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Gary John Colquhoun a Thesis Submitted in Fulfilment of The DEVELOPMENTS TO GRAPMCAL MODELLING METHODS AND THEIR APPLICATION IN NUNUFACTURING SYSTEMS ANALYSIS AND DESIGN Gary John Colquhoun A thesis submittedin fulfilment of the requirementsof Liverpool John Moores University for the degreeof Doctor of Philosophy April 1996 ACKNOWLEDGEMENTS An enormousdebt of gratitude is owed to Ray Baines my supervisor, friend, mentor and advisor for the last nine years. I-Iis enthusiasm,unstinting support, incisive critique and encouragement were freely given at a stage in his own careerthat gave him little time for the luxury of research. Through his humour I have kept a senseof proportion andby his exampleI have learnt the need for comniitment. To my wife lean, my backboneand inspiration through yearsof part thne study and for her support through the changesthat shook our fives ten yearsago - this is the last, I promise. My thanks to the present Director of the School of Engineeringand Technology Managementat Liverpool John Moores University and the past headsof the Department of Mechanical, Marine and Production Engineeringwho have provided their supportthroughout the work. I would alsolike to acknowledgethe contributionof CannonIndustries, Scholl Consumer Products andBSD SteelService Centres for supportingthe casestudies reported in the thesis. In particular SteveMon at BSD Leedsfor his enthusiasticsupport of the useof modelling. ABSTRACT Systemsmodelling methods have evolved out of the need to understandand analysecomplex human/machine/objectsystems. This researchaims to contribute to the use of static graphical modelling methods as a meansof gaining insight, analysing,designing and developing strategies for changein manufacturingenterprise systems. The research is introduced through a discussion of the factors underlying modelling in manufacturing enterprises. The successof IDEF methods in the US defence manufacturing industry has strongly influenced this work and their developmentis reviewed. Findings from a survey of published IDEF methods research are reported and an investigation of IODEFo modelling practice in the UK is accomplishedusing a survey of modelling practitioners. The surveys and a comparative analysis of a range of modelling methods provide a basis to contextualise IDEFo modelling and review the potential to expand its capability. Reference models for manufacturingsystems are analysedand an BDEForeference model casestudy is used to demonstratetheir capacity to provide significant improvementsin aspectsof the modelling process. An investigation of systemsarchitectures and frameworks provides a precursor to proposalsto combine IDEFo and IIDEF3 methods in the context of a manufacturing enterprise modelling framework. A modelling approachis developedby combiningthe two methodsin a novel composite IDEFO- 3 method that has the capability to describe the behavioural characteristicsof manufacturing systems. The model syntax is refined and tested and an IIDEFO-3methodology is developed. The new method is validated through a casestudy in a batch manufacturingcompany currently undergoing re-organisation to expand its manufacturingcapability. IDEFO-3 is shown to be capable of capturing and representingthe perceptionsof domain experts, providing sufficient resolution for analysis and substantiallyinfluencing the design of an improved TO BE model. The research concludes that IDEFO-3 is able to represent features of systems hitherto not possible to describe using IDDEFoor IIDEF3 as individual methods, that it allows meaningful analysisand that it can effectively contribute to manufacturingenterprise systemsanalysis and design. iii CONTENTS ACFNOWLEDGEDvlENTS ii ..................................................................................... ABSTRACT iH ............................................................................................................ CONTENTS iv ........................................................................................................... LIST OF FIGURES viii ................................................................................................. LIST OF TABLES )d .................................................................................................. NOMENCLATURE xii ................................................................................................ CHAPTER 1 INTRODUCTION 1.1 PREAMBLE 1 ................................................................................. 1.2 M[ANUFACTURING GLOBAL CONTEXT 2 -A ........................... 1.3 SYSTEMS CONCEPTS 4 ................................................................ 1.3.1 Manufacturing Systems 6 ............................................................. 1.3.2 System 7 complexity and modelling................................................ 1.4 IDEFo FUNCTIONAL MODELLING 9 ........................................... 1.5 RESEARCH OBJECTIVES 10 .......................................................... 1.6 RESEARCH M[ETHODOLOGY 11 ................................................... 1.7 CONTRIBUTION TO KNOWLEDGE 12 ......................................... 1.8 VALIDATION OF TIHE RESEARCH 13 .......................................... CHAPTER 2 THE IDEF METHODS 2.1 INTRODUCTION 15 ......................................................................... 2.2 A REVIEW OF TIiE ICAM PROGRAMME 15 ................................ 2.3 A FUSTORICAL PERSPECTIVE OF THE IDEF METHODS 18 ..... 2.3.1 A development IDEFo 18 reviewof tile of ....................................... 2.3.2 The development IDEF 20 of associated methods............................ 2.4 THE LATEST GENERATION OF IDEF METHODS 22 .................. CHAPTER 3 PUBLISHED IDEFo AND IDEF3 RESEARCH 3.1 INTRODUCTION 25 ......................................................................... 3.2 STANDARD REFERENCE SOURCES 26 ........................................ 3.3 A STATE OF THE ART REVIEW OF IDEFo 27 ............................. 3.3.1 Category1: Descriptions basic 28 andreviews of principles............ 3.3.2 Category2: Performance 29 evaluations,and comparisons ............. 3.3.3 Category3: Proposed 32 enhancementsof the method ..................... 3.3.4 Category4: Applications 36 of themethod ...................................... 3.4 A REVIEW OF PUBLISBED IDEF3 RESEARCH 37 ....................... 3.5 A SURVEY OF IDEFo PRACTITIONERS 40 ................................... iv 3.5.1 Questionnairedesign 40 ................................................................... 3.5.2 Results 41 of the survey.................................................................. 3.5.3 An 46 analysisof surveyresults ...................................................... 3.6 CONCLUSIONS 49 ........................................................................... CHAPTER 4A COMPARATIVE ANALYSIS OF MANUFACTURING ENTERPRISE SYSTEMS ANALYSIS AND DESIGN METHODS 4.1 INTRODUCTION 52 ......................................................................... 4.2 CONTEXT FOR A COMPARATIVE ANALYSIS 53 ....................... 4.3 SOFT SYSTEMS MODELLING METHODS 55 .............................. 4.4 INFORMATION SYSTEM MODELLING METHODS 57 ............... 4.5 'IS'MODELLING METHODS IN THE CONTEXT OF MANUFACTURING SYSTEMS 62 .................................................. 4.6 'HARD' SYSTEMS MODELLING METHODS 63 .......................... 4.7 GRAPHICAL REPRESENTATION 64 ............................................. 4.8 A STRUCTURED COMPARATIVE ANALYSIS 65 ........................ 4.9 CONCLUSIONS 71 ........................................................................... CHAPTER5 REFERENCESTRUCTURESFOR NL4NUFACTURING ENTERPRISE MODELLING 5.1 I1,4TRODUCTION 74 ........................................................................ 5.2 MANUFACTURING SYSTEMS ARCI-HTECTURES 74 ................. 5.2.1 CIM-OSA 76 .............................................................................. 5.2.2 TheZachman Framework 78 ....................................................... 5.3 REFERENCE MODELS FOR KANUFACTURING SYSTEMS 82 .................................................................................... 5.3.1 ne applicationof an IDEForeference model of process plannin .................................................................................82 5.3.2 Derivingan AS-IS modelusing a genericmodel of process plannin .................................................................................85 5.3.3 Conclusions the 86 on useof a referencemodel ............................ 5.4 A MANUFACTURING ENTERPRISE MODELLING FRAMEWORK 90 ............................................................................ 5.4.1 Conclusionsfrom themanufacturing enterprise modelling - framework . ..............................................................................93 CHAPTER 6A COMPOSITE BEHAVIOURAL MODELLING APPROACH 6.1 INTRODUCTION 102 ......................................................................... 6.2 A BLUEPRINT FOR ENTERPRISE MODELLING METHODS. 103 6.3 STAGE I-A CASE STUDY USING IDEFo AND IDEF3 105 ........... 6.3.1 A 1 110 reviewof stage ................................................................. A3.1 IDEFO 224 ..................................................................................................... A3.2 IDEF3 ...................................................................................................226 A3.3 IDEFo AND IDEFix MODELLING TOOLS ........................................227 A3.4 IDEF1 ...................................................................................................231
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