Application of hybrid analytic hierarchy process and graph theoretic approach for analysis of barriers of high setup time

PurposeIn the era of the circular economy, the economic growth of a country is highly dependent on the sustainable performance of the manufacturing sector. In today’s increasingly competitive world, it is important to constantly improve the manufacturing or service industry. Quality with quantity is a main characteristic, which helps a company stay in the competition. Flexibility and responsiveness to customer demands are very important for success. Generally, additional time is needed for setup caused by poor design of equipment. At this point, the terms continuous process improvement and single-minute exchange of dies (SMED) as an approach of lean manufacturing come into play. Lean manufacturing system has been identified as an approach for improving the performance of the process and product.Design/methodology/approachIn this paper, high setup time is considered as major problem in the industry and a major cause and effect for high setup time was found. On the basis of the literature review and experts’ opinions, four categories of barriers, namely method, manpower, machine and tools are identified. In this study, a hybrid approach comprising of the analytic hierarchy process (AHP) and graph theoretic approach (GTA) has been used. First, prioritization of different categories of barriers by AHP has been done, and second, GTA has been applied for finding the barriers' intensity index. Based on this study, machine and manpower barriers have emerged as major hurdles in the high setup time of machine. The proposed framework will help organizations quantify barriers in high setup time in different manufacturing processes, thereby developing effective strategies for sustainable production.FindingsFindings of this research will contribute to ensuring sustainable competitive advantages, but it has some limitations. Development of the permanent matrix equation for barriers of high setup time is complex and lengthy when barriers are more in number. Absolute and relative values considered while quantifying the intensity of barriers are based on experts’ opinions, which may be inconsistent. In spite of these limitations, organizations can use an illustrated approach to quantify the barriers, thereby developing strategies for successful implementation of high setup time for making them sustainable in the global market. Organizations can also benchmark their sustainability preparedness with the best in the industry. As a future scope of study, high setup time can be reduced by using SMDE technology can be further validated through an empirical and case-based approach to generalize the findings.Research limitations/implicationsAuthors remain confined only to setup time. The approach is generalizable and can be extended in other areas. As a future scope of study, high setup time can be reduced by using single minute die exchange technology and can be further validated through an empirical and case-based approach to generalize the findings.Practical implicationsThe study guides and facilitates researchers and practitioners in using the most appropriate techniques such as AHP and GTA for empirical studies and in developing, modifying and/or reviewing application frameworks for production. It also guides implementation experience regarding high setup time by using advanced techniques such as single point die exchange (SMDE), which can be beneficiary for both developing and developed country contexts. Industries can accelerate implementation by understanding and using most important AHP, GTA and SMDE techniques.Originality/valueLean manufacturing system has been identified as an approach for improving the performance of the process and product. A lean manufacturing system is part of corporate culture, like tools and approaches. High setup time can be classified as waste for the company. Reduction in time is a direct way to increase the productivity and profit. Therefore, there is a need to reduce the time by using some new lean methodology. In global industry, different techniques are used for reduction of time.