Modelling of manufacturing process complexity

Gaining momentum in several fields of study is the recognition of the need for a viewpoint that includes the human element as an integral part of the modem production system beyond traditional ergonomics. The "intellectual capital" is as much of a resource as money, materials, software and hardware. A model that considers the human players in tandem with the physical elements is needed to provide insights into the sensitivities of the manufacturing system. Using Systems Analysis and Design methods, a framework has been developed, which is valid for different perspectives and environments, to assess the elements of manufacturing complexity. The manufacturing complexity index allows people with diverse backgrounds to rapidly evaluate alternatives and risks with respect to the product, process or operation tasks. In this paper, the technique for evaluating the process complexity metric is presented. An analysis is performed comparing the relative process complexity for a power steering pump bracket that is manufactured in a CNC machining cell and a dedicated line. The areas of complexity are clearly evident. This provides insight for risk assessment as this systematic approach can be used to "mathematically" show tradeoffs for each important criterion during the design stages.