IDEAS home Printed from https://ideas.repec.org/a/inm/ormnsc/v50y2004i1p83-98.html
   My bibliography  Save this article

Benefits of Skill Chaining in Serial Production Lines with Cross-Trained Workers

Author

Listed:
  • Wallace J. Hopp

    (Department of Industrial Engineering and Management Sciences, Northwestern University, Evanston, Illinois 60208-3119)

  • Eylem Tekin

    (Department of Operations Research, University of North Carolina at Chapel Hill, Chapel Hill, North Carolina 27599-3180)

  • Mark P. Van Oyen

    (Department of Information Systems and Operations Management, Loyola University Chicago, 25 East Pearson Street, Chicago, Illinois 60611-2196)

Abstract

To gain insight into the potential logistical benefits of worker cross-training and agile workforce policies, we study simple models of serial production systems with flexible servers operating under a constant work-in-process (CONWIP) release policy. Two important and interrelated issues are: (a) how to decide which skill(s) are strategically most desirable for workers to gain, and (b) how to coordinate these workers to respond dynamically to congestion. We address these by considering two cross-training strategies: a straightforward capacity-balancing approach, which we call cherry picking (CP), and an innovative overlapping zone strategy that we call skill chaining. Our comparison shows that skill-chaining strategies have the potential to be robust and efficient methods for implementing workforce agility in serial production lines.

Suggested Citation

  • Wallace J. Hopp & Eylem Tekin & Mark P. Van Oyen, 2004. "Benefits of Skill Chaining in Serial Production Lines with Cross-Trained Workers," Management Science, INFORMS, vol. 50(1), pages 83-98, January.
    • Handle: RePEc:inm:ormnsc:v:50:y:2004:i:1:p:83-98
    DOI: 10.1287/mnsc.1030.0166
    as

    Download full text from publisher

    File URL: http://dx.doi.org/10.1287/mnsc.1030.0166
    Download Restriction: no
    File URL: https://libkey.io/10.1287/mnsc.1030.0166?utm_source=ideas
    LibKey link: if access is restricted and if your library uses this service, LibKey will redirect you to where you can use your library subscription to access this item
    ---><---

    References listed on IDEAS

    as
    1. Emil Zavadlav & John O. McClain & L. Joseph Thomas, 1996. "Self-Buffering, Self-Balancing, Self-Flushing Production Lines," Management Science, INFORMS, vol. 42(8), pages 1151-1164, August.
    2. Chung-Yee Lee & George L. Vairaktarakis, 1997. "Workforce Planning in Mixed Model Assembly Systems," Operations Research, INFORMS, vol. 45(4), pages 553-567, August.
    3. McClain, John O. & Thomas, L. Joseph & Sox, Charles, 1992. ""On-the-fly" line balancing with very little WIP," International Journal of Production Economics, Elsevier, vol. 27(3), pages 283-289, October.
    4. Askin, Ronald G. & Iyer, Anand, 1993. "A comparison of scheduling philosophies for manufacturing cells," European Journal of Operational Research, Elsevier, vol. 69(3), pages 438-449, September.
    5. Avishai Mandelbaum & Martin I. Reiman, 1998. "On Pooling in Queueing Networks," Management Science, INFORMS, vol. 44(7), pages 971-981, July.
    6. John O. McClain & Kenneth L. Schultz & L. Joseph Thomas, 2000. "Management of Worksharing Systems," Manufacturing & Service Operations Management, INFORMS, vol. 2(1), pages 49-67, July.
    7. John J. Bartholdi & Donald D. Eisenstein, 1996. "A Production Line that Balances Itself," Operations Research, INFORMS, vol. 44(1), pages 21-34, February.
    8. Oded Berman & Richard C. Larson & Edieal Pinker, 1997. "Scheduling Workforce and Workflow in a High Volume Factory," Management Science, INFORMS, vol. 43(2), pages 158-172, February.
    9. Richard Conway & William Maxwell & John O. McClain & L. Joseph Thomas, 1988. "The Role of Work-in-Process Inventory in Serial Production Lines," Operations Research, INFORMS, vol. 36(2), pages 229-241, April.
    10. Gerard M. Campbell, 1999. "Cross-Utilization of Workers Whose Capabilities Differ," Management Science, INFORMS, vol. 45(5), pages 722-732, May.
    11. Stephen C. Graves & Brian T. Tomlin, 2003. "Process Flexibility in Supply Chains," Management Science, INFORMS, vol. 49(7), pages 907-919, July.
    12. William C. Jordan & Stephen C. Graves, 1995. "Principles on the Benefits of Manufacturing Process Flexibility," Management Science, INFORMS, vol. 41(4), pages 577-594, April.
    13. B. Curtis Eaves & Uriel G. Rothblum, 1988. "A Discrete Time Average Cost Flexible Manufacturing and Operator Scheduling Model Solved by Deconvexification Over Time," Operations Research, INFORMS, vol. 36(2), pages 242-257, April.
    Full references (including those not matched with items on IDEAS)

    Most related items

    These are the items that most often cite the same works as this one and are cited by the same works as this one.
    1. Seyed M. Iravani & Mark P. Van Oyen & Katharine T. Sims, 2005. "Structural Flexibility: A New Perspective on the Design of Manufacturing and Service Operations," Management Science, INFORMS, vol. 51(2), pages 151-166, February.
    2. Eylem Tekin & Wallace J. Hopp & Mark P. Van Oyen, 2002. "Benefits of Skill Chaining in Production Lines with Cross-Trained Workers: An Extended Abstract," Manufacturing & Service Operations Management, INFORMS, vol. 4(1), pages 17-20.
    3. Askin, Ronald G. & Chen, Jiaqiong, 2006. "Dynamic task assignment for throughput maximization with worksharing," European Journal of Operational Research, Elsevier, vol. 168(3), pages 853-869, February.
    4. Sennott, Linn I. & Van Oyen, Mark P. & Iravani, Seyed M.R., 2006. "Optimal dynamic assignment of a flexible worker on an open production line with specialists," European Journal of Operational Research, Elsevier, vol. 170(2), pages 541-566, April.
    5. Sigrún Andradóttir & Hayriye Ayhan & Douglas G. Down, 2001. "Server Assignment Policies for Maximizing the Steady-State Throughput of Finite Queueing Systems," Management Science, INFORMS, vol. 47(10), pages 1421-1439, October.
    6. S.M.R. Iravani & J.A. Buzacott & M.J.M. Posner, 2005. "A robust policy for serial agile production systems," Naval Research Logistics (NRL), John Wiley & Sons, vol. 52(1), pages 58-73, February.
    7. Seyed M. R. Iravani & Bora Kolfal & Mark P. Van Oyen, 2007. "Call-Center Labor Cross-Training: It's a Small World After All," Management Science, INFORMS, vol. 53(7), pages 1102-1112, July.
    8. Eser Kırkızlar & Sigrún Andradóttir & Hayriye Ayhan, 2012. "Flexible Servers in Understaffed Tandem Lines," Production and Operations Management, Production and Operations Management Society, vol. 21(4), pages 761-777, July.
    9. Wallace J. Hopp & Seyed M. R. Iravani & Biying Shou, 2005. "Serial Agile Production Systems with Automation," Operations Research, INFORMS, vol. 53(5), pages 852-866, October.
    10. Chen, Jiaqiong & Askin, Ronald G., 2006. "Throughput maximization in serial production lines with worksharing," International Journal of Production Economics, Elsevier, vol. 99(1-2), pages 88-101, February.
    11. Sayin, Serpil & Karabati, Selcuk, 2007. "Assigning cross-trained workers to departments: A two-stage optimization model to maximize utility and skill improvement," European Journal of Operational Research, Elsevier, vol. 176(3), pages 1643-1658, February.
    12. Gregory Dobson & Tolga Tezcan & Vera Tilson, 2013. "Optimal Workflow Decisions for Investigators in Systems with Interruptions," Management Science, INFORMS, vol. 59(5), pages 1125-1141, May.
    13. Sigrún Andradóttir & Hayriye Ayhan & Douglas G. Down, 2007. "Compensating for Failures with Flexible Servers," Operations Research, INFORMS, vol. 55(4), pages 753-768, August.
    14. Eser Kırkızlar & Sigrún Andradóttir & Hayriye Ayhan, 2010. "Robustness of efficient server assignment policies to service time distributions in finite‐buffered lines," Naval Research Logistics (NRL), John Wiley & Sons, vol. 57(6), pages 563-582, September.
    15. John Boudreau & Wallace Hopp & John O. McClain & L. Joseph Thomas, 2003. "On the Interface Between Operations and Human Resources Management," Manufacturing & Service Operations Management, INFORMS, vol. 5(3), pages 179-202, September.
    16. Wallace J. Hopp & Seyed M.R. Iravani & Biying Shou & Robert Lien, 2009. "Design and control of agile automated CONWIP production lines," Naval Research Logistics (NRL), John Wiley & Sons, vol. 56(1), pages 42-56, February.
    17. Gnanlet, Adelina & Gilland, Wendell G., 2014. "Impact of productivity on cross-training configurations and optimal staffing decisions in hospitals," European Journal of Operational Research, Elsevier, vol. 238(1), pages 254-269.
    18. John O. McClain & Kenneth L. Schultz & L. Joseph Thomas, 2000. "Management of Worksharing Systems," Manufacturing & Service Operations Management, INFORMS, vol. 2(1), pages 49-67, July.
    19. Sigrún Andradóttir & Hayriye Ayhan, 2005. "Throughput Maximization for Tandem Lines with Two Stations and Flexible Servers," Operations Research, INFORMS, vol. 53(3), pages 516-531, June.
    20. Achal Bassamboo & Ramandeep S. Randhawa & Jan A. Van Mieghem, 2012. "A Little Flexibility Is All You Need: On the Asymptotic Value of Flexible Capacity in Parallel Queuing Systems," Operations Research, INFORMS, vol. 60(6), pages 1423-1435, December.

    Corrections

    All material on this site has been provided by the respective publishers and authors. You can help correct errors and omissions. When requesting a correction, please mention this item's handle: RePEc:inm:ormnsc:v:50:y:2004:i:1:p:83-98. See general information about how to correct material in RePEc.

    If you have authored this item and are not yet registered with RePEc, we encourage you to do it here. This allows to link your profile to this item. It also allows you to accept potential citations to this item that we are uncertain about.

    If CitEc recognized a bibliographic reference but did not link an item in RePEc to it, you can help with this form .

    If you know of missing items citing this one, you can help us creating those links by adding the relevant references in the same way as above, for each refering item. If you are a registered author of this item, you may also want to check the "citations" tab in your RePEc Author Service profile, as there may be some citations waiting for confirmation.

    For technical questions regarding this item, or to correct its authors, title, abstract, bibliographic or download information, contact: Chris Asher (email available below). General contact details of provider: https://edirc.repec.org/data/inforea.html .

    Please note that corrections may take a couple of weeks to filter through the various RePEc services.

    IDEAS is a RePEc service. RePEc uses bibliographic data supplied by the respective publishers.