Optimizing Safety Stock Levels in Modular Production Systems Using Component Commonality and Group Technology Philosophy: A Study Based on Simulation

<jats:p>Modular production and component commonality are two widely used strategies in the manufacturing industry to meet customers growing needs for customized products. Using these strategies, companies can enhance their performance to achieve optimal safety stock levels. Despite the importance of safety stocks in business competition, little attention has been paid to the way to reduce them without affecting the customer service levels. This paper develops a mathematical model to reduce safety stock levels in organizations that employ modular production. To construct the model, we take advantage of the benefits of aggregate inventories, standardization of components, component commonality, and Group Technology philosophy in regard to stock levels. The model is tested through the simulation of three years of operation of two modular product systems. For each system, we calculated and compared the safety stock levels for two cases: (<mml:math xmlns:mml="http://www.w3.org/1998/Math/MathML" id="M1"><mml:mrow><mml:mn fontstyle="italic">1</mml:mn></mml:mrow></mml:math>) under the only presence of component commonality and (<mml:math xmlns:mml="http://www.w3.org/1998/Math/MathML" id="M2"><mml:mrow><mml:mn fontstyle="italic">2</mml:mn></mml:mrow></mml:math>) under the presence of both component commonality and Group Technology philosophy. The results show a reduction in safety stock levels when we linked the component commonality with the Group Technology philosophy. The paper presents a discussion of the implications of each case, features of the model, and suggestions for future research.</jats:p>