Optimization of Manufacturing Process and Facility Design Using MFCA and TOC

Abstract

　This paper represents a theoretical study to maximize resource productivity and throughput using Material flow cost accounting (MFCA) and Theory of constraints (TOC) as outlined by Tobita (2013) [6]. As a case study of the metal stamping industry (small and medium‐sized enterprises) with a goal to achieve loss reduction using MFCA and TOC we also build on the work of Nakajima (2015) [7].

　In our research, we introduced both methods into the industrialization stage, instead of the existing production process and facility stage, in order to pursue a greater level of optimization. We also introduced the use of a biomaterial used for tissue engineering and regenerative medicine. This material is presently the focus of much attention in the medical industry. As the results of our study show we can reduce system costs by over 40% (Electric power consumption) when we construct a new facility. In addition, the overall manufacturing cost of the material can be reduced by almost 30%. We also found that the process throughput can be dramatically improved by as much as a 57% reduction.