A lean production system design for semiconductor crystal-ingot pulling manufacturing using hybrid Taguchi method and simulation optimization. Issue 3 (17th January 2020)

• Record Type: Journal Article
• Authors: Yang, Taho; Wen, Yuan-Feng; Hsieh, Zong-Rui; Zhang, Jianxia
• Is Part Of: Assembly automation. Volume 40:Issue 3(2020)
• Page Start: 433
• Page End: 445
• Publication Date: 2020-01-17
• Subjects: Lean manufacturing -- Simulation optimization -- Taguchi method -- Crystal-ingot pulling -- Dispatching; Automation -- Periodicals; Automatic machinery -- Periodicals; Assembly-line methods -- Periodicals; Industrial engineering -- Periodicals; 670.42705
• DOI: 10.1108/AA-11-2018-0193
• Languages: English
• ISSNs: 0144-5154

Abstract

Abstract : Purpose: The purpose of this study is to propose an innovative methodology in solving the lean production design from semiconductor crystal-ingot pulling manufacturing which is an important industry. Due to the complexity of the system, it is computationally prohibited by an analytical approach; thus, simulation optimization is adopted for this study. Design/methodology/approach: Four control factors that affect the system's performance, including the pulling strategy, machine limitations, dispatching rules and batch-size control, are identified to generate the future-state value stream mapping. Taguchi two-step procedure and simulation optimization are used to determine the optimal parameter values for a robust system. Findings: The proposed methodology improved the system performances by 6.42 and 12.02 per cent for service level and throughput, respectively. Research limitations/implications: This study does not investigate operations management issues such as setup reduction, demand forecasting and layout design. Practical implications: A real-world crystal-ingot pulling manufacturing factory was used for the case study. The results are promising and are readily applied to other industrial applications. Social implications: The improved performances, service level and throughout rate, can result in an improved customer satisfaction level and a reduced resources consumption, respectively. Originality/value: The proposed methodology innovatively solved a practical application and the results are promising.