System of Systems Approach in Production: Theory to Action

Abstract

System of Systems (SoS) is a novel approach in practical field which has been widely studied and applied recognizably in military context by department of defense (DoD). But being versatile, the approach has a lot of potential to deliver in various other areas as well, for example, it is now on the verge to transcend the boundaries of defense system, and ready to be applied in industrial sector. This manuscript based dissertation mainly investigates and explores the last phrased facet, and offers a common platform for operational research and complex System of Systems. At the outset, focus of the study is to understand and pave the way to build theory of SoS. The established thoughts are marshaled while new insights are developed to shed light on the emerging concept of SoS. It tries to help resolve the identity crisis of SoS by proposing two edges of chaos, that is, SoS and monolithic systems self-organize at two opposite edges. Upon this understanding, it traces out the incapacitation of traditional military techniques for asymmetric warfare. The research also spotlights the necessity of creation of a generic System of Systems Architecture Framework (SoSAF) in line with the Department of Defense Architecture Framework (DoDAF). Then the academic research shifts its accent towards production systems. First of all, it attempts to answer the fundamental question whether production system falls under the scope of SoS or not, by devising and utilizing a general purpose framework for categorizing systems. It applies the SoS concepts in this field using the earlier proposed SoSAF paradigm to introduce a unique architecture for production system in three designing process phases. After that the research moves ahead to come up with a pioneering approach for managing risks of large complex SoS. The new methodology of System of Systems Axiomatic Risk Management (SoSARM) put forward here is an Axiomatic Risk (AR) based decomposition for resolving coupled risks. The developed theory and ideas have also been demonstrated for a typical production system following a step by step hierarchical approach which proved to be a very simple yet comprehensive concept to handle interdependent risks of multiple domains. In order to narrow the research sphere, the dissertation goes on to unearth the need to radicalize Lean Manufacturing (LM) with state of the art SoS concepts. Towards this objective, a new management framework has been designed and elaborated for an ‘SoS Lean' or ‘Smart Lean' system by assimilating SoS approach with LM. Aimed at supplementing to the SoS Engineer's repertoire, System of Systems Dynamics-SoSD (adapted from system dynamics) philosophy has also been proposed to model and simulate the aspects of SoS with the expectation to further enrich the notion. Based on the theory and frameworks established, rest of the research exploration focuses specifically on textile industry for their in depth assay and validity by performing two shop floor case studies. The first case study demonstrates a holistic perspective of a textile weaving mill located in Pakistan using stock and flow diagrams of SoSD. SoSD continuous modeling and simulation interventions proved to be a very effective modus operandi in strategic decision making support for capacity expansion of a weaving company. Then for the second case study accomplished at a spinning mill, a Smart Lean Spinning Framework was envisaged amalgamating SoS ideas with the prudently screened and selected tools of LM that are apt to textile industry. Subsequently, the proposed framework was modeled and simulated through DES to evaluate the impacts of diverse parameters culminating in successful implementation of the Smart Lean