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Frontiers of Mechanical Engineering

ISSN 2095-0233

ISSN 2095-0241(Online)

CN 11-5984/TH

Postal Subscription Code 80-975

2018 Impact Factor: 0.989

Front. Mech. Eng.    2014, Vol. 9 Issue (3) : 218-232    https://doi.org/10.1007/s11465-014-0309-7
RESEARCH ARTICLE
Modelling and analysis of FMS productivity variables by ISM, SEM and GTMA approach
Vineet JAIN1,*(),Tilak RAJ2
1. Department of Mechanical Engineering, Amity University Haryana, Gurgaon 122413, India
2. Department of Mechanical Engineering, YMCA University of Science and Technology, Faridabad 121006, India
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Abstract

Productivity has often been cited as a key factor in a flexible manufacturing system (FMS) performance, and actions to increase it are said to improve profitability and the wage earning capacity of employees. Improving productivity is seen as a key issue for survival and success in the long term of a manufacturing system. The purpose of this paper is to make a model and analysis of the productivity variables of FMS. This study was performed by different approaches viz. interpretive structural modelling (ISM), structural equation modelling (SEM), graph theory and matrix approach (GTMA) and a cross-sectional survey within manufacturing firms in India. ISM has been used to develop a model of productivity variables, and then it has been analyzed. Exploratory factor analysis (EFA) and confirmatory factor analysis (CFA) are powerful statistical techniques. CFA is carried by SEM. EFA is applied to extract the factors in FMS by the statistical package for social sciences (SPSS 20) software and confirming these factors by CFA through analysis of moment structures (AMOS 20) software. The twenty productivity variables are identified through literature and four factors extracted, which involves the productivity of FMS. The four factors are people, quality, machine and flexibility. SEM using AMOS 20 was used to perform the first order four-factor structures. GTMA is a multiple attribute decision making (MADM) methodology used to find intensity/quantification of productivity variables in an organization. The FMS productivity index has purposed to intensify the factors which affect FMS.

Keywords FMS      ISM      EFA      SEM      GTMA     
Corresponding Author(s): Vineet JAIN   
Online First Date: 02 September 2014    Issue Date: 10 October 2014
 Cite this article:   
Vineet JAIN,Tilak RAJ. Modelling and analysis of FMS productivity variables by ISM, SEM and GTMA approach[J]. Front. Mech. Eng., 2014, 9(3): 218-232.
 URL:  
https://academic.hep.com.cn/fme/EN/10.1007/s11465-014-0309-7
https://academic.hep.com.cn/fme/EN/Y2014/V9/I3/218
Sr. No.Description of dataRangeDescription of firms
1Number of employeesLess than 1005
101-50025
501-100060
1001-300025
More than 3,00010
2Turnover (US$ million)Less than 1010
11-2045
21-10040
101-20020
More than 20010
Tab.1  Data of the responding companies
Sr. No.Qualitative measure of FMS factorAssigned value of FMS factor
1Exceptionally low1
2Extremely low2
3Very low3
4Below average4
5Average5
6Above average6
7High7
8Very high8
9Extremely high9
10Exceptionally high10
Tab.2  Inheritance of FMS factor
Sr. No.Qualitative measure of interdependence of FMS factorAssigned value (fij)
1Very strong5
2Strong4
3Medium3
4Weak2
5Very weak1
Tab.3  Values of interdependence of FMS factor
Variables201918171615141312111098765432
1VVOOOVOVVVVVVVVVVVO
2OOOOOOOOOOOVOOOOOV
3OOOOOOOOOOOOOOOOO
4VVVVOOOVVVAVVVVV
5OOOOOOOOOOOOOOO
6AAVVOAOVVOAAAA
7OOVVOAOVVOAAA
8OOVVOAOVVVAO
9AAAAAAVOVAA
10VVVVOVOVVV
11VVVVAAOVV
12OOOOOAAO
13OOAAAAO
14OOOOOO
15VVVVX
16VVVV
17AAA
18AA
19X
Tab.4  Structural self-interactive matrix
Variables1234567891011121314151617181920
110111111111110100011
201100000010000000000
300100000000000000000
400011111101110001111
500001000000000000000
600000100000110001100
700000111101110001100
800000111001110001100
900000100100101000000
1000010111111110101111
1100000000101110001111
1200000000000100000000
1300000000000010000000
1400000000100101000000
1500000111001110111111
1600000000101010111111
1700000000100010001000
1800000000100010001100
1900000100100000001111
2000000100100000001111
Tab.5  Initial reachability matrix
Variables1234567891011121314151617181920
110111111111111*11*1*1*11
20110000001001*01*01*1*1*1*
300100000000000000000
400011111101111*001111
500001000000000000000
600000100000110001100
700000111101111*00111*1*
80000011100111000111*1*
900000100100101000000
100001011111111011*1111
1100000000101110001111
1200000000000100000000
1300000000000010000000
1400000000100101000000
1500000111001110111111
1600000000101010111111
1700000000100010001000
1800000000100010001100
1900000100100000001111
2000000100100000001111
Tab.6  Final reachability matrix
No.VariablesReachability setAntecedent setIntersection setlevel
3Unit labor cost31, 2, 33I
5Customer satisfaction51, 4, 55I
12Unit manufacturing cost121, 4, 6, 7, 8, 9, 10, 11, 12, 14, 1512I
13Throughput time131, 2, 4, 6, 7, 8, 10, 11, 13, 15, 16, 17, 1813I
14Set up cost9, 141, 4, 7, 9, 149, 14II
17Reduction in material flow171, 2, 4, 6, 7, 8, 10, 11, 15, 16, 17, 18, 19, 2017III
18Reduced work in process inventory181, 2, 4, 6, 7, 8, 10, 11, 15, 16, 18, 19, 2018IV
6Reduction in scrap percentage61, 4, 6, 7, 8, 10, 15, 19, 206V
19Capacity to handle new product19, 201, 2, 4, 7, 8, 10, 11, 15, 16, 19, 2019, 20VI
20Ability to manufacture a variety of product19, 201, 2, 4, 7, 8, 10, 11, 15, 16, 19, 2019, 20VI
11Manufacturing lead time & setup time111, 4, 7, 8, 10, 11, 15, 1611VII
7Reduction in rework percentage7, 81, 4, 7, 8, 10, 11, 157, 8VIII
8Reduction of rejection7, 81, 4, 7, 8, 10, 11, 157, 8VIII
16Use of automated material handling devices15, 161, 10, 15, 1615, 16VIII
4Effect of tool life41, 4, 104IX
10Trained worker101, 1010X
1Training111XI
2Financial incentive222XI
Tab.7  Iterations (Level of Variable)
Variables3512139141718619201178151641012Drive Power
3100000000000000000001
5010000000000000000001
12001000000000000000001
13000100000000000000001
9001011001000000000004
14001011000000000000003
17000110100000000000003
18000110110000000000004
6001100111000000000005
19000010111110000000006
20000010111110000000006
11001110110111000000008
70011111111111100000012
80011001111111100000010
150011001111111111000012
16000110110111001100009
40111111111111100100014
100011101111111111110015
11111111111111111111019
2100100110110001001019
Dependence power3311131251413101111866543311
Tab.8  Conical matrix
Fig.1  An interpretive structural model showing the levels of FMS productivity variables
Sr. No.DimensionsVariables/ItemsFactor loadingCronbach’s alpha
1PeopleTrainingFinancial incentiveUnit labor cost0.8490.8540.8510.909
2QualityEffect of tool lifeCustomer satisfactionReduction in scrap percentageReduction in rework percentageReduction of rejection0.8560.8080.8210.8420.7890.953
3MachineEquipment utilizationTrained workerManufacturing lead time & setup timeUnit manufacturing costThroughput timeSet up cost0.8030.8510.8340.7800.7540.6400.942
4FlexibilityAutomationUse of automated material handling devicesReduction in material flowReduced work in process inventoryCapacity to handle new productAbility to manufacture a variety of product0.8480.8450.8300.8390.7640.8180.937
Tab.9  Extraction method: Principal Component Analysis, Rotation Method: Varimax with Kaiser Normalization with Reliability Statistics (EFA result)
Fig.2  Path diagram of SEM
Sr. No.DimensionsVariables/ItemsStandardized estimatep-value (* significant at p<0.001)AVECR
1PeopleTraining0.894*0.780.91
Financial incentive0.945*
Unit labor cost0.803*
2QualityEffect of tool life0.939*0.800.95
Customer satisfaction0.883*
Reduction in scrap percentage0.916*
Reduction in rework percentage0.886*
Reduction of rejection0.841*
3MachineEquipment utilization0.881*0.720.94
Trained worker0.948*
Manufacturing lead time & setup time0.911*
Unit manufacturing cost0.885*
Throughput time0.727*
Set up cost0.723*
4FlexibilityAutomation0.907*0.730.94
Use of automated material handling devices0.906*
Reduction in material flow0.880*
Reduced work in process inventory0.865*
Capacity to handle new product0.827*
Ability to manufacture a variety of product0.725*
Tab.10  Confirmatory factor analysis results
PeopleQualityMachineFlexibility
People0.780
Quality0.2700.800
Machine0.3250.4540.720
Flexibility0.2250.2700.2970.730
Tab.11  Discriminant Validity
Fig.3  Digraph for factors
Permanent function at the subsystem/system levelMaximum valueMinimum valueCurrent value
PerP1*136394888
PerP2*2328646001128676
PerP3*1447520770629856
PerP4*14727802756634644
PerP*676.64×101811.97×101145.67×1018
Tab.12  Maximum and minimum values of the permanent function
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