A conceptual hybrid framework for industrial process improvement: integrating Taguchi methods,Shainin System and Six Sigma

Design of Experiments (DoE) has evolved as powerful industrial statistics tool for managing and improving processes in diverse industries. The three broad approaches of DoE in practice: classical or traditional methods, Taguchi methods and Shainin System (SS), have their merits and demerits for a extensive industrial experimentation. Nonetheless, the power of these DoE approach is not fully harnessed in established process improvement frameworks in industries. On the other side, Six Sigma DMAIC is a well-accepted methodology for improving process capability through focus on customer’s requirement (CTQ). The use of DoE in traditional DMAIC framework is limited to quantification of influence factors on CTQ. To offer a contribution to this paucity, this paper proposed a conceptual Six Sigma/DOE hybrid framework aiming to integrate SS, Taguchi methods and Six Sigma DMAIC for process improvement in complex industry environment. A case on improving DF generation process in shock absorber assembly was developed to validate the effectiveness of the framework for intricate problem-solving.     

Data mining driven DMAIC framework for improving foundry quality – a case study

Six Sigma Define-Measure-Analyze-Improve-Control (DMAIC) methodology has been widely used across industries as the best systematic and data driven problem solving approach for quality improvement. Statistical Design of Experiment (DOE) is used in the ‘Improve’ stage for obtaining optimal process settings for significant variables contributing towards quality improvement. But, DOE is an offline activity requiring time and other resources for conducting experiments and analyses. Further, there are many small and medium scale enterprises that cannot afford to conduct DOE. Under such practical constraints, it is desirable to apply DMAIC using online process data under day-to-day production situations or with little changes in process settings without compromising production. In this article, we propose a DMAIC framework, driven by data mining techniques for defect diagnosis and quality improvement where historical and online process data can be effectively utilised. We have used two decision tree algorithms namely, Classification and Regression Tree and Chi-squared Automatic Interaction Detection in developing the proposed framework. The proposed approach is applied in an Indian grey iron foundry where conducting DOE is not a feasible option for the management. The result demonstrates a significant reduction in casting defect and validates the practical viability of this approach.     

Planning a cost-effective cellular manufacturing process—a case study

The drive key is one of the most important high-precision components of aircraft braking systems. In this paper, a cost-effective drive key manufacturing process is developed. This proposed manufacturing process makes use of near net shape manufacturing, CNC machining, and cellular manufacturing methods. To make the proposed process a reality, proper engineering changes of the parts along with group technology are applied to the product design, in conjunction with the pro posed manufacturing methods. In addition, a general spread sheet program is developed for each style of fixture module to assist in part program coding. Moreover, statistical process control (SPC) is implemented to verify product quality and accept the product at the point of manufacture. It is observed that the implementation of the proposed drive key cellular manufacturing process results in a tremendous improvement in quality, throughput and productivity as well as a drastic reduction in manufacturing operations, workholding fixtures, cutting tools, and inspection media.     

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.     

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.     

Case study in Six Sigma methodology: manufacturing quality improvement and guidance for managers

This article discusses the successful implementation of Six Sigma methodology in a high precision and critical process in the manufacture of automotive products. The Six Sigma define–measure–analyse–improve–control approach resulted in a reduction of tolerance-related problems and improved the first pass yield from 85% to 99.4%. Data were collected on all possible causes and regression analysis, hypothesis testing, Taguchi methods, classification and regression tree, etc. were used to analyse the data and draw conclusions. Implementation of Six Sigma methodology had a significant financial impact on the profitability of the company. An approximate saving of US$70,000 per annum was reported, which is in addition to the customer-facing benefits of improved quality on returns and sales. The project also had the benefit of allowing the company to learn useful messages that will guide future Six Sigma activities.     

Fuzzy integrated QFD,FMEA framework for the selection of lean tools in a manufacturing organisation

Lean Manufacturing (LM) is a well-established system to improve performance of any manufacturing industry by eliminating wastes through globally accepted tools and techniques. Industries are trying to adapt lean principles in order to optimise the resources like people, equipment, material and schedule for being efficient in the competitive market. This paper proposes an integrated approach for selecting appropriate lean tools in reliable lean perspective to enhance these critical resources. The approach exercise a hybrid model which uses fuzzy QFD to prioritise the critical resources in relation with identified wastes and fuzzy FMEA to assess the risk associated with each sub elements to address lean implementation. For waste identification, plant layout and Value Stream Mapping are considered. The model is demonstrated based on the data collected from a manufacturing industry to illustrate the application. Significant improvements are quantified with the help of future state map and plant layout.     

Quality management and performance: a comparison between the UK and Turkey

Purpose: The aim of this article is to detail the correlation between quality management, specifically its tools and critical success factors, and performance in terms of primary operational and secondary organisational performances.

Design/methodology/approach: Survey data from the UK and Turkey were analysed using exploratory factor analyses, structural equation modelling and regression analysis.

Findings: The results show that quality management has a significant and positive impact on both primary and secondary performances; that Turkish and UK attitudes to quality management are similar; and that quality management is widely practised in manufacturing and service industries but has more statistical emphasis in the manufacturing sector. The main challenge for making quality management practice more effective lies in an appropriate balanced use of the different sorts of the tools and critical success factors.

Originality/value: This study takes a novel approach by: (i) exploring the relationship between primary operational and secondary organisational performances, (ii) using service and manufacturing data and (iii) making a cross-country comparison between the UK (a developed economy) and Turkey (a developing economy).

Limitations: Detailed contrast provided between only two countries.     

Alternate Routing Strategies in Batch Manufacturing: An Evaluation

Batch manufacturing firms are experiencing significant changes because of technological developments in work center design, such as flexible manufacturing systems (FMS) and planning/control tools like computer-aided process planning (CAPP). These new developments provide production managers with some solutions to a number of complex problems. For example, numerical-controlled (NC) machine center installations are effective in providing quality parts because of tight tolerance specifications built into the equipment. However, these highly efficient centers create bottlenecks that constrain shop throughput, since production planners tend to rely too much on them. To help improve manufacturing planning, we introduce an important element to the batch production scheduling component of CAPP's mission—evaluating possible alternate routes. Production scheduling encompasses job route selection as well as machine center assignment (loading), job releasing, and setting due dates. In this paper, three routing strategies requiring different levels of shop floor information are tested and evaluated using computer simulation. Shop performance is measured by total cost and traditional measures of job flow time, lateness, and tardiness.     

Beyond the Skinner Box: The Design and Management of Organization-Wide Performance Systems

A discussion of the need for organizational behavior management practitioners to shift their application paradigm from a dyadic perspective to a systems perspective is presented. Such a shift would improve the identification of performance improvement opportunities, reduce the effects of unintended contingency interactions, and help ensure sustainable improvement efforts. Nine performance system tools are described that assist the analyst in the design of a performance system and its long-term management and maintenance. A manufacturing case study describing the application of these tools is provided.     

A human - computer interactive approach based on activity - section analysis for BPR

In any business process reengineering (BPR) project, a thorough understanding of various tasks and activities of the organization is required. Very often this idea is captured using a simple flow chart or static representation diagram. The weakness here is that the process design complexity is not adequately represented by the use of flow charts, and this allows for limited human-computer interaction during the process design and analysis. In this paper, we propose an enhanced flow chart approach; the concept of activity-section flow chart to support BPR, which is a combination of the existing activity flow chart and section flow chart. Using this approach, a human-computer interactive model for BPR is developed. This model can identify the unreasonable activity loops and excessive business rounds between sections by the adjacent and reachable matrices. Via the human-computer interaction, the process can be revised by human experience. This approach provides an efficient tool for BPR of large-scale systems. It has been applied to the material supply management system of an iron and steel works, and satisfactory results have been achieved.     

A FRAMEWORK AND MEASUREMENT INSTRUMENT FOR JUST-IN-TIME MANUFACTURING

While Just-in-Time (JIT) manufacturing has emerged as one of the major tools to enhance manufacturing competitiveness, no attempt has been made to develop a reliable and valid measurement instrument for empirical research in JIT. Without such an instrument, generalization beyond the immediate sample is difficult or misleading. We have proposed a JIT framework and developed a valid and reliable instrument with 16 summated scales for dimensions that capture essential aspects of JIT useful in assessing its impact in manufacturing environments. In addition, we discuss in detail the interactive nature of JIT practice. And, we propose a step-by-step approach to reliability and validity testing. Four JIT practices (equipment layout, pull system support, supplier quality level, and Kanban) are identified as major contributing factors to JIT performance.     

AN INTEGRATIVE APPROACH TO PROCESS PARAMETER SELECTION

This case study of a process improvement project from the Hewlett-Packard Analytic Products Group illustrates a number of important approaches for operations strategy. First, we show how process control in capillary tube manufacturing led to a significant improvement in tubing strength, a quality measure that relates to the frequency of tube defects at a particular stress level. Next, we show how one particular approach used for experimental design and process improvement was considerably more economical than another standard method. In conclusion, we link the process characteristics such as defect frequency to strategic measures such as company revenue and investment to underscore the strategic importance of process control.     

7 Getting There from Here: Research on the Effects of Work–Family Initiatives on Work–Family Conflict and Business Outcomes

Abstract

Many employing organizations have adopted work–family policies, programs, and benefits. Yet managers in employing organizations simply do not know what organizational initiatives actually reduce work–family conflict and how these changes are likely to impact employees and the organization. We examine scholarship that addresses two broad questions: first, do work–family initiatives reduce employees’ work–family conflict and/or improve work–family enrichment? Second, does reduced work–family conflict improve employees’ work outcomes and, especially, business outcomes at the organizational level? We review over 150 peer‐reviewed studies from a number of disciplines in order to summarize this rich literature and identify promising avenues for research and conceptualization. We propose a research agenda based on four primary conclusions: the need for more multi‐level research, the necessity of an interdisciplinary approach, the benefits of longitudinal studies that employ quasi‐experimental or experimental designs and the challenges of translating research into practice in effective ways.     

Integration of IPA and QFD to assess the service quality and to identify after sales service strategies to improve customer satisfaction – a case study

Customer satisfaction is considered very essential nowadays as it shows how firms are dedicated to afford quality products or services to their customers. Retaining the existing customer and acquiring the new customers are the basic objectives of any organisation and after sales service (ASS) has acquired a strategic role as a mean to achieve customer satisfaction. Importance–performance analysis (IPA) and quality function deployment (QFD) are the powerful tools successfully applied in many fields. However, studies on application of these tools in investigating the ASS quality and customer satisfaction seems to be scarce. This article investigates linking of IPA, which is a simple and effective customer satisfaction tool and QFD in the improvement of ASS attributes in an effort to determine the appropriate ASS strategic action plans to be adopted with the objective of enhancing customer satisfaction. In this study, a customer-driven model is proposed to examine the importance of the various ASS attributes and the performance of the organisation via questionnaire survey, and through the IP analysis, the areas to be focused are identified to help the decision makers in devising suitable policies, to improve the ASS performance. This is achieved through the employment of QFD that will help decision makers in the strategic planning to attain better customer satisfaction. A case study is carried out to exhibit the effectiveness of the developed model in a firm involved in manufacturing the home appliances.     

Monitoring the improvement of an overall industrial performance based on a Choquet integral aggregation

The design and use of performance measurement systems (PMSs) have received considerable attention in recent years. Indeed, industrial performances are now defined in terms of numerous criteria to be synthesized for overall improvement purposes. The analysis of the literature leads to the conclusion that most of the proposed approaches deal with a qualitative approach of this multi-criteria issue. But only a few quantitative models for PMSs have been proposed in order to better monitor the continuous improvement cycle. Among them, the one proposed by the authors, based on a Choquet integral aggregation operator, allows to express an overall performance according to subordination and transverse interactions between the criteria involved. But, as this model is nonlinear, it is useful to define pieces of information aimed at aiding the manager to improve the performance situation. Thus, this article is a contribution to the managers’ requirements for optimizing the improvement of the overall performance versus the allocated resources. In this view, indexes of efficiency and predictive improvement are proposed. The approach is applied to a case study submitted by a company manufacturing kitchen and bathroom furniture which wants to upgrade the monitoring of its “environment and quality improvement plan”.     

The new production theory for health care through clinical reengineering: a study of clinical guidelines--Part I

Drucker writes that the emerging theory of manufacturing includes four principles and practices: statistical quality control, manufacturing accounting, modular organization, and systems approach. SQC is a rigorous, scientific method of identifying variation in the quality and productivity of a given production process, with an emphasis on improvement. The new manufacturing economics intends to integrate the production strategy with the business strategy in order to account for the biggest portions of costs that the old methods did not assess: time and automation. Production operations that are both standardized and flexible will allow the organization to keep up with changes in design, technology, and the market. The return on innovation in this environment is predicated on a modular arrangement of flexible steps in the process. Finally, the systems approach sees the entire process as being integrated in converting goods or services into economic satisfaction. There is now a major restructuring of the U.S. health care industry, and the incorporation of these four theories into health care reform would appear to be essential. This two-part article will address two problems: Will Drucker's theories relate to health care (Part I)? Will the "new manufacturing" in health care (practice guidelines) demonstrate cost, quality, and access changes that reform demands (Part II)?     

Determinants and barriers to lean implementation in food-processing SMEs – a multiple case analysis

This study explored contextual or determining factors and their impacts on lean manufacturing in small- and medium-sized enterprises (SMEs) operating in food-processing industries. In order to get an in-depth insight into the real situation at the work floor, this study adopted a multiple-case-study research approach. The inherent characteristics of food industries, such as mandatory quality assurance requirements, low shelf life of food products, and the extremely volatile demand and supply presented barriers to lean manufacturing adoption. In addition, the challenges of ‘change’ in an SME environment are distinct from those faced by large organizations. The small size of the plant, the traditional setup, and inflexible layout make it difficult to implement lean manufacturing in food-processing SMEs. The knowledge of contextual factors influencing lean manufacturing adoption in food processing SMEs will be a contribution to current knowledge. Many studies have explored lean constructs and tools, while far fewer have explored the crucial element of actually implementing these. The study will also help practitioners to anticipate potential obstacles and take proper measures to deal with them during lean implementation.