Aligning manufacturing strategy and levels of automation: A case study

Research has shown that alignment between manufacturing strategy and decisions regarding automation are often of an ad hoc nature, i.e. the support for automation decisions is poor. Support tools to find an appropriate level of automation are thus needed in order to achieve more efficient and robust production systems. The methodology presented in this paper contains five sub-processes where the chosen level of automation is aligned with the manufacturing strategy. Together they form an automation strategy, which secures a desired direction of the firm and also supports robustness and reliability of the manufacturing system due to the holistic approach chosen.     

Schedule nervousness in a manufacturing system: a case study

Schedule nervousness has received significant attention from the academics for almost three decades. However, the majority of published works on schedule nervousness have relied upon experimental results as a basis for making conclusions and there appears to be very little field-based evidence presented in the relevant literature. This paper presents a case study of schedule nervousness based on field observations in a shoe manufacturing company in Indonesia. A model to quantify nervousness is also presented. This study provides an insight that schedule nervousness is an important issue in practice and efforts to quantify nervousness, as well as to understand how it occurred, are necessary in order to reduce nervousness.     

A model for an integrated manufacturing system implementation in China: a case study

This paper describes a process which a company adopted to enhance her manufacturing system in a step-by-step manner. In order to increase the competitiveness of the company, the authors have identified a number of improvement strategies which were specific to the economic and political environment in China. The center of the strategies is a vision of an integrated manufacturing strategy. The detailed design and implementation of this vision is conducted through the proposed systematic manufacturing strategic analysis. The integration process encompasses various elements such as Total Quality Management (TQM), Manufacturing Resources Planning (MRPII) and Real-Time Monitoring System (RTMS), it emphasises not only the use of appropriate modern technology but also the management of technology change. In this paper, a concept model is used to describe the integration process, the detailed implementation is also elaborated using a proposed implementation process model. By adopting the integrated manufacturing system, and through continuing improvement, the productivity and hence the profitability of the company is increased. It is anticipated that the integrated approach to the design and implementation of manufacturing systems will be an important contribution towards the manufacturing strategy in a labour intensive environment such as China.     

Understanding the complexity of knowledge integration in collaborative new product development teams: A case study

Knowledge integration is important in collaborative new product development (Co-NPD). The research literature shows that the way actors create a shared understanding about the new to create products is a quality indicator of Co-NPD. This study investigates what factors influence the creation of a shared understanding in Co-NPD. The results show factors at three different levels; the actor, project and company level. Additionally, there exist relationships across the factors. The related factors form four different types of interfaces. The interfaces differ from each other since different types of collaborative mechanisms exist within them.     

Production planning and inventory control in a company manufacturing PC parts: A case study

In this paper, we present a case study on the production planning and inventory system in a company manufacturing personal computer (PC) parts. In the case study, the targets are specified for developing a system for production planning and inventory control. The current state of the company is analysed for clarifying the points necessary to achieve the targets. Also, a system based on the analysis is proposed and its effects are estimated.     

A case study of production expansion planning in a soft-drink manufacturing company

This paper discusses the problem of production expansion planning in a soft-drink manufacturing company. We first formulate the problem as a large-scale transportation problem by making some realistic simplifications. We then program the transportation algorithm on a spreadsheet software to help solve the problem on a microcomputer. Through this case study we demonstrate how some standard OR technique can be combined with low-cost microcomputers to become an effective management tool to handle complex management decision problems.     

Flexible manufacturing systems performance in U.S. automotive manufacturing plants: a case study

Flexible manufacturing systems (FMS) philosophy is a key weapon in achieving global manufacturing competitiveness. It encompasses a wide range of dimensions to improve all aspects of operational performance metrics. The aim of the study is to examine the current state of flexibility adoption in U.S. automotive manufacturing facilities and its impact on operational performance metrics. It utilizes survey questionnaire developed based on previous work in U.S. manufacturing industry. The survey was originally distributed to 420 facility managers in the U.S. domestic automotive industry. It was revealed that 70% of the respondents had implemented all 15 flexibility dimensions listed in the questionnaire. The data analysis conducted shows that implementation of certain flexibility dimensions will lead to significant improvement in specific operational performance metrics. This considerable finding can be used as a guide for manufacturing managers to achieve certain objectives in operational performance improvement in a rapidly changing environment.     

Implementation of S-DBR in four manufacturing SMEs: a research case study

Production planning and control systems (PPCs) are tools that have a major effect on the performance of manufacturing companies. An inappropriate determination of the applicability of PPCs could seriously jeopardise the ability to achieve competitive priorities. This mistake can be expensive for any company, but proper implementation is particularly critical for small and medium enterprises (SMEs), which are characterised by limited access to financial resources. Simplified Drum–Buffer–Rope (S-DBR) is a PPC control approach that is characterised by minimum detail in the planning stage and a primary emphasis on the control of execution. Therefore, this approach is a suitable choice for the highly variable context of SMEs. This study aims to explore the practical issues related to S-DBR implementation in four Ecuadorian SMEs through case study research. The case analysis within this study first identifies the choices made in the implementation process design within the four companies according to process and product characteristics. We then conduct a cross-case analysis to explore the effects of the S-DBR implementation process designs on a group of performance measures. Our research findings provide new insights into the S-DBR implementation process in the context of SMEs, and the effects of this approach on performance measures.     

A systematic model for assessing innovation competence of Hong Kong/China manufacturing companies: A case study

Although having moved to mainland China, Hong Kong manufacturing plus trading industry is still the largest contributor to Hong Kong GDP. However, they are facing great challenges like higher cost, lower value adding, higher pollution, and lower efficiency these years. Many of them have to be closed or moved out of the southern part of China. These companies have recognized the urgency to upgrade them by innovation. This paper reports a research that aims to analyze the innovation competence in Hong Kong manufacturing companies. The project starts with literature review and the development of a conceptual model. A structured interview guide was developed then. The model was used to evaluate the innovation competence of 7 case companies via a training and consultancy program. The literature provides a long list of critical factors or enablers for innovation (Badawy, 2011). However, they are all listed as linear, separate factors. This research proposes a multi-level model for assessing innovation competence which allows researchers to investigate strategic factors, operational factors and innovation process, separately.     

Assessment of systemic greenness: a case study of tyre manufacturing unit

Abstract

In this paper, we develop an assessment framework to evaluate the systemic greenness of a tyre manufacturing unit by capturing the interactions between the green practices implemented. By reviewing the existing literature, we propose a stakeholder-based green practices framework comprising of operation strategy practices, process practices, employee practices, regulatory practices, customer practices, competition practices, social practices, and supplier practices. The empirical data on the interactions of green practices between and within stakeholders are collected by conducting a detailed case study of a large radial tyre manufacturing unit in India. We use graph-theoretic approach to incorporate the interactions between different green practices and assess the systemic greenness of the case organisation. Based on the systemic greenness attained, we rank the green practices within stakeholders and also between the stakeholders. We conduct scenario analysis to develop a systemic greenness index and a scale to assist practitioners in evaluating and benchmarking the greenness performance. We also discuss implications for theory and practice along with the inherent limitations.     

Measuring business performance in the high-tech manufacturing industry: A case study of Taiwan's large-sized TFT-LCD panel companies

The nature of competition in the high-technology manufacturing industry has changed dramatically over the last two decades, and any of the traditional indicators of business performance are insufficient today. We have identified a new set of financial and non-financial performance indicators that can be used by high-tech manufacturing companies and have developed a business performance evaluation model. A data envelopment analysis (DEA), an analytic hierarchy process (AHP), and a fuzzy multi-criteria decision-making approach are used in the model. Data from large-sized thin-film transistor liquid-crystal display panel companies in Taiwan were collected via a field survey and from various published databases and were fed into the model to determine the relative business performance of the companies. We hope that our findings will help high-tech manufacturing executives determine their companies’ strengths and weaknesses and lead to future improvements in business operations.     

Implementation of holonic scheduling and control in flow-line manufacturing systems: die-casting case study

The success of a flow-line manufacturing system depends on effective production scheduling and control. However, it has been found that current flow-line manufacturing scheduling and control algorithms lack the flexibility to handle interruptions or resource breakdowns; hence, system performance drops automatically and rapidly when interruptions occur. The objective of this research is to investigate if the performance of a flow-line manufacturing system can be improved by integrating agent-based, holonic scheduling and production control. A holonic manufacturing scheduling model has been developed and implemented into a die-casting manufacturing flow line throughout a simulation model. The analysis takes into account the comparisons of overall performances of the system models with the holonic scheduling and conventional scheduling approaches. Simulation results indicate that the holonic manufacturing scheduling and control can significantly increase the uptime efficiency and the production rate of the flow-line manufacturing system.     

Just-in-time in ATO vehicle manufacturing: The Minivan-Piaggio V.E. case study

The system adopted by Piaggio V.E. to run the production of 'Minivan' aims at conciliating the manufacturing philosophy 'just-in-time' JIT with the creation of a wide range of end-product codes. Some general assumptions for a JIT production, with small lot sizes, are described together with their implementation in the operationorganizing system adopted by Piaggio V.E. for the 'Minivan' assembly line. The strategy pursued by Piaggio V.E. for the Minivan focuses on the quality of the product and the level of service in the form of fast order cycle and a high number of options offered on catalogue. According to the logic of an ATO production system, the customer orders a customized product and the manufacturer does not keep any finished inventory, but aims at effective management of the information flows.     

Implementing lean sigma framework in an Indian automotive valves manufacturing organisation: a case study

The manufacturing organisations have been witnessing a key transition to lean manufacturing paradigm so as to eliminate waste. Concurrently, six sigma methodology has been widely used for reducing the defects. In order to attain the combined benefits of these two approaches, the amalgamated lean sigma framework has originated. Lean sigma framework proves drawbacks, such as lack of systematic and scientific management and feeble lean anchorage. In order to overcome these deficiencies, this article contributes a refined lean sigma framework, and its effectiveness has been test implemented in an Indian automotive valves manufacturing organisation. The implementation benefits are described in this article.     

A study of expediting practices in manufacturing firms

Abstract

This paper presents the results of an empirical investigation of one of the most common yet least optimized production management practices—expediting. The intention of this study was to generate quantitative insight into issues that underlie expediting decision making, such as the relative frequency of various causes of expediting, commonly used expediting strategies and tactics, and the interaction of expediting and the production scheduling environment in use. The study centered around a survey sent to 1768 manufacturing staff personnel, with 182 usable questionnaires returned. It is hoped that the data and conclusions presented in this paper will be of use to production management researchers who are interested in expediting as a managerial decision.     

Differences and similarities in managing technological collaborations in research,development and manufacturing: a case study

This case study is aimed at exploring the characteristics of technological collaborations (TC) in the different phases of the innovation process. While the literature widely discussed the motives for collaboration and the organizational forms that can be adopted, little is known on the role of the phase of the innovation process in the collaboration in shaping its original form. Empirical evidence from 18 in-depth case studies allows to highlight how TC in research, development and manufacturing intrinsically differ in terms of content, motivations and partners involved. We also argue that these characteristics lead to different organizational forms of collaboration, in terms of number of partners, contractual formalization, structure of control, time horizon and density of relationships. The most common organizational forms adopted, respectively, in research, development and manufacturing collaborations are discussed. Finally, we derive guidelines for managers that are facing decisions about external technology sourcing or are managing TC evolving from one phase of the innovation process to another.     

The implementation of digital technologies for operations management: a case study for manufacturing apps

Abstract

Manufacturing applications address business to business (B2B) with highly customised applications developed for specific requirements, offering highly specialised solution-oriented and service-based software components, systems, and digital tools that aim at a fast and accurate decision-making support system. The purpose of this paper is to describe the implementation of digital technologies for operations management using manufacturing or engineering apps (eApps), for product design and manufacturing processes. In particular, starting from the specific needs of two companies from mature European industries as automotive and food, this work depicts how this kind of solutions can support companies and improve their operations. In particular, related benefits and challenges faced for the full implementation of the developed tools are highlighted. Moreover a business model to exploit the manufacturing apps is also proposed. The business model proposed for the exploitation of the eApps supports the commercialisation of all the revenue streams offered by this rapidly growing sector taking into account the specific needs of the concerned stakeholders through a diversified value proposition.     

Business intelligence and analytics value creation in Industry 4.0: a multiple case study in manufacturing medium enterprises

Abstract

Medium enterprises (MEs) form a majority of enterprises in several regions, yet they are underrepresented in the literature. The digital transformation known as Industry 4.0 (I4.0) brings new data streams into enterprises. MEs and large enterprises will both leverage business intelligence and analytics (BI&A) to improve their business performance, so the study of the conditions favouring value creation of BI&A is of interest. However, there are few studies focusing on the impact of business intelligence and analytics (BI&A) on value creation in I4.0 and none focusing on MEs. Using a multiple case-study design, this paper explores factors linked to BI&A business value creation in manufacturing MEs that are undergoing an I4.0 transformation. Findings suggest enterprises resources and capabilities are not sufficient to predict business value: organizational learning and organizational culture have a non-negligible influence for MEs.     

Implementation of manufacturing strategy: A select study of Indian process companies

This paper presents findings of an extensive survey of Indian process companies. Based on the survey, three companies have been selected for detailed case studies. Their experiences in the manufacturing strategy process are analysed. Although the companies represented diversity in terms of product type, sales volume, longevity and geographic location, they shared several commonalities including use of advanced manufacturing technologies. The process of strategy formulation varied among the companies in terms of participants, complexity and degree of formalization. Competitive priorities, order winners and critical success factors are identified for these companies. Based on strategic manufacturing issues, manufacturing competence index for the companies has been worked out.     

The company-wide effects of just-in-time manufacturing within an integrated materials handling system: a case study

Abstract

The paper describes the formulation of a cellular manufacturing methodology to allow the use of an automated guided vehicle system (AGVS) in a difficult environment. The resulting methodology allowed just-in-time operation on the factory floor. The methodology was also shown to provide benefits additional to those associated with AGV usage, namely increased integration of the manufacturing control departments of the organization, and increased efficiency of their MRP system.