Modular design of integrated databases in production management systems

Abstract

Complexity is a serious problem with respect to the application of information technology in the field of production management. This paper presents an overview of the more fundamental problems encountered and proposes a solution for some of those problems in the form of modular decomposition of the conceptual database structure. It is argued that the complexity of information systems is closely connected to the complexity of the organization. Therefore a condition for the realization of integrated information systems for production management is a simplification of the organizational structure by way of defunctionalization and the forming of autonomous units.     

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.     

A generic accounting model to support operations management decisions

Information systems are generally unable to generate information about the financial consequences of operations management decisions. This is because the procedures for determining the relevant accounting information for decision support are not formalised in ways that can be implemented in information systems. This paper describes a formalised procedure, which is based on the following theoretical propositions: (i) cost behaviour is described on the basis of a company's contracts for purchasing and selling resources, and (ii) hierarchical relationships between decisions are recognised, because some decisions have to be made earlier than others. Earlier decisions determine the feasible alternatives for later decisions (e.g. through constraints in available production capacity or components), and the plans that supported the earlier decisions serve as instructions for later decisions. The procedure can be implemented in information systems to provide accounting information in case later decisions deviate from these instruc tions (within the limits of the real-world constraints) because new information becomes available.     

An examination of the ISO 9001:2000 standard and its influence on the integration of management systems

Abstract

Analysis of the literature and examination of the various models of integration and testing in the field, have revealed five key issues relating to management system integration. This paper examines the recently published ISO 9001 : 2000 quality management system standard to see how it addresses these issues, under the headings of compatibility, scope and organizational culture. The examination reveals that while compatibility with the ISO 14001 and OHSAS 18001 standards has been improved in some areas, a different approach and model of a management system has been used. The paper suggests that differences in the scope of the standards are also likely to give rise to different sub-cultures which will hinder integration, and scope and culture are more important than compatibility. This leads the authors to conclude that new models of integration should be based on an approach and definitions which can be used in any management system, as well as an integrated one. Models of an integrated management system should also emphasize the need for no significant differences in the scope of the integrated systems, and a strong culture which supports the main requirements of TQM.     

Selection and implementation of a PPC system

There are many computer-aided production planning and control (PPC) systems available on the market which can provide a solution to the complex task of production planning and control. However, the question remains, how can a company find an optimal system from the vast amount of available systems? This article proposes that a company, having decided to buy one of the available systems, starts a project for selection and implementation of the PPC system.     

Quality management in outsourced global fashion supply chains: an exploratory case study

Abstract

Outsourcing production is common in the fashion industry but can lead to quality defects. This paper thus sheds light on how quality is managed in outsourced fashion supply chains. We propose a new trilogy for managing quality control in outsourced fashion supply chains: (1) manufacturer quality assessment, (2) quality management in production and (3) quality inspection and assurance. We implement an exploratory case study methodology. Through a qualitative case study of a leading global Japanese fashion retailer that outsources production mainly to China, we contribute to quality management studies by developing a new quality control trilogy for outsourced supply chains. Our findings can provide fashion retailers with guidance on controlling product quality in outsourced supply chains and developing strategies for improving supply chain performance. We also demonstrate the importance of contract and relationship management, supply chain integration and quality visibility in enhancing product and process quality in outsourced fashion supply chains.     

An information system for Just-In-Time

In recent years, U.S.'s worldwide industrial and economic leadership has been seriously challenged by many foreign countries. In order to counter the problem, many U.S. manufacturing companies have sought effective materials management systems such as MRP and the ‘Just-In-Time’ (JIT) system as used by many Japanese companies. Even through many practitioners and academicians have been studying the JIT concept and have recommended ways of adapting the concept to the U.S. manufacturing environment, not very many organizations are enjoying benefits of JIT system in full scale because of misunderstanding of information needs in JIT system. The objectives of this paper are (1) to identify information requirements of the materials management systems under JIT concept, (2) to compare them against the requirements under MRP system, and (3) to propose an integrated management information system to support materials management system in JIT environment. The goal of this paper is to facilitate more effective implementation of the JIT system, and stimulate further research on the subject matter.     

Experimental earliness/tardiness production planning with the due window system

In order to use the philosophy of JIT to improve the production planning method of MRP-II, we propose the experimental software system of the earliness/tardiness produc tion planning problem with due window. By means of the approaches and model reported in this paper, the optimal production planning can be achieved. The recommended model extends the problem of due window from the shop scheduling level into the aggregated planning level of mass manufacturing systems. Simulation results have demonstrated that the experimental software is a useful tool for the production management of repetitive manufacturing enterprises.     

Integrating risk and performance management in quality management systems for the development of complex bespoke systems (CBSs)

Abstract

Risk and performance management are at the core of complex bespoke systems (CBSs). CBSs are developed to customer–specified requirements in terms of structure, functionality and conformance. This article examines how risk and performance management are integrated as essential systems in the successful development of projects across multi-organizational functions in complex bespoke system (CBS) organizations. The article argues for the development of a quality management system that consists of two sub-processes: quality control and quality development. Using three case studies from engineering companies, we provide evidence and insights of the way change control, quality development and quality performance are developed in innovating business solutions.     

New views and visions on product structures

Abstract

The paper deals with different viewpoints in product structuring knowledge. Special interest is paid to a new viewpoint called control structure. The necessity for such a concept is based on the penetration of product oriented manufacturing systems (factories, workshops and cells) together with the related distribution of production management decision making. Control structure is an aggregated control oriented viewpoint on the product structure hiding the details of the work operations and materials requirements at the lower levels of decision making. Thus control structures are also intended for the integration and loosely coupled co-ordination of control units. The paper also strongly advocates the application of interactive graphics in the manipulation of product structure information. A practical system developed is demonstrated as a vehicle for implementing the concepts introduced.     

Editorial for special issue on: humanitarian operations management

Abstract

Over the past decades, there has been increasing interest in studying humanitarian operations management. The mismatch between global humanitarian needs and the resources available, together with chronic vulnerability in many parts of the world, continues to have a direct bearing on the lives of millions of people in need of assistance. It also means that donors have to re-double their efforts to respond to disasters in a more efficient and effective manner. International humanitarian organizations (IHOs) often deal with a mix of disaster response and development programmes simultaneously. This operational mix entails disaster cycle management challenges such as project and programme planning of multi-objective global logistics, balancing earmarked donations for disaster response with budget needs for development programmes, and determining the push-pull boundaries in the supply chain, particularly with the increase in cash transfer programmes. The main purpose of this special issue is to report on research in humanitarian operations management. This special issue attempts to explore and examine the above topical issues at strategic, operational and technical levels.     

Can you have your cake and eat it? Investigating trade-offs in the implementation of green initiatives

Abstract

Is it possible for manufacturing or service businesses that pursue green initiatives to ‘have it both ways’? In the words of some researchers in the corporate sustainability field, the answer is ‘no’. According to those authors, executives who attempt to implement a green agenda in their firms will encounter tensions/trade-offs at various levels and in different forms. Assessment of these trade-offs is a critical issue in the formulation and implementation of corporate sustainability strategies. Similarly, some authors in the operations management field affirm that, due to the limitations of all manufacturing and service systems, trade-offs in their operations are inevitable. In order to provide insights into these important issues, our paper investigates potential trade-offs in the implementation of a green initiative in a SME that manufactures cleaning products. The results show that there is a trade-off between the green initiative pursued by the SME and its overall production costs. Interestingly, once other problems were resolved, this trade-off did not stop the SME from implementing the green initiative. Important implications for practitioners and researchers are discussed, and opportunities for future investigations are outlined.     

Measuring agri-food supply chain performance and risk through a new analytical framework: a case study of New Zealand dairy

Abstract

Many researchers and practitioners have long recognized the significance of measuring performance. Although general guidelines for measuring business performance are widely available, no appropriate measurement frameworks have been developed for measuring agri-food supply chain performance. Particularly, food quality and risk-related indicators have not been well integrated into existing performance measurement systems. Our research, therefore, addresses this knowledge gap by first providing an in-depth review of extant performance measurement systems and frameworks. It then develops an analytical framework by extending the Supply Chain Operations Reference (SCOR) model which has been extensively implemented across non-food industries. The analytical framework is further validated by utilizing a case study of 50 farmers and 10 dairy companies, operating in the New Zealand dairy industry.

Our pilot testing and subsequent findings show that the individual metrics interlocked with the analytical framework are in-line with the key industrial practices adapted by the New Zealand dairy industry. In addition, the framework is flexible and scalable to evaluate and benchmark other agri-food supply chains – ranging from fresh products such as fruits and vegetables to processed foods such as canned fruits. The findings further show that the detailed information required for measuring the level-3 SCOR metrics is not easily available in the industry, as researchers need to access specific company records that may be confidential. Consequently, this study provides how agri-food supply chain managers can employ our new analytical framework in-conjunction with the SCOR model for a deeper understanding of the complicated performance measurement indicators applied in their agri-food production systems and relevant supply chains.     

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.     

Changing Conceptions of Employee Compensation

Abstract

This paper reviews and discusses many differing forms of incentive compensation systems that are being used in today's organizations. The review traces the roots of bonus compensation from individual piece-work plans through the adoption of organization-wide gainsharing plans to the growing recognition of open-book management. Reasons for the shift in units of analysis from the individual employee to the work team or organization as a whole are discussed. Explanations are also given for why many companies are beginning to concentrate on outcomes rather than process measures as indicators of organizational success. Lastly, suggestions for enhancing the research agenda and bridging the gap between science and practice are provided for the scientists and practitioners of organizational behavior management.     

Long‐Term Contracting: The Role of Private Information in Dynamic Supply Risk Management

We examine the critical role of evolving private information in managing supply risk. The problem features a dyadic channel where a dominant buyer operates a multiperiod inventory system with lost sales and fixed cost. He replenishes from a supplier, whose private state of production is vulnerable to random shocks and evolves dynamically over time. We characterize the optimal inventory policy with a simple semi‐stationary structure; it distorts order quantity for limiting information rent only in the initial period; the optimal payment compensates for production cost in every period but concedes real information rent only in the initial period. These properties allow us to derive an easy‐to‐implement revenue‐sharing contract that facilitates ex ante strategic planning and ex post dynamic execution. This work advances our understanding on when and how to use private information in dynamic risk management.     

An integrated lean and green approach for improving sustainability performance: a case study of a packaging manufacturing SME in the U.K.

Abstract

Competitive landscape, informed consumers and stringent regulations have forced many manufacturing small- and medium-sized enterprises (SMEs) to focus on operational efficiency along with sustainability issues in recent years. While many manufacturing organisations have been taking lean initiatives for the past few years for operational excellence, an impulsive rush to adopt lean without a strategic deployment vision has led to scattered implementation of lean tools and projects without desired success. Many researchers and practitioners prescribe value stream mapping as a foundation for lean transformation initiatives; however, little empirical work is available on the symbiosis of lean and green paradigms to reap maximum benefits. This research, through a systematic methodology and a novel tool called Green Integrated Value Stream Mapping (GIVSM), integrates both paradigms in a case study on a U.K. packaging-manufacturing SME. Applying the GIVSM demonstrates that simultaneous deployment of lean and green paradigms have synergistic effect for improving both operational efficiency and environmental performance. In addition, continuous improvement framework with sustainable procurement is proposed to overcome the lean-green misalignments. This study also provides a guiding reference for practitioners to undertake similar improvement projects and identifies opportunities to expand this academic research on integrated lean-green approach into other industry sectors.     

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.     

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.