CONCURRENT MANUFACTURING SYSTEM OPTIMIZATION FOR TWO-PRODUCT OPERATION

Product/process design and optimization are typically aimed at a single product for a single customer. Such approach, however, often leads to underutilization of available production capacity. It is therefore reasonable for the manufacturer to make an effort to minimize available excess capacity to improve overall facility performance. Excess capacity can be allocated to the production of another product/process design, which can be also independently optimized. However, exploring possible synergies between the two products/processes may bring higher benefits. This paper presents a case where a manufacturing process (plastic blow moulding) was shared among two different products for two different customers, each with a different set of needs. These customer needs were mapped into core value-creating processes, recognizing both the differences in their requirements as well as the similarities in their expectations. Conflicting differences in complexity, production volumes and quality requirements were reconciled using QFD_based approach, and led to improved customer satisfaction and cost performance.