AHP에 의한 생산성과 향상기법의 중요도 평가에 관한 연구

Abstract

오늘날과 같이 치열한 국제경쟁에서 많은 제조기업들은 경쟁력 향상의 일환으로 초미세가공기술(microelectronics) 또는 정보기술을 생산과정에 접목시킨 CAD/CAM, FMS, MRPⅡ 등의 AMT(advanced manufacturing technology)와 정보기술 이외의 생산시스템혁신을 위한 생산관리기법인 JIT, TQM, TPM 등의 IMP(innovative managerial practice)를 도입하고 있다. 이는 제조기업의 실무종사자들이 AMT와 IMP를 기업의 경쟁력을 향상시키는 중요한 기법으로 인식하고 있기 때문이라 생각된다. 그러나 이들 생산시스템의 변화프로그램인 AMT와 IMP기법들이 생산성과에 미치는 영향에 대한 연구는 미진하다. 따라서 본 연구는 기업운영에 있어서 생산전략의 중요성을 이해하고 생산성과의 평가요소는 어떤 것이 있으며 이 요소들의 특성을 인지하고 실증적 연구를 통하여 시장경쟁의 전략적 차원에서 생산시스템의 성과향상프로그램인 AMT와 IMP기법들이 생산성과에 미치는 중요도를 평가하기 위하여 연구목적을 다음과 같이 설정하였다. 첫째, 기초연구로서 생산전략의 경쟁수단과 성과평가시스템의 이론적 배경을 통하여 생산성과 평가의 중요성을 인식하고 생산성과평가의 척도들을 조사하고 생산성과평가의 모형을 제시하였다. 둘째, 생산시스템의 성과향상프로그램인 AMT와 IMP가 생산성과 평가요소들에 대하여 어느 정도의 중요도를 지니고 있는지를 실증연구를 통하여 분석하였다. 셋째, 이와 같은 분석을 토대로 급격한 환경변화와 격심한 경쟁에서 지속적인 생산성과향상에 기여할 수 있는 합리적인 대안의 선택방향을 제시하였다. 특히, 조선 산업은 다양한 분야의 엔지니어링기술이 복합적으로 적용되는 산업으로 컴퓨터기술의 이용도가 타 산업분야에 비해 높으며, CAD/CAM을 중심으로 한 선박의 설계 및 생산시스템의 핵심 기술개발이 국제경쟁력 제고에 매우 필요한 기술이다. 따라서 본 논문에서는 조선 기업의 생산시스템의 핵심기술이라 할 수 있는 CAD/CAM, MRP2/ERP의 중요성도 확인해 보았다.

In order to cope with the pressure of international competition, many manufacturing companies have implemented new philosophies and new technologies. Many companies have responded to these competitive demands by implementing advanced manufacturing technologies(AMT), innovative managerial practices(IMP), and emphasizing quality, delivery, innovation and flexibility to meet customer needs in their corporate objectives. For several decades, performance measurement(PM) systems in use in manufacturing enterprises have remained unchanged in spite of significant transformations witnessed in management accounting approaches and production processes. The so-called traditional evaluation systems are currently outdated, no longer adequate and compatible to evaluate the new operating methods. As a result, many consultants, academics, and professionals have suggested that the new performance measurement approaches should support the day-to-day operations and provide managers, supervisors, and operators with information that is both timely and relevant. Innovative managerial practices(IMP) such as TQM, JIT, and TPM have often been referred to as components of "World Class Manufacturing". While there are many success stories and much research on TQM, JIT, and TPM, there are also documented cases of failure in the implementation of these programs. There has been insufficient research on the relationships between these programs and their combined impact on manufacturing performance. In this study, we identified the interrelationship between the three programs. The rapid developments in manufacturing technologies such as CAD/CAM, MRPⅡ, FMS, Robotics, and others, known collectively as advanced manufacturing technology(AMT), have changed the concept of competition and manufacturing role in it. Today, manufacturing technology has acquired a strategic significance that is unparalleled in the industrial history so far. The advantages of new manufacturing technologies have been widely proclaimed as part of the factory in the future. These advantages include large flexibility and control of the manufacturing processes. The objective of this research was to evaluate the priority from AMT and IMP for improving manufacturing performance in shipbuilding enterprises. The research consists of several principal steps. The first step was to design critical criteria in evaluating manufacturing performance in shipbuilding enterprises. The second step was to develop sub-criteria of the critical criteria. The third step was to develop a four level AHP(Analytic Hierarchy Process) structure using the critical criteria, sub-criteria and techniques from AMT and IMP. The fourth step was to develope the pair-wise comparison matrix by each level of AHP structure, which was based on survey data collected at the H shipbuilding enterprise. And the last step was to evaluate the priority from AMT and IMP by using AHP analysis. For detail research this study classified three categories ; served year on their job, one's place of duty, age. The results of AHP analysis did not show clear difference in the priority between 5 techniques of AMT and IMP in terms of manufacturing performance of the shipbuilding enterprise. Thus, each critical criterion was assigned modified weights and examined the priority change of techniques by conducting performance sensitivity analysis. Findings of this study can be summarized as follows; First, the result of this study presented bases for production managers of H shipbuilding enterprise to select AMT and IMP techniques in case of production strategy. The result of this study can also present guideline to improve manufacturing performance for the same kind of small and medium shipbuilding enterprises. We identified MRP2/ERP have the operational excellence in priority of manufacturing cost and flexibility ; CAD/CAM have the operational excellence in priority of quality and CAD/CAM is the most important manufacturing performance improvement technique in shipbuilding enterprise. Second, this study presented basic guidelines to minimize the trial and errors of implementation process and to improve the implementation performance for the shipbuilding enterprise considering or adopting AMT and IMP. Namely, to achieve the manufacturing performance effectively, we need to adopt the IMP based on AMT. Third, in our empirical study, we identified CAD/CAM and MRP2/ERP have the operational excellence among AMT. TQM and TPM have the operational excellence among IMP. Forth, in adopting IMP, field managers of 50 years over prefer TPM, while 50 years under TQM. Such evaluation corresponds with benchmarking research report(2005) about operations of IMP, St. Gallen Univ. We identified TPM, TQM, JIT is the best implementing sequence to achieve the manufacturing performance effectively based on preceding researches and our empirical study. There are several limitations in this study, like most empirical study. The following recommendations were some limitations. First, as in all survey research, a necessary assumption in data collection was that respondent had sufficient knowledge to answer the items and they answer the questions conscientiously and truthfully. In this study there were some biases of questions, because they take a serious view of their job. Second, this study selected manufacturing cost, quality, flexibility as evaluation criteria of manufacturing performance improving technique. But in case other financial or non-financial evaluation criteria are selected, a little different results may be found out. Third, according to this study the competitive strategies of most Korean shipbuilding enterprises were quality, manufacturing cost. We have expected the results but flexibility, one of more important future competitive strategy will be main tasks of the shipbuilding enterprises: how they realize and cope with the importance of it. The following recommendations are provided for future research: First, this study has attempted applying the AHP model in world-class shipbuilding enterprise. More researches are needed on the applicability of the proposed AHP model in many manufacturing companies. So we can contribute improving global competitiveness by changing manufacturing performance measurement criteria and alternatives for automobile and electronic industries in our country. Second, using other multi-criteria decision making methods available, more comparative studies are needed to clarify the numerous methods that might support the development of performance measures and selection of IMP and AMT.