Re-distributed manufacturing and the food-water-energy nexus: opportunities and challenges

Abstract

Addressing the intersection of two important emerging research areas, re-distributed manufacturing (RDM) and the food-energy-water (FEW) nexus, this work combines insights from engineering, business and policy perspectives and explores opportunities and challenges towards a more localized and sustainable food system. Analysis centred on two specific food products, namely bread and tomato paste reveals that the feasibility and potential of RDM vary with the type of food product and the supply chain (SC) components. Physically, energy efficiency, water consumption and reduction of waste and carbon footprint may be affected by scale and location of production activities and potentials of industrial symbiosis. From the business perspective, novel products, new markets and new business models are expected in order for food RDM to penetrate within the established food industry. Studies on policies, through the lens of public procurement, call for solid evidence of envisioned environmental, social and economic benefits of a more localized food system. An initial integrated framework is proposed for understanding and assessing food RDM and the FEW nexus.     

Redistributed Manufacturing and the Impact of Big Data: A Consumer Goods Perspective

Abstract

Digitalization and the growth of big data promise greater customization as well as change in how manufacturing is distributed. Yet, challenges arise in applying these new approaches in consumer goods industries that often emphasize mass production and extended supply chains. We build a conceptual framework to explore whether big data combined with new manufacturing technologies can facilitate redistributed manufacturing (RDM). Through analysis of 24 consumer goods industry cases using primary and secondary data, we investigated evolving manufacturing configurations, their underlying drivers, the role of big data applications, and their impact on the redistribution of manufacturing. We find some applications of RDM concepts, although in other cases existing manufacturing configurations are leveraged for high volume consumer goods products through big data analytics and market segmentation. The analysis indicates that the framework put forward in the paper has broader value in organizing thinking about emerging interrelationships between big data and manufacturing.     

A vision of re-distributed manufacturing for the UK’s consumer goods industry

Abstract

The linear production of consumer goods is characterised by mass manufacture, multinational enterprises and globally dispersed supply chains. Redistributed manufacture (RDM) is an emerging topic, which seeks to enable a transition of the current linear model of production and consumption, by taking advantage of new technologies. This paper aims to explore the challenges, opportunities and further research questions to set a vision of Redistributed manufacturing for the UK’s consumer goods industry. To set this vision, a literature survey was conducted followed by a qualitative enquiry where PESTLE¹ aspects of RDM were analysed. This analysis was interpreted through a roadmap. As a result of this roadmap, four RDM characteristics (i.e. customisation, use of digital technologies, local production and the development of new business models) were identified. These characteristics helped to set the future vision of RDM in the UK’s consumer goods sector.     

Additive manufacturing technology adoption: an empirical analysis of general and supply chain-related determinants

Despite experiencing immense growth in the past decade, additive manufacturing (AM) technologies—colloquially known as 3D-printing—are still rarely used in industrial fabrication. Being at the interface between technology, innovation, behavioral science and operations management research, this paper identifies multifaceted factors that determine the decision to adopt AM technologies for the production of industrial parts. A review of the relevant literature revealed eight potential factors. These can be classified into four interdisciplinary categories: technology-related factors, firm-related-factors, market structure-related factors, and supply chain-related factors. Special focus is placed on the impact of supply chain-related issues, because there are indicatives that these aspects have an influence on the decision to adopt AM technologies since AM may offer distinct opportunities for both, the supply- and demand-side of a firm’s operations. No work in the field of manufacturing technology adoption has examined the role of such inter-organizational factors before. The results of an empirical study among 195 firms indicate that demand-side benefits and compatibility are the main determinants of AM technology adoption. This suggests that not only intra- but also inter-organizational factors should be considered when investigating the adoption of technological innovations. Furthermore, it is carved out that the adoption of AM technologies has an interdisciplinary nature.     

Insights from big Data Analytics in supply chain management: an all-inclusive literature review using the SCOR model

Abstract

When supply chain management (SCM) intersects with Big Data Analytics (BDA), uncountable opportunities for research emerge. Unfortunately, how analytics can be applied to supply chain processes is still unclear for both academics and industries. To better connect SC processes needs and what BDA offer, we present a structured review of academic literature that addresses BDA methods in SCM using the supply chain operations reference (SCOR) model. The literature since 2001 is reviewed to provide a taxonomy framework resulting in a nomenclature grids and a SCOR-BDA matrix. The most important result of this paper indicates a clear disparity and points to an urgent need to bring the efforts closer in a collaborative way for more intelligent use of BDA in SCM. Furthermore, this paper highlights a misalignment between data scientists and SC managers in BDA applicability. It also highpoints upcoming research tracks and the main gaps that need to be stunned.     

Additive manufacturing’s impact and future in the aviation industry

Additive manufacturing (AM) is a technology that has the potential to change the future of aviation supply chains and how the aviation industry designs, manufactures and repairs aircraft in the future. The purpose of this research was to shed light on the current and future states of AM in the aviation industry. From focus groups with nearly 50 aviation professionals from aircraft original equipment manufacturers (OEMs), suppliers, maintenance repair overhaul providers, and AM service providers and AM production firms, we found that the adoption of AM will be triggered by the accumulated AM experience in the industry, the stability of AM technology and the development of new aircraft generations. For AM to be finally adopted, aircraft OEMs must actively manage several success factors and monitor numerous control factors identified and discussed in this research. AM will supplement traditional manufacturing processes at least in the short to midterm, likely grow exponentially and offer benefits for players in the aviation supply chain.     

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.     

The management of international manufacturing networks: a missing link towards total management of global networks

Abstract

The purposes of this article are to provide a brief overview of the research on international manufacturing networks (IMNs), identify corresponding gaps and provide background for the papers published in this special issue. First, this article shows the importance of addressing the management of IMNs, especially in times of global turbulence as a result of new economic, political and technological trends. Second, it highlights research into the management of IMNs as a missing link in the Operations Management (OM) discipline, as most of the current OM research neglects the fact that the internal structures and relationships of multi-plant organizations inside firms play a critical role in how a supply chain/network operates and relies mostly on scholars in other fields for insights into high-level and strategic issues in the management of global operations. Finally, this article argues there is still a lot to do in order to develop new theories towards the total management of global networks that can holistically analyze different global (intra- and inter-firm multi-functional) networks and address the complex interdependencies between them.     

Prioritising indicators in improving supply chain performance using fuzzy AHP: insights from the case example of four Indian manufacturing companies

Abstract

In this contribution, we aim to prioritise the indicators to enhance the organisational supply chain’s (SC) effectiveness from an industrial perspective. It will help industries to develop strategies for managing the SC effectively and ensuring improvement in performance continuously. To achieve this, this work proposes to use a two-phase research methodology. First, 36 SC performance improvement indicators are recognised from a literature survey and from field and industrial expert’s inputs. Secondly, a structural model is proposed using the fuzzy analytical hierarchy process (AHP) to prioritise the indicators strategically to improve the SC performance. The fuzzy AHP method helps determine the priority of concerns of the identified indicators under fuzzy surroundings. Inputs in this research are taken from four ancillary Indian plastic manufacturing firms. Research findings indicate that collaborations and information exchange dimension indicators obtained the highest priority in improving SC performance. The model proposed is considered very useful for the SC managers/practitioners/decision-makers to understand better and distinguish the essential SC performance improvement indicators and to take systematic decisions specifically to improve the performance of business in a SC context. Sensitivity analysis was conducted to examine the priority ranking of the indicators.     

Effects of key enabling technologies for seru production on sustainable performance

Demand uncertainty, economic globalization, and environmental deterioration force factories to innovate their manufacturing systems for achieving sustainable performance. Seru production, which is the latest manufacturing mode developed in Japan, attracts broad attention from both academia and practitioners. The overwhelming majority of existing works on seru production focus on economic performance unilaterally, while neglecting the environmental and social performance. This paper investigates the effects of key enabling technologies for seru production on sustainable performance. Firstly, four key enabling technologies for seru production are identified through systematic review, and an evaluation indicator system of sustainable performance in the context of seru production is developed. Then, the hypotheses about the effects of the identified key enabling technologies for seru production on sustainable performance are proposed on the basis of previous research achievements, theoretical analysis, and practical observations. Finally, the hypotheses are tested through structural equation modeling. Except for two hypotheses which are not supported and one which is indirectly supported, all other hypotheses are verified. The research results show that the four key enabling technologies for seru production have different effects on the three dimensions of sustainable performance. The achievements of this work are of significance to improve the comprehensive understanding of seru production, as well as to develop practical methods to implement sustainable operations.     

A taxonomy of international manufacturing networks

Abstract

Manufacturing firms with multiple product groups do not need to involve all factories in the production of all product groups. Some factories may specialize on a small set of products, while others participate in the manufacturing of a broader set of products. However, current theories on international manufacturing networks do not explain in detail how organizations design international manufacturing networks for different products or product groups involving different sets of factories. This research investigates 20 product group networks at five global manufacturing firms. We distinguish between three types of factories: component manufacturing factories, assembly factories, and integrated factories (having both component manufacturing and assembly). Furthermore, we identify four network types: linear, divergent, convergent, and mixed structures. These four types exhibit distinctly different characteristics in terms of key characteristics, factory roles, product types, process types, market types, sourcing, and key managerial challenges. Most networks are relatively small – on an average consisting of four factories and some contain a number of subnetworks that are self-sufficient in terms of material flow and serve separate market regions. We identify two new types of factory roles related to component manufacturing competences, which we call ‘strategic feeder’ and ‘full lead’.     

Product architecture,global operations networks,and operational performance: an exploratory study

Abstract

This paper investigates the relationships between product architectures and global operations networks and their impact on operational performance, based on survey data from 82 Swedish manufacturers. We find that modular and integral product architectures are associated with different characteristics of the global operations network, and that global operations network designs are characterised by three dimensions: network, plant and supply chain. The key aspects are network structure (configuration as well as coordination), plant focus (scale or scope) and the locus of supply chain capabilities (internal or external).     

Cloud manufacturing system for sheet metal processing

Abstract

Cloud computing is changing the way industries and enterprises run their businesses. Cloud manufacturing is emerging as an approach to transform the traditional manufacturing business model, while helping the manufacturer to align production efficiency with its business strategy, and creating intelligent factory networks that enable collaboration across the whole enterprise. Many production planning and control (PPC) problems are essentially optimisation problems, where the objective is to develop a plan that meets the demand at minimum cost or maximum profit. Because the underlying optimisation problem will vary in the different business and operation phases, it is important to think about optimisation in a dynamic mechanism and in a number of interlinked sub-problems at the same time. Cloud manufacturing has the potential to offer decision support as a service and medium of communication in PPC. To solve these problems and produce collaboration across the supply chain, this paper provides an overview of the state of the art in cloud manufacturing and presents a model of cloud-based production planning and production system for sheet metal processing.     

Responding to discontinuities in product-based service supply chains in the COVID-19 pandemic: Towards transilience

PurposeIn this study, we identify and characterise how organisations have responded, in ways ranging from restoration to radical change, to discontinuities in their product-based service (PBS) supply chains during the COVID-19 pandemic.Design/methodology/approachFollowing a theoretical approach that integrates transilience and panarchy theory as a response strategy in PBS supply chains, our qualitative study involved collecting data through 19 semi-structured interviews at six manufacturing firms during the first 6 months of the COVID-19 pandemic (i.e., March to August 2020) and triangulating the findings with the secondary data and that from an industry workshop. Following an inductive approach, we performed thematic data analysis in Nvivo software package.FindingsThe findings suggest characterising discontinuities in PBS supply chains as unmanageable external supply-side, demand-side or interactional discontinuities or other manageable deliberate or forced organisational discontinuities. Following that characterisation, we developed a conceptual framework combing both resilience and transformation into new service opportunities.Research limitations/implicationsWe gained insights into the first-response abilities and ways of coping among manufacturing firms during the COVID-19 pandemic. Though our findings capture a contemporary, eye-of-the-storm perspective on future directions, a longitudinal study on the pandemic could further validate and extend the modes of response that complement mitigation with the ability to accelerate change or innovation of internal process or external service offerings.Originality/valueCombining current literature with lessons learned from the firms' immediate responses, this paper's overview and characterisation of discontinuities following the COVID-19 outbreak in PBS supply chains demonstrate how manufacturing firms can foster transilience. As such, it integrates product-based supply chain discontinuities into the domain of service-based supply chains.     

Manufacturing networks and supply chains: an operations strategy perspective

The purpose of this paper is to analyze manufacturing networks and supply chains from an operations strategy perspective. These two areas have traditionally been treated as separate research tracks, but with the ongoing globalization of markets and operations there is a need to integrate these complementary disciplines to study networks of facilities. In this paper we examine the two research areas based on two structural decision categories in an operations strategy, viz. facilities and vertical integration. We present a typology for the analysis of network systems resulting in four basic network configurations. Coordination of activities within the network is contingent upon the configuration, thus resulting in four coordination approaches. The configuration and coordination analyzes can be used as a foundation for further research in the context of integrating manufacturing network and supply chain theory.     

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.     

Inventory record inaccuracy – The impact of structural complexity and lead time variability

This article presents a rigorous prospective analysis of the impact of Inventory Record Inaccuracy (IRI) on complex multi-echelon Supply Chains (SCs). Specifically, key operational factors (i.e., the magnitude of the error, frequency of the inventory audits and lead time variability) and SC structure are systematically assessed. We find that the detrimental effects of IRI are exacerbated by the structural complexity of the SC and lead time variability. Furthermore, we show how the efficacy of countermeasure strategies may vary depending on SC configuration and operational conditions. These results allow us to provide interesting managerial recommendations to guarantee investment in prevention and correction strategies.     

中国企业呼唤敏捷制造战略

本文简述了敏捷制造战略的主要思想,指出在中国实施敏捷制造战略是当务之急。为此,需要从中国制造业的实际出发解决敏捷化的制造单元技术,以敏捷方式集成制造单元等关键问题。本文认为中国的敏捷化制造单元的构建可基于独立制造岛,提出了以虚拟企业方式实施中国的集团化经营战略的设想。     

Supply chain configuration conundrum: how does the pharmaceutical industry mitigate disturbance factors?

How a supply chain (SC) is configured can have a significant impact on the performance of global firms. More specifically, disturbance factors (i.e. those factors associated with uncertainty and risk) are increasingly important considerations. This paper focuses on endogenous, exogenous and environment-related SC disturbance factors and their relative importance when configuring global SCs. Three alternative scenarios of SC configurations for European-based pharmaceutical firms are identified – insource nearshore, outsource nearshore and outsource offshore. Through a multi-phase, mixed-methods approach we find that the top five disturbance factors managers should be aware of while configuring their SCs are quality defects, unforeseen and random interruptions in manufacturing processes, order processing difficulties, untimely delivery of products and a mismatch between market demand and supplier responsiveness. This study is able to provide insights into the impact of disturbance factors on the SC configuration strategy for Big Pharmas (BPs). We show that SC disturbances influenced the decision to bring production back home (reshoring) or to a closer location (nearshoring). To mitigate the effects of disturbances many BPs recalibrated their SC configurations by insourcing core products, outsourcing non-core products offshore and developing offshore insourcing capabilities through ‘captives’.