A Group AHP-based Tool to Evaluate Effective Factors Toward Leanness in Automotive Industries

Zulkifli, 'RM.Yusuff, 3y Ismail and 4S.M.H. HojjatilDepartment ofIndustrial Engineering and Management, Gachsaran Branch, lAD, Gachsaran, Iran'DepartmentofMechanical and Manufacturing Engineering, UPM, Malaysia3Department ofManufacturing Engineering, UMP, Malaysia4Department ofIndustrial Engineering, ShirazBranch, lAD, Shiraz, IranAbstract: In dealing with global markets and international standards the organizations require the use ofengineering methods ofnew management. Lean manufacturing is one ofthe management philosophies, as asystematic approachregarding to eliminating waste inthe productionprocess byusing all assets ofa company.The aim ofstudy was to identify the challenges faced by the automotive industry inIran. The next objectivesare to identify and prioritize factors that would support implementation of Lean Manufacturing in theautomotive industry. The methodology is based on two phases, with in Phase 1 (qualitative), ten effectivefactors (10 Ms) were selected. Moreover inthis phase more than50 sub-factorswere identified inthe researchliterature. In Phase 2 (quantitative), experts were asked to assign an importance value to each factor and thegroup AHP technique was used to prioritize the effective factors and sub-factors.The result ofthis study canbe used for lean managers, experts and senior managers who wantto implement lean in companies. Itshowsthe mainfactors to leanness andto prioritize them.Keywords: Group analytic hierarchy process (GAHP), leanness, automotive industry, effective factor, 10MsINTRODUCTIONAutomotive industries play an important role in theoverall development of cOlllltries (Mather et al., 2007).Automotive industries are facing the challenges ofglobalization; therefore, the need for an integratedapproach to continuous assessment of these challengesIS essential (Forouzan and Mirassadallahi, 2008).Countries that are changing after revolution, suchas Iran,face additional challenges. Manufacturing firms willexperience changes during this transition and factorssuch as: performance, technology, cost competitiveness;product quality, after-sales servIce and customersatisfaction will be differentiation factors in the markets(Moutabian, 2005). Consequently, in dealing withglobalmarkets and international standards, organizations requirethe use of new engineering methods of management.LeanManufacturing (LM) whichhas evolved and is nowreferred to as Leanthinking, is one ofthese managementphilosophies. Managementphilosophies allow a businessthe opportunity to measure and analyze the execution ofthe process so that lead to continuous improvement(Owaied