Application of Systems-Theoretic Analysis to Work Movement in Production Systems

Abstract

In the aerospace industry, long product lifecycles, life extension programs, and highly specialized manufacturing capabilities combine to produce a challenge for Original Equipment Manufacturers (OEMs) in providing aftermarket support for fielded products. These factors drive the need for a work movement capability, where production of a product is physically relocated from one facility to another. The dynamics of work movement efforts are especially challenging when external suppliers are involved.

This thesis presents the results of an application of Causal Analysis based on Systems Theory (CAST) to a loss of producibility following the movement of a production process from a supplier to an aerospace OEM. In addition to the principal analysis, background information is presented on the relevant production systems and processes, company structure, and the theoretical basis of the CAST process in Systems-Theoretic Accident Model and Processes (STAMP) and systems theory.

In this thesis, CAST is shown as an effective tool for analysis of production systems by its ability to explain the loss of producibility that occurred following the work movement in question. In addition, the thesis demonstrates the utility of the STAMP control structure model for organizational analysis, and recommendations are provided to improve the functioning of production management organizations.