Development of Enterprise Human System Modelling Framework in Support of Cellular Manufacturing Lean Operation

R. Abdullah, H. Hashim, M.N.A. Rahman, M.R. Salleh


Static or enterprise model stems from the need to understand the potential effect of certain parameters on the system performance. This paper describes the development of the human system framework focusing on the aspects of human attributes and human dynamics in the effort to achieve a leaner operation in the cellular manufacturing operation. The aim of this study is to propose a model to improve the accuracy in modelling human workload and competency based on the theoretical frameworks. Existing frameworks and models were reviewed and two models (M2M mathematical model and CIMOSA) were identified as the theoretical framework for this study. A new human system framework was designed with the improvement on the operator competency accuracy using Maynard Operational Sequence Technique. The new framework was also primarily designed to suit the cellular manufacturing environment through the inclusion of the equipment competency. As a result, company’s management is expected to be better informed on operator utilisation, man-machine configuration and operator non-value added activities.

Full Text:



S. K. Singh and M. K. Singh, “Evaluation of productivity, quality and flexibility of an advanced manufacturing system,” Journal of The Institution of Engineers: Series C, vol. 93, no. 1, pp. 93–101, 2012.

Y. K. Son and C. S. Park, “Economic measure of productivity, quality and flexibility in advanced manufacturing systems,” Journal of Manufacturing System, vol. 6, no. 3, pp. 193–207, 1987.

G. Battisti and A. Iona, “The UK productivity gap in the service sector: do management practices matter?,” International Journal of Production Performance Management, vol. 58, no. 8, pp. 727–747, 2009.

H. Singh, “A review and analysis of the state-of-the-art research on productivity measurement,” Industrial Management Data System, vol. 100, no. 5, pp. 234–241, 2006.

T. Grünberg, “A review of improvement methods in manufacturing operations,” Work Study, vol. 52, no. 2, pp. 89–93, 2003.

J. Antony, “Six sigma vs lean: some perspectives from leading academics and practitioners,” International Journal of Production Performance Management, vol. 60, no. 2, pp. 185–190, 2011.

F. A. Abdulmalek and J. Rajgopal, “Analyzing the benefits of lean manufacturing and value stream mapping via simulation: a process sector case study,” International Journal of Production Economics, vol. 107, no. 1, pp. 223–236, 2007.

B. Singh, S. K. Garg, S. K. Sharma, and C. Grewal, “Lean implementation and its benefits to production industry,” International Journal of Lean Six Sigma, vol. 1, no. 2, pp. 157–168, 2010.

R. Pew and S. Baron, “Perspectives on human performance modelling,” Automatica, vol. 19, no. 6, pp. 663–676, 1983.

L. Allender, “Modeling human performance: impacting system design, performance, and cost,” Simulation Series, vol. 32, no. 3, pp. 139–144, 2000.

K. Birdi, C. Clegg, M. Patterson, A. Robinson, C. B. Stride, T. D. Wall, and S. J. Wood, “The impact of human resource and operational management practices on company productivity: a longitudinal study,” Personal Psychology, vol. 61, no. 3, pp. 467–501, 2008.

P. O. Siebers and U. Aickelin, “A first approach on modelling staff proactiveness in retail simulation models,” Journal of Artificial Societies and Social Simulation, vol. 14, no. 2, pp. 1-25, 2011.

B. A. Norman, W. Tharmmaphornphilas, K. L. Needy, B. Bidanda, and R. C. Warner, “Worker assignment in cellular manufacturing considering technical and human skills,” International Journal of Production Research, vol. 40, no. 6, pp. 1479–1492, 2002.

T. S. Baines, R. Asch, L. Hadfield, J. P. Mason, S. Fletcher, and J. M. Kay, “Towards a theoretical framework for human performance modelling within manufacturing systems design,” Simulation Modelling and Practical Theory, vol. 13, no. 6, pp. 486–504, Sep. 2005.

S. K. Parker, T. D. Wall, and J. L. Cordery, “Future work design research and practice: towards an elaborated model of work design,” Journal of Occupational and Organisational Psychology, vol. 74, no. 4, pp. 413-440, 2001.

C. Viswesvaran and D. S. Ones, “Perspectives on models of job performance,” International Journal of Selection and Assessment, vol. 8, no. 4, pp. 216–226, 2000.

D. D. Souza and A. C. Wills, Objects, components, and framework with uml: the catalyst approach. Massachusetts: Addison Wesly Longman, 1998.

M. Jahangirian, T. Eldabi, A. Naseer, L. K. Stergioulas, and T. Young, “Simulation in manufacturing and business: a review,” European Journal of Operation Research, vol. 203, no. 1, pp. 1–13, 2010.

T. Masood and R. H. Weston, “Modelling framework to support decision-making in manufacturing enterprises,” Advance Decision Science, vol. 2013, pp. 1-23, 2013.

S. Khalil, R. H. Weston, and J. O. Ajaefobi, “People at work: modelling human performance in shop floor for process improvement in manufacturing enterprises” in IFIP Advances in Information and Communication Technology, Heidelberg, Berlin, vol. 307, pp 274-281, 2009.

G. Zülch and M. Becker, “A simulation-supported approach for man-machine configuration in manufacturing,” International Journal of Production Economics, vol. 125, no. 1, pp. 41–51, May 2010.

C. F. Chien, W. C. Chen, and S. C. Hsu, “Requirement estimation for indirect workforce allocation in semiconductor manufacturing,” International Journal on Production Research, vol. 48, no. 23, pp. 6959–6976, 2010.

L. Ma, W. Zhang, H. Fu, Y. Guo, D. Chablat, and F. Bennis, “A framework for interactive work design based on motion tracking, simulation and analysis,” Human Factors Manufacturing, vol. 20, no. 4, pp. 339–352, 2010.

M. Langer and D. Söffker, “Event-discrete formal representation of a semi-automated manufacturing process as framework for human guidance and assistance concepts: analysis and application,” International Journal on Production Research, vol. 53, no. 8, pp. 2321-2341, 2015.

A. Abdmouleh, M. Spadoni, and F. Vernadat, “Distributed client/server architecture for cimosa-based enterprise components,” Computers in Industry, vol. 55, no. 3, pp. 239–253, 2004.

M. N. A. Rahman, R. Abdullah, and S. N. Khalil, “Human system modeling technique for semiconductor assembly and test,” Applied Mechanics of Material, vol. 761, pp. 624–628, 2015.

G. Egilmez, B. Erenay, and G. A. Süer, “Stochastic skill-based manpower allocation in a cellular manufacturing system,” Journal of Manufacturing System, vol. 33, no. 4, pp. 578-588, 2014.

J. O. Ajaefobi, R. H. Weston, B. Wahid, and A. Rahimifard, “Integrated approach to modelling human systems as reuseable components of manufacturing workplaces,” International Journal of Computer Integrated Manufacturing, vol. 23, no. 3, pp. 195–215, 2010.

R. Abdullah and R. Muhammad, “Man to machine ratio (M2M) technique for labor productivity improvement,” in Malaysian Technical University Conference, Johor, 2006, pp. 1–6.

R. Abdullah, N. Omar, and S. R. Kamat, “Work study for overall process efficiency at manufacturing company,” in International Conference on Engineering Education, Madinah, Kingdom of Saudi Arabia, 2013, pp. 22–25.

M. N. A. Rahman, R. Abdullah, and N. J. Kamarudin, “Work study techniques evaluation at back-end semiconductor manufacturing,” in International Conference on Design and Concurrent Engineering, Melaka, 2012, pp. 313–318.

© Journal of Advanced Manufacturing Technology