes. With the process platform, the company can manage ECs effectively, through defining both BOMs and BOMfrOs based on different values of variety parameters in accordance with design changes. For any EC proposal, the systematic analysis of possible implementations of the ee change, i.e., new item design, is required. In their previous production, such analysis was rR time and effort-consuming. With the process platform, the company can perform the analysis effectively. First, the generic product and process structures eliminate the time to ev analyze the costly and/or technically infeasible product items to implement the proposal. The reason is that the two generic structures provide all the technically and economically iew feasible designs for both motors and the constituent items. Consequently, the process platform confines the analysis of infeasible implementation by considering the company’s On existing design and manufacturing capabilities. Second, the simultaneous derivation of BOMs and the corresponding BOMfrOs in response to possible design proposals enables ly 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 Page 20 of 36 multiple functions in the company to assess concurrently the impacts with respect to time and cost of changes on activities to be carried out in their own functional areas. The combination of the functional requirements in the order in Table 1 necessitate new bracket assembly. Thus the company has performed ECC on the process platform, as shown in Figure 11. After processing the order and conducting engineering changes, the motor in terms of BOM is obtained, as shown in Table 2. http://mc.manuscriptcentral.com/tprs Email: ijpr@lboro.ac.uk 20 Page 21 of 36 <<<<<<<<<<<<<<<<<<<<<Insert Figure 11 Here>>>>>>>>>>>>>>>>>>> <<<<<<<<<<<<<<<<<<<<<<Insert Table 2 Here>>>>>>>>>>>>>>>>>>> 5.3. Production job planning A production job encompasses a series of tasks to be finished for producing an item, be it a part, an assembly, or an end-product. A production job may not directly correspond to a customer order nor does it necessarily have to be related to a particular one. They are rP Fo either to satisfy needs that arise from customer orders or to simply serve for inventory purpose. On the other hand, any production jobs relate to known product design, more specifically BOMs which are a common representation format of design. Accordingly, production job planning is to specify due dates, lot sizes, a picking list of all required ee material items and a corresponding list of manufacturing resources and associated rR operations, i.e., a production process. With the integrated generic product-process structure, the process platform not only ev provides the company with a planning standard, according to which all reporting formats of the traditional BOMs and production processes for an item can be generated but also iew facilitates the company to create jobs and to plan their variations. According to the production need, the company derives the BOM of an item to be produced from the On process platform by instantiating a set of variety parameters with respect to the set of value instances that define the item. Interested readers can refer to the approach to deriving ly 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 International Journal of Production Research BOMs from a process platform in (Jiao et al., 2007a; Zhang, 2007). Since in the process platform, the company has integrated both the generic and specific product and process data by a set of variety parameters and their value instances, for any customer order, the company derives the proper BOM in conjunction with the corresponding BOMfrO level by level along the generic product-process structure embedded in the process platform. In addition, the company adopts the concept of generic http://mc.manuscriptcentral.com/tprs Email: ijpr@lboro.ac.uk 21 International Journal of Production Research planning (Jiao et al., 2007a; Zhang, 2007) to ensure the selection of proper product data and production process data. The company generates the complete production job data by considering the corresponding due date and lot size. This is accomplished by associating the BOM data with the corresponding BOMfrO data based on the materials-operations links embedded in the process platform. In materials-operations links, product items of the proceeding rP Fo operations become the material items of the immediately following operations. The company also adopts some constraints of job sequence when generating the set of production job data. One example of sequence constraints is that the job making a parent item cannot be started until the jobs producing its child items are completed or partially ee finished. The obtained production job data not only are necessary for the company to carry rR out production execution activities but also are essential for the company to perform production control activities, e.g., checking the availability of materials and manufacturing ev resources so as to ensure the completion of the relevant jobs within the due dates. In addition, the company has improved the maintenance and modification of iew production job data based on the process platform. The reason is that the only required work of modifying an existing set of production job data in accordance with new customer On orders is to copy the relevant data and paste them in another file rather than modifying the process platform. Table 3 shows the corresponding production job data in accordance with ly 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 Page 22 of 36 the motor in Table 2 obtained through the process of planning production jobs, shown in Figure 12. <<<<<<<<<<<<<<<<<<<<<<<<Insert Table 3 Here>>>>>>>>>>>>>>>>>> <<<<<<<<<<<<<<<<<<<<<<Insert Figure 12 Here>>>>>>>>>>>>>>>>>> http://mc.manuscriptcentral.com/tprs Email: ijpr@lboro.ac.uk 22 Page 23 of 36 While the above three processes have their different focus areas, they have certain overlap due to the adoption of the process platform in Figure 9. The common sub-process is circled by red double lines in the three processes. 6. CONCLUSIONS In view of the significance of process platforms for managing production of high product variety in manufacturing environments nowadays, this study proposed to model rP Fo process platforms with focus on the application processes. Accordingly, the OOVDML was put forward to cope with the modeling difficulties. The industrial example has revealed several advantages of the OOVDML for modeling process platform’s application. ee First, the diagrammatic representation visualizes an overall picture of process platform’s application process in a holistic view. This, in turn, provides a starting point for companies rR to understand, analyze and further improve the process in consideration. Second, the welldefined syntax and semantics offer a thorough understanding and rigorous interpretation of ev activities, personal, their relationships, etc. in process platform’s application processes. iew Consequently, in conjunction with the diagrammatic representation they enable companies to be aware of the impacts of any changes to activities, personal and their relationships on the application processes. Third, the OO modeling techniques along with the texts allow On the application processes to be documented easily at different levels of granularity, which provides different people with their own interests. ly 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 International Journal of Production Research Nevertheless, the OOVDML has its limitations. With focus on the modeling of process platform’s application processes, the OOVDML does not pay attention to a process platform itself. Consequently, it cannot shed light on the variety of constituent elements and their complicated relationships inherent in a process platform. This may provide an opportunity to extend this study. In future research, a comprehensive modeling language/formalism may be developed based on several well-defined modeling techniques. http://mc.manuscriptcentral.com/tprs Email: ijpr@lboro.ac.uk 23 International Journal of Production Research Such a comprehensive modeling language should be able to capture and model both process platforms and their application processes. The resulting models can, thus, be expected to reflect the interactions between process platforms and their application, based on which companies can make improvements on process platforms and/or application processes eventually. Another avenue for directing future research would be to develop a computer-aided rP Fo system incorporating the OOVDML. Companies’ legacy systems may be integrated with such a system so that the system is able to capture real-time data and information, thus providing more accurate information for companies to make right decisions in adding, removing, modifying activities in the application processes. ACKNOWLEDGEMENTS rR ee The author would like to thank two anonymous reviewers and the editor for their insightful and constructive comments on the earlier version of this paper. REFERENCES iew ev Baudin M., Manufacturing Systems Analysis. 1990, Yourdon Press Computing Series. Booch G., Object-Oriented Analysis and Design. 1994, Benjamin/Cummings Publishing Company, Inc. On Grabowski H., Furrer M., Renner D. and Schmid C., Implementation of information system supporting engineering process based on World Wide Web. In: Scholz-Reiter, ly 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 Page 24 of 36 B., Stickel, E. (Eds.), 1994, Business Process Modeling, Springer, Berlin. Hajdu M., Networks Scheduling Techniques for Construction Project Management. 1997, Kluwer Academic Publishers, Dordrecht. Harland C., Knight L., Lamming R. and Walker H., Outsourcing: Assessing the risks and benefits for organizations, sectors and nations. International Journal of Operations & Production Management, 2005, 25, pp. 831-850. http://mc.manuscriptcentral.com/tprs Email: ijpr@lboro.ac.uk 24 Page 25 of 36 Harmon P., Understanding UML: The Developer’s Guide: With a Web-based Application in Java. 1998, Morgan Kaufmann Publishers, San Francisco. http://www.idef.com/Home.htm Jacobson I., The Object-Oriented Software Engineering. 1992, Addsion-Wesley Publishing Company. 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Business Process Modeling, 1996, Springer, Berlin. http://mc.manuscriptcentral.com/tprs Email: ijpr@lboro.ac.uk 27 International Journal of Production Research rR ee rP Fo End EndProduct Product (P) (P) ev AP4 (WAP4,TAP4,SAP4) QA1 A1 A1 QI2 I2 (WAP3,TAP3,SAP3) (WAP1,TAP1,SAP1) (WMP2,TMP2,SMP2) AP3 MP2 QCI C1 QA11 A11 A11 QC5 C5 R2 AP2 (WAP2,TAP2,SAP2) QC3 C3 Assembly Assembly (A) (A) W – Work Center Q – Quantity Per MP QI1 I1 (WMP1,TMP1,SMP1) MP1 QC4 C4 Raw Material (R) : Assembly Process QC6 C6 R1 Purchased Part (C) S – Setup T – Cycle time : Manufacturing Process Intermediate Part (I) ly AP AP1 On QC2 C2 QA12 A12 A12 iew 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 Page 28 of 36 Figure 1: The integrated generic product-process structure of a process platform http://mc.manuscriptcentral.com/tprs Email: ijpr@lboro.ac.uk 28 Page 29 of 36 (a) Generic Product Structure (b) Generic Process Structure End End Product Product(P) (P) QA1 A1 A1 QCI QA11 A11 A11 C1 QC2 C2 QSA12 A12 A12 Q2 I2 QC5 C5 QC6 C6 R2 (WMP2, TMP2,SMP2) Intermediate Part (I) Purchased Part (C) MO : Manufacturing Operation (W ,T ,SAO ) AP 4 1 (W ,T ,SAO ) AP W – Work Center AP4 AO (WAP1, TAP1,SAP1) AP1 AP4 AO1AP4 AO2AP4 AP4 1 AP4 2 MP1 (WMP1, TMP1,SMP1) (WMP1, TMP1,SMP1) MP1 1 MO (W ,T MP1 MP1 MO 1 ,SMO MP1 1 ) MP1 MP2 R1 Raw Material (R) : Assembly Operation AP 4 2 AO (WAP2, AP2 TAP2,SAP2) (WAP4, TAP4,SAP4) AP4 (WAP4, TAP4,SAP4) (WAP3, AP3 TAP3,SAP3) QI1 I1 QC3 QC4 C3 C4 Assembly Assembly(A) (A) AO AP4 rP Fo : Assembly Process MP S – Setup Q – Quantity Per : Manufacturing Process T – Cycle time Figure 2: The generic product and process structures of a process platform PA2: Preparing materials ActivityName ActivityAttribute Responsible person = material handler processing time = range from x hours to y hours ActivityOperation Prepare() {… prepare the required materials according to the work order…} (a) PAC notation (b) A production activity example rR ee Figure 3: Notation of a PAC and a production activity example ev ar1 J9 xxx xxxx SequentialJunction (J9 is the identity) iew ArrowLink (ar1 is the identity) Figure 4: An ArrowLink and a SequentialJunction ar2 ar5 ar3 Signal(ar1) signal(ar2) signal(ar3) signal(ar4) ar8 ar7 J1 ar6 ly J2 PA2:... ar1 On PA1:... ar4 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 International Journal of Production Research PA3:... Signal(ar5) signal(ar6) signal(ar7) signal(ar8) Figure 5: A fragment of a production process flow http://mc.manuscriptcentral.com/tprs Email: ijpr@lboro.ac.uk 29 International Journal of Production Research PA3 i: Selecting option A PA1:Receiv ing customer order PA2:Analyzing customer require ments ar2 ar1 J2 ar3 ar3i ar3 j PA3 j: Selecting option B J1 ar3 k Signal(ar3) event(e3i) signal(ar3i), Signal(ar3) event(e3j) signal(ar3j), Signal(ar3) event(e3k) signal(ar3k) PA3 k: Selecting option C rP Fo Figure 6: The tag attached to J2 ee xx A StartPoint with attribute An AchievementPoint without attribute rR Figure 7: Example notations of StartPoint and AchievementPoint iew ev Vibration Motor Armature Assembly Frame Assembly Coil Assembly Washer Frame Bracket Assembly Magnet Assembly Weight ly On 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 Page 30 of 36 Bracket A Bracket B Terminal Shaft : Parts Coil Commutator Magnet Magnet Housing : Assemblies Figure 8: The common product structure of a motor family http://mc.manuscriptcentral.com/tprs Email: ijpr@lboro.ac.uk 30 Page 31 of 36 Operation Sequence Vibration Motor Material requirement X – Quantity Per S – Setup Intermediate Part T – Cycle Time Avm (W-Avm,T-Avm,S-Avm) Subassembly W – Workcenter XQw Weight Purchased Part XQmb Mainbody XQrh Rubber Holder Operation Raw material Amb (W-Amb,T-Amb,S-Amb) XQaa Armature Assembly rP Fo XQfa Frame Assembly Aaa (W-Aaa,T-Aaa,S-Aaa) XQs Shaft XQca Coil Assembly XQba Bracket Assembly Afa (W-Afa,T-Afa,S-Afa) XQf XQm XQba Frame Magnet Bracket A Aba (W-Aba,T-Aba,S-Aba) XQbb Bracket B XQt Terminal (W-Aca,T-Aca,S-Aca) Aca XQtp XQcm Tape Commutator XQc Coil ee (W-Mc,T-Mc,S-Mc) Mc RMc (W-Mf, Mf T-Mf, S-Mf) RMf (W-Mba, (W-Mbb, (W-Mt, Mba T-Mba, Mbb T-Mbb, Mt T-Mt, S-Mba) S-Mbb) S-Mt) RMba RMbb RMt rR Figure 9: The process platform of the motor family iew ev ly On 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 International Journal of Production Research http://mc.manuscriptcentral.com/tprs Email: ijpr@lboro.ac.uk 31 International Journal of Production Research PA2:Selecting proper options ar1 J1 ar61 J2 ar82 responsible person = material handler Prepare(){… prepare the required materials according to the generated PJD...} event 2: required material calculated Store(){… store the undelivered vibration motors…} event 3: required resources calculated event 4: delivery date postponed iew Signal(ar83) ዊ signal(ar84) signal(ar9) ar7 event 1: due date and lot size calculated ev ar84 PA51:Preparing the materials Signal(ar63) ዊ signal(ar7) signal(ar71) rR ar83 ar71 PA72:Storing the motors J8 ar9 J6 Produce(){… start to produce the vibration motors after all the preparations are ready...} Signal(ar72) signal(ar81), Signal(ar72) event(e4) signal(ar82) Generate(){… generate a set of PJD based on the BOM and the BOMfrO data for the vibration motor...} ar62 ar72 responsible function = prod. dept. ee ar81 PA4:Generating a set of PJD Signal(ar51) ዊ event(e2) ዊ event(e3) signal(ar61) ዊ singal(ar62) PA6:Producing the motors J4 ar51 Prepare(){… prepare the required manufacturing resources based on the generated PJD...} J7 Deliver(){… deliver the motors to the customer within the due date...} Signal(ar41) ዊ event(e1) signal(ar5) J5 ar3 ar21 PA71:Delivering the motors responsible func. = shipping dept. Derive(){… derive the BOM and the BOMfrO from the process platform at the same time…} PA52:Preparing the required manufacturing resources ar63 ar2 Receive(){… receives orders for a large number of vibration motors…} ar4 Signal(ar31) signal(ar4) Signal(ar21) signal(ar3) PA1:Receiving the customer orders receiving frequency = irregular ar31 ar41 Select options(){… select the proper options from the process platform in accordance with the functional features specified in the customer order...} Signal(ar1) signal(ar2) PA3: Deriving the BOM and the BOMfrO data J3 ar5 Customer order processing flow rP Fo Figure 10: Processing the customer order in Table 1 ly On 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 Page 32 of 36 http://mc.manuscriptcentral.com/tprs Email: ijpr@lboro.ac.uk 32 Page 33 of 36 J2 PA1:Receiving EC application J1 ECC process flow ar2 ar1 request source=external or internal ar21 PA2:Deriving the BOM and BOMfrO ar3 Derive(){… derive the relevant BOM and BOMfrO in accordance with the customer order from the process platform…} Receive(){receive EC application either from internal or external…} Signal(ar51) signal(ar6) Signal(ar21) signal(ar3) Signal(ar31) signal(ar4) ar31 Signal(ar1) signal(ar2) J3 ar4 PA4:Selecting design parameters and corresponding values ar51 ar6 evaluation method = xxx test Evaluate(){… evaluate the feasibility and reliability of the new design...} J5 Signal(ar73) event(e2) signal(ar82) Location = shop floor ar73 Test(){… test the new design at a small quantity in order to find the potential problems…} event 2: pilot run failed event 3: new design rejected by customer Responsible = sales personnel J7 Signal(ar41) signal(ar72) signal(ar82) signal(ar91) signal(ar5) PA8:Adding new data J8 ar83 ar92 Inform(){… inform the customer of the change, new design and the testing result...} rR event 1: evaluation failed ar81 Gather(){… gather info. for the requested change and analyze...} PA7:Informing the customer ee ar82 processing time = depend on the nature of requested change Add data(){… add the new BOM and BOMfrO data to the process platform…} ar93 ar61 ar71 Signal(ar73) signal(ar81), Signal(ar61) event(e1) signal(ar72) PA6:Pilot running ar41 ar91 Signal(ar61) signal(ar71), PA3:Gathering information and analyzing J4 Select(){… select proper design parameters and corresponding values based on the analysis result...} ar72 J6 ar5 Signal(ar83) signal(ar92), Signal(ar83) event(e3) signal(ar91) Signal(ar93) signal(ar10) J9 ar10 PA5:Evaluating new design rP Fo ev Figure 11: An ECC process in relation to the customer order in Table 1 iew ly On 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 International Journal of Production Research http://mc.manuscriptcentral.com/tprs Email: ijpr@lboro.ac.uk 33 International Journal of Production Research ar22 PA1: Deriving a BOM in accordance with the functional requirements in the customer order PA2: Deriving the corresponding BOMfrO data processing time = 3 hours or so J1 ar1 processing time = 3 hours or so Derive(){… derive the set of BOMfrO data from the process platform in conjunction with the derivation of the BOM…} ar21 Production job planning process flow Derive(){… derive the corresponding BOM data level by level from the process platform…} Signal(ar1) signal(ar21) ar24 Signal(ar24) signal(ar23) event(e1) signal(ar3) J2 ar42 ar3 Event 1: due data and lot size calculated ዊ signal(ar22) ar23 rP Fo PA41:Carrying out the relevant production control activities PA3:Generating the set of PJD Generate(){… generate the set of PJD for the motor based on the derived BOM and BOMfrO data incorporating the additional info. such as the lot size and due date…} ar31 ar41 responsible person = production personnel Control production(){… use the set of PJD to check the availability of the materials and manufacturing resources as required…} responsible person = planner Modify PJD(){… modify the set of PJD for different customer orders…} signal(ar43)ዊsignal(ar44) rR Signal(ar31) PA42:Modifiying the set of PJD for new customer orders J3 responsible person = planner ee signal(ar41) ዊ ዊsignal(ar32) signal(ar5) signal(ar42)ዊ signal(ar32) ar44 ar43 ar5 ar32 J4 ev Figure 12: Planning production jobs for the customer order in Table 1 iew ly On 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 Page 34 of 36 http://mc.manuscriptcentral.com/tprs Email: ijpr@lboro.ac.uk 34 Page 35 of 36 Table 1: A customer order Order #: xxxxx Due date:xxxxx Customer Info.:xxxxxxx Delivery:xxxxxxx Volume: 50 Description:xxxxxxxxxx Functional Requirements: Rubber Holder. Color = Red Weight. Width = 5mm Shaft. Diameter = 3mm Shaft. Length = 16mm Frame. Thickness = 3mm Frame. Length = 20mm Magnet. Length = 14mm Bracket A. Shape = L Bracket A. Color = Red Bracket A. Width = 6mm Bracket B. Shape = L Bracket B. Color = Red Bracket B. Width = 6mm Terminal. length = 6mm Terminal. Width = 5mm Tape. Color = Red Tape. Width = 3mm Commutator. Thickness = 2mm rR ee rP Fo Table 2: The motor specified in the customer order in Table 1 ev Hierarchy Level Generic Item Parameter Value Parameter Value Quantity per 1 1 1 .2 .2 .2 ..3 ..3 ..3 ..3 ...4 ...4 ...4 C_R W_5 3mm 16mm D_3 L_16 3mm 20mm 14mm L Red 6mm L Red 6mm 6mm 5mm 1mm 3mm 2mm T_3 L_20 L_14 S_L C_R W_6 S_L C_R W_6 L_6 W_5 1 1 1 1 1 1 1 1 1 D_1 W_3 T_2 1 1 1 ly ..3 Red 5mm On ..3 ..3 Rubber holder Color Weight Width Mainbody Armature Assy Frame Assy Bracket Assy Diameter Shaft Length Coil Assy Frame Thickness Length Length Magnet Bracket A Shape Color Width Bracket B Shape Color Width Terminal Length Width Coil Diameter Tape Width Commutator Thickness iew 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 International Journal of Production Research 1 1 1 1 http://mc.manuscriptcentral.com/tprs Email: ijpr@lboro.ac.uk 35 International Journal of Production Research 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 Page 36 of 36 Table 3: The PJD for producing the motor in Table 2 Job Sequence no. no. 20 50 Operation Fo Work center Tool Machine rP Cycle time (Sec./item x Lot Size) Component/Material (Quantity) Product (Lot size) Component job no. 1 9.25 x 50 Weight (1x50) Rubber Holder (1x50) MainbodyAssy(1x50) Vibration Motor (1x50) N/A N/A 19 1 9.25 x 50 Armature Assy (1x50) Frame Assy (1x50) Bracket Assy (1x50) Mainbody Assy (1x50) 18 15 13 Supporting holderI PalletII 1 5.00 x 50 Armature Assy (1x50) 17 1 5.00 x 50 Coil Assy (1x50) 16 1 4.50 x 50 Wsitting jigI WcaulkingheadI - vm WcaulkingMcI Vibration motor assembly WC-A ee 19 40 Mainbody assembly FcaulkingMcHS - mb AinsertingMcV WC-A 18 30 Armature assembly WC-A - aa 17 20 Coil assembly - ca WC-A Guiding jigIII 16 30 Coil fabrication WC-M - c Cwinding McV5 TrayII Sinserting and Soldering Mc. Labor No./wc Fixture Caulking bladeII Bracket holderL rR FholderI MholderVII ev 15 20 Frame assembly - fa FMpressingMc. WC-A 14 10 Frame fabrication - f FstampingMcI WC-M Die 13 20 Bracket assembly - ba Bfusing McII. WC-A BinserterV 12 10 10 10 Bracket A fabrication Bracket B fabrication Terminal fabrication - ba BinjectionMc04 BadjustorA BlocatorA WC-M - bb BinjectionMc04 BadjustorA Bprealignment jigI WC-M - t Tcutting McI WC-M DieII TholderIII Holder01 Bpressing jigAI Coil Assy (1x50) Shaft (1x50) Coil (1x50) Tape (1x50) Commuter (1x50) Raw Material (1set x50) Coil (1x50) Frame Assy (1x50) N/A 1 4.50 x 50 Magnet (1x50) Frame (1x50) 1 5.00 x 50 Raw Material (1set x50) Frame (1x50) N/A 1 4.00 x 50 Bracket A (1x50) Bracket B (1x50) Terminal (1x50) Bracket Assy (1x50) 12 1 1 1 5.25 x 50 5.25 x 50 Raw Material (1set x50) Bracket A (1x50) Bracket B (1x50) Terminal (1x50) N/A iew 5.00 x 50 On http://mc.manuscriptcentral.com/tprs Email: ijpr@lboro.ac.uk 14 ly 36