CONCEPTUAL DESIGN OF LEAN PRODUCTION SYSTEMS THROUGH AN AXIOMATIC APPROACH

In this paper, we are to present a practical application of Axiomatic Design (AD) methodology as a roadmap to lean production, in a car body assembly line. In addition to product development, AD has already been applied for manufacturing system design but we tend to expand its application to production system design, which besides manufacturing includes all activities required to satisfy customer needs. AD theory provides a framework to simplify the whole problem. According to the AD principles, a hierarchical structure for conceptualization of lean philosophy has been developed. This structure originates in lean manufacturing principles. We argue that three essential bases of lean production are organizational capabilities, technological capabilities, and value stream analysis, represented as top DPs in the structure. These basic capabilities are interdependent and self-reinforcing. Among these DPs, organization capabilities would take priority over other others because implementation lean practices in a company require a lean organization. Therefore, DP2 'Developing required organizational capabilities for lean production' is decomposed to lower levels first. This is performed by means of zigzagging. Having completed conceptually the production system design through AD, we have developed an operational procedure for implementation practices. The main stages of the procedure are 1) Develop a lean strategy. 2) Train the employees. 3) Eliminate nonessential infrastructural resources. 4) Performance measurement. 5) Establish a baseline. 6) Identify opportunities. 7) Prioritize opportunities. 8) Develop and implement the lean improvement plan. 9) Measure, monitor, and improve. 10) Hold the gains. 11) Strive for perfection. While the hierarchical structure act as a guideline, the procedure specifies the course of actions. both of them could be applied for other applications. We are trying to redesign this production system based on the conceptual model, represented as AD structure, as well as the operational procedure.