Measuring and Identifying Appropriate Levels of Flexibility: A Novel Approach and Use Case in the Automotive Industry

Manufacturing systems need to adapt to internal and external uncertainties, and flexibility is a crucial component to achieve this. Industry 4.0 and smart manufacturing systems have made flexibility and reconfigurability essential pillars of modern manufacturing. Determining the appropriate level and type of flexibility can help reduce costs and enable systems to respond quickly. This paper explores various types of flexibility outlined in existing literature and proposes new types that can significantly impact the production system. To classify these flexibilities, a two-dimensional grid is presented that considers decision horizons (strategic, tactical, and operational levels) and physical dimensions of the system (resource, workshop, factory, and supply chain). A universal measurement method based on three criteria is also proposed to ensure that a measurement method is applicable to all types of flexibility. These criteria include the range of variation, response time, and the number of alternative solutions. Finally, a real case study is presented to illustrate the application of the proposed method. The case study involves the introduction of a new product in the automotive industry, and the obtained results are discussed.