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.
All Science Journal Classification (ASJC) codes