Selection of methods,techniques and tools for system analysis and for the integration of CIM-elements in existing manufacturing organizations

Abstract

Implementation of computer-aided and integrated manufacturing systems requires one to consider all areas of the company in order to ensure a homogeneous and continuous evolutionary system development. Therefore, planners of computer integrated manufacturing (CIM) systems need a concept to come to a coherent selection of methods for those system development. In this paper a concept is introduced which allows an interdisciplinary team of system developers (engineers, industrial economists, personnel economists) a coherent choice of methods for system development. As examples, three methods applicable to the problem of CIM-implementation into organizations are evaluated.     

CIM implementation for job-shop environments

Abstract

Abstract. The small to medium-sized job-shop manufacturing industry can benefit most from the implementation of computer integrated manufacturing (CIM) technology, to meet the increasing demand for high-quality and economically priced products. The injection mould making industry is a typical representative for this group, where a manufacturer would generally produce moulds which consist of parts that are standard to every mould type or very similar. Thus, manufacturing techniques, such as group technology (GT), and production planning and control (information) management systems could make significant contributions in improving the efficiency of design and production operations.

The objective of the project, presented in this paper, was the development of a GT-based classification and coding (C/C) system for injection mould parts especially for the design and process planning phases, and the development of a production planning and shop-floor control (SFC) information management system.

An extensive investigation was carried out on existing GT-based C/C systems. This investigation, followed by a thorough examination of many injection mould parts for determining geometric similarities, led to the development of part families (classes) required for GT implementation. An OPITZ-type GT system was developed, thereafter, for the C/C of the manufactured parts of the target company.

The production planning and control software that has been developed for the target company utilizes a relational data base management system. It consists of 13 application programs, which provide a tool of organizing information for efficient production planning and SFC. The programs are designed to cover all manufacturing operations of a job from the proposal to the final testing stage. Shop orders and dispatch lists are created using this software for effective and prioritized SFC. Shop status and job status reports are generated based on feedback information received through time card entries.     

GIM and logistics in the factory of the future

Abstract

In the future, the competitive strength of industry will depend on its ability to realize flexible production systems, to install intelligent EDP-systems and to link them to a goal-orientated logistic system. Currently, a lot of new strategies, concepts and approaches for production arc being promoted and discussed, often in a spirit of controversy: CIM (computer integrated manufacturing), 'production logistics’, and JIT (just-in-time production) have become familiar concepts which have one thing in common: new structures in production will be necessary. However, the overall effect of CIM is often very small in comparison to the investment for realizing this concept. The main reason is that such projects are missing a logistic orientation. A continuous flow of information and material as envisaged by the logistics principle requires not only that all automation components can be integrated on the technical level, but also that all relevant functions and sectors can be integrated organizationally.     

Critical success factors of TQM: A select study of Indian organizations

In the context of TQM, it is essential that the organizations identify a few key critical success factors, which should be given special attention for ensuring successful implementation of TQM program. The concept of critical success factors (CSFs) and their use in supporting planning efforts was originated from the approach associated with the development and implementation of management information systems. This paper represents a review of the literature on CSFs and supported by various philosophies of TQM. Such factors are considered as conducive to the success of TQM implementation. Based on an exploratory study of Indian organizations engaged in manufacturing and services, CSFs have been identified.     

Implementing workforce development in health care: A conceptual framework to guide and evaluate health service reform

Abstract

The term ‘workforce development’ is increasingly popular in the health-care field. It appears to encompass a range of human and organizational development activity. However, there has been limited explication of the concept of workforce development in Australian health care at area health service levels. It is timely to develop a framework for workforce development and processes to guide any evaluation of the implementation of workforce development strategies. This paper presents a framework that has been developed through consultative processes in an area health service and an associated review of literature.     

Reengineering of a supply chain management system: A case study

A business process reengineering (BPR) project concerning a supply chain management (SCM) system of a heavy machinery manufacturing company has been discussed in this paper. The BPR implementation process model has been described. The principal objective of this project has been to bring about radical changes in the mind sets, management styles and systems of a very mature but large organization in India. The implementation process has been very successful because the model has been explored by an organizational development initiative. BPR is both feasible and worthwhile in business only when ideas and ideals are put willingly in practice; and is practised in a collaborative mode to get closer to the people, especially at the floor level, and to customers and suppliers.     

A low-cost approach to computer-integrated manufacturing in a small chemical unit

Many firms are considering CIM as a means of reducing costs and increasing quality. Sometimes, however, a major problem in this kind of project seems to be the high investments involved. In this paper a methodology for developing a low-cost CIM application is presented. The proposed methodology was successfully experimented in a small chemical unit of one of the leading producers of nylon in the world. The paper reports on the design and implementation of the computer-integrated manufacturing and the associated costs and benefits.     

Reviewing Implications of Urban Growth Management and Spatial Governance in the Global South

ABSTRACT

Urban containment policies have been applied in the global north as a strategy towards creating compact urban development. In the south the urban growth management discourse have been part of planning practice for the past three decades. There are however several reasons, both structural and political that have contributed to its limited success. The purpose of the research is to review practices of growth management in the south in an attempt to find lessons from the implementation of different mechanisms. The study focuses on the challenges of growth management mechanisms and its associated spatial governance approaches.     

Management innovation: a dynamic analysis of the implementation phase over time

Abstract

We develop management innovation theory, providing insights into the role of time in the implementation phase. The management innovation literature has sought to empirically identify factors that facilitate or hinder management innovation implementation from a static perspective. To address the evolution of these factors’ resistance, a temporal perspective is appropriate, but an analysis of these factors’ evolution over time is lacking. We identify the inhibiting factors that influence the management innovation implementation phase over time and address ways in which they evolve.We conduct a comparative longitudinal and dynamic analysis based on two intermediate-sized enterprises and address the obstacles that emerge during the implementation phase of a specific management innovation: lean manufacturing. Our results highlight different categories of inhibiting factors: some inhibiting factors appear at the beginning of the implementation phase with high intensity and then fade over time; conversely, other inhibiting factors appear later and then increase in intensity.     

Aspects of manufacturing strategy

Abstract

It is becoming increasingly important for manufacturing organizations to articulate clear and coherent manufacturing strategies that support their long term business objectives. In particular, manufacturing strategy should take conscious account of the competitive posture adopted by the organization in each of the product/market segments in which it has decided to participate. This paper discusses the various ways in which a systemic manufacturing strategy can contribute to an organization's competitiveness, and the processes by which such a strategy can be developed. Some important and often neglected issues concerning the development of the individual components of a manufacturing strategy are examined and the problems and issues of strategy implementation are discussed.     

Layered supervisory control architecture for reconfigurable automation

The development of control systems and supporting software remains one of the greatest obstacles to the widespread implementation of highly adaptive reconfigurable automation technology. This paper will present the structure of a modular automation control system designed to support rapid reconfiguration and redeployment of automation components. The paper will first present the concept of a layered system architecture and the use of modular automation components to support the construction of a wide variety of automated systems. This layered system architecture is then applied to the proposed modular supervisory control system responsible for configuring and driving automated production resources. Each of the control components comprising this modular control system will be presented.     

Productivity gains by cellular manufacturing

This paper discusses some of the major factual results and discussions of the effects of implementation of a cellular manufacturing environment on the productivity of people, management and facilities, as was experienced in this study. It is suggested that significant improvements at very low costs are possible at managerial, and other work force levels, by introduction of appropriate production management systems. This is based on analysis of the changes in production costs and more importantly the behaviour of employees brought about by a first time implementation of cellular manufacturing in a company.     

The propagation of lean thinking in SMEs

Abstract

Small and Medium-sized Enterprises (SMEs) play a pivotal role in economic growth, industrial output, and employment creation. However, SMEs are often ignored by researchers as far as the adoption of lean is concerned in comparison to Large Enterprises (LEs). Therefore, the literature regarding lean implementation in SMEs is not conspicuous, and many SMEs have only a limited understanding and awareness of lean. This paper offers a comprehensive literature review with a focus on the implementation of lean in SMEs and explores the applicability of lean thinking in such environments. An attempt is made to provide an analysis of lean practices that have been applied in SMEs and critical success factors for lean transformation in SMEs. It also contributes to the field of lean implementation research by proposing a framework for lean in SMEs and identifies the scope of future research.     

Diversity training pitfalls and possibilities: An exploration of small and mid-size US organizations

Abstract

This qualitative, exploratory study examines the development and implementation of diversity training in small and mid-size organizations in a Midwestern region of the United States. The results are contrasted with diversity best practices and found lacking in key elements identified as most likely to yield success. Specifically, the organizations in this study did not provide training beyond awareness level, failed to conduct front-end needs assessment, provided little if any in-depth evaluation of diversity training and showed varying support for diversity endeavors from the leadership and through connecting diversity training with other systemic initiatives. The article concludes with recommendations for additional exploration of adapting effective diversity training practices to minimize pitfalls and maximize possibilities in small and mid-size systems.     

Hybrid heuristic for design of cellular manufacturing systems

Cell design in Cellular Manufacturing Systems (CMS) assumes significance due to the incremental nature of implementation. In this study a hybrid heuristic has been developed considering incremental aspect of implementation. The heuristic identifies complete cells (if they exist), otherwise forms a CMS with combination of regular cells and a remainder cell which caters to the needs of exceptional parts/operations. The heuristic has been tested with the standard problems in the literature. It is found that the proposed heuristic produces superior solutions in 62.22% cases and the same solutions in the remaining cases. Further, statistical testing has been conducted and found that the performance of the proposed heuristic is significantly better than the existing methods.     

Do makerspaces represent scalable production models of community-based redistributed manufacturing?

Abstract

This research explores the development of local community-based ‘makerspaces’ as potential scalable forms of redistributed manufacturing (RDM). Makerspaces are rapidly emerging in post-industrial economies and have been identified as a catalyst of local regeneration in urban areas. However, their role in local production systems is limited. There is a gap in the literature, with respect to the evolution of makerspaces and their productive contribution. The purpose of this paper therefore is to identify, classify and examine the different types of makerspaces. Our focus is on the implementation characteristics that enable industrial production activity to take place. First, we used Leximancer (to identify from the literature) three types of makerspace. Second, we then identify five RDM implementation characteristics. The characteristics were integrated together to form the RDM-makerspace implementation model. Third, case studies were purposively selected to test and advance this model. They were subsequently classified as a Type 1 (educational), Type 2 (design) or Type 3 (production) makerspace. Only one of the case studies was classified as a fully evolved Type 3 production space. The findings concur with the literature that makerspaces tend to be primarily Type 1 or Type 2. Finally, the contribution to local production theory is emphasized.     

EF-based strategies for productivity improvements at wet-etch stations

Abstract

In complex manufacturing environments, Cycle Time (CT) reductions obtained at critical production steps could generate considerable productivity improvements and lead to capacity increases at no investment costs. A wet-etch station operating in a real semiconductor manufacturing plant has been modelled to investigate the impact of different assignment strategies on CT performance. Assignment strategies based on the “Earliest Finish” (EF) concept have been developed and their productivity efficiency compared with a workload balance-based strategy. The EF-based strategies differ from each other for both computational complexity and amount of real-time information required. Encouraging results obtained for a high detail level EF strategy have inspired the development of conceptually similar strategies characterised by reduced implementation efforts. Fundamental implementation constraints, suggested by the manufacturing engineers familiar with the wet-etch station, have been taken into account throughout the different stages of this study. CT reductions ranging between 11% and 28% could be achieved at the modelled wet-etch station.     

Development and implementation of a knowledge-based system for the dynamic scheduling of a two-stage production process

Abstract

This paper discusses the implementation of a knowledge-based system for the dynamic scheduling of a two-stage production process. It is an interactive, real-time, menu-driven system written in Prolog. The system architecture is delineated and the rules and problem-solving logic to be used under various dynamic situations are described. Results of a sample system test session are included to illustrate its use.     

A routine-based framework implementing workload control to address recurring disturbances

Abstract

This research focuses on responsiveness in high variety manufacturing environments. To achieve it, the article proposes to develop Dynamic Response Capabilities (DRCs) of the manufacturing system defined as the abilities to readjust the planned operating parameters of workload, capacity, and lead time, in the wake of disturbances. To inform their development, built on the Workload Control theory, a routine-based framework is proposed. The framework supports an integrated approach for the implementation of adaptive decision-making routines for workload, capacity, and lead time readjustments at different stages in the order fulfilment process. Findings from two empirical cases show the appropriateness of the framework to develop and utilise DRCs in different settings of disturbances. Results of a simulation study, with one of the case companies, also shows the effectiveness of the framework to drive performance improvements in presence of recurring disturbances leading to demand variability.     

Exploring the Effects of Cultural Variables in the Implementation of Behavior-Based Safety in Two Organizations

Abstract

The present case study examines how culture can influence behavior-based safety in different organizational settings and how behavior-based safety can impact different organizational cultures. Behavior-based safety processes implemented in two culturally diverse work settings are described. Specifically, despite identical implementation plans, similarities and differences in the actual implementation of the two behavior-based safety processes are presented with an emphasis on the effects of employee-driven decisions. Data on both implementations and outcome measures are provided. The results are discussed with respect to the potential impact of specific cultural variables.