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.     

Understanding the emergence of redistributed manufacturing: an ambidexterity perspective

Abstract

This paper extends operations strategy theory on efficiency and flexibility trade-offs to the emergent phenomenon of redistributed manufacturing (RDM). The study adopts a multiple-case design including five small and five large pharmaceutical firms. We propose that organizations can gain the efficiency benefits of centralized manufacturing and the flexibility advantages of RDM by building an ambidexterity capability. To build such a capability, large firms can structurally partition their manufacturing and supply management functions, with one sub-unit managing centralized production and the other RDM. Smaller enterprises can build an ambidexterity capability by creating the right organizational context, where multi-skilled workers switch between efficient and flexible tasks. This paper contributes to theory by explaining the emergence of RDM using an organizational ambidexterity lens, laying the groundwork for new theory development in the field. We provide managers with a practical example of how to build an ambidexterity capability to realize flexibility and efficiency advantages.     

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.     

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.     

Supply chain reconfiguration opportunities arising from additive manufacturing technologies in the digital era

Abstract

The aim of this study is to explore the impact of additive manufacturing (AM) technologies on the configuration opportunities of supply chains (SCs) within the digital manufacturing era. To this effect, we first conduct a critical taxonomy of existing research efforts and then propose an integrated decision-making process for the design and management of SCs defined by digital manufacturing technologies. Following, we provide an integrated framework for future SC reconfiguration opportunities arising from the adoption of AM on a supply network setting. Our analysis demonstrates the significant ramifications of AM techniques on SC configuration and sustainability performance as opposed to conventional value networks; however, existing research is evidently limited due to scope related challenges and the inherent complexity at the manufacturing echelon of the respective supply networks.     

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.     

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.     

An Integrated Framework for Measuring Product Development Performance in High Technology Industries

We present an integrated framework for measuring product development performance. The framework consists of a three stage model for exploring the relationships between metrics used by design, manufacturing, marketing functions, and overall commercial success. Using a cross‐sectional survey of 383 product development professionals working on 38 product development projects in the high‐tech electronic assembled goods manufacturing sector, we provide empirical evidence of the proposed framework. The findings indicate that in the high‐tech manufacturing sector (1) commercial success of new product development projects is primarily determined by market share, (2) gain in market share is primarily driven by lower unit cost and not by technical performance, and (3) reduction in unit cost is primarily driven by the increased speed of new product development and not by the R&D budget. The study failed to identify any significant association between R&D budget and technical performance, and development speed and technical performance.     

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.     

Managing international manufacturing at plant and plant network levels – insights from five case studies

Abstract

In this study, we develop understanding of management of international manufacturing by a combined analysis of manufacturing firms’ plant networks and roles of individual plants within them. We elaborate the framework of Ferdows (1989 Ferdows, K. 1989. “Mapping International Factory Networks.” In Managing international manufacturing, edited by K. Ferdows, 3–21. Amsterdam, The Netherlands: Elsevier Publishers. [Google Scholar]) at plant and network levels by analyzing data collected from five plant networks of global manufacturing companies and propose an enhanced framework consisting of four main role types with eleven plant roles, which have implications on the network level. The findings give interesting and novel insights into management of international manufacturing; we conclude that plant roles are more complex than conventionally considered and understanding of international manufacturing requires elaborated analysis at both plant and network levels.     

Improving operational plant performance in international manufacturing networks: the effects of integrative capabilities and plant roles

Abstract

This study adopts the resource-based view to examine how two integrative capabilities of a plant embedded in a manufacturing network enhance operational performance: the capability to connect with other plants in its manufacturing network (a networking capability, NC), and the capability to integrate manufacturing processes with new product development processes (a new product development capability, NPDC). Our model tests the indirect effect of NC on cost, quality, flexibility and delivery through NPDC. Furthermore, we test if the relationship between NC and NPDC depends on the strategic role of the plant. Using survey data from a sample of 521 plants, we confirmed the mediating effect of NPDC. However, the moderation effect was not confirmed. Our findings reveal that plants can deploy NPDC capabilities, fostered by NC, independently from their role in the network. This study contributes to the understanding of plant capabilities and plant roles in manufacturing networks.     

大数据行为研究趋势:一个“时空关”的视角

本文从"时空关",即时间、空间、关联3个维度来分析近十余年大数据行为研究的进展,总结近年来本课题组的相关研究结果,并探讨未来发展趋势。各种时空大数据的广泛采集和应用取得了突破性的进展,推动了有关人类流动行为的研究;与此同时,社会网络和社会媒体大数据的发展把人们关联行为的研究推向新高度。流动性和关联性以及这两个方向的交融构成了大数据行为研究的基本范畴,而通过"时空关+"不同内容和场景形成了大数据应用的广泛格局。大数据行为研究面临的主要挑战是如何解决大数据分析中的内生性问题,未来的研究将更加重视通过随机实验、田野实验或者自然实验等方法来做因果推断。大数据行为研究的"时空关+"为探讨人类行为的基本规律以及各种应用场景提供了一个崭新的视角。     

存在二手市场时耐用品垄断厂商再制造策略研究

运用稳态均衡分析方法，利用消费者效用模型分析存在二手市场时耐用品垄断厂商再制造策略选择问题。通过模型分析得到，耐用品垄断厂商选择再制造策略的条件为：新耐用品成本、再制造成本以及旧耐用品贬值率低于临界值，而消费者认可程度高于临界值。耐用品垄断厂商选择再制造策略不仅会对新耐用品市场产生挤兑效应，而且也会对二手市场产生挤兑效应。存在旧耐用品再利用率的临界值，当耐用品垄断厂商的旧耐用品再利用率高于该临界值时，选择再制造策略可以提高消费者对耐用品的需求量，产生市场增长效应；新耐用品的生产成本正向影响市场增长效应。     

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.     

Linking long-term capacity management for manufacturing and service operations

For firms that combine manufacturing and service operations in one system, the task of managing capacity is not straightforward. New goods and services may not have the same set of competitive priorities, and the models and concepts available in the literature for service operations differ from those for manufacturing operations. We address this problem and review the concepts and models for capacity management in the long term in both streams of literature, i.e. manufacturing and services, to develop a unified framework for manufacturing and service operations. The framework creates transparency between new goods manufacturing and service operations, since the same long-term capacity management structure is used for both product types, as well as between capacity strategy and planning strategy, since new goods and services are treated simultaneously. In the framework, the concepts of chase and level strategies are redefined for service operations to allow for integration with manufacturing operations. A case study demonstrates the usefulness of the integrated approach for long-term capacity management.     

Learning from suppliers: a framework for operation innovation in small and medium sized enterprises

Abstract

Inter-firm learning though partnering with suppliers is often considered as a relatively cheap way to develop the knowledge necessary for innovating operations procedures. SMEs may benefit, especially from the inflow of information, as they face multiple restrictions on innovating manufacturing or delivery processes due to their small size and limited resources. Based on the two studies – a logistic regression analysis and a configuration analysis – evidence was found that small- and medium-sized enterprises (SME) need to integrate knowledge sources in distinct knowledge configurations. In particular, it is shown that an operation process innovation (OPI) strategy for SME is incomplete if it does not find a way to combine internal and external knowledge to innovate operation procedures. The main contribution of this paper is to uncover the precise composition of effective knowledge configurations, which leads to innovation.     

日本制造企业新产品开发过程中模糊前端创新的效果分析

本文对日本制造企业新产品开发(NPD)过程中模糊前端(FFE)创新成功的关键因素进行了大样本分析,开发并构建了FFE创新要素与NPD项目绩效之间的因果关系模型.根据513家日本制造企业NPD项目的调查数据,运用AMOS验证因果关系模型,我们得出两个重要结论:在FFE阶段,技术和市场的不确定性减少越多,NPD项目的效率越高;开发前项目初始规划强度越大,开发过程中市场和技术的不确定性就越少.而且相对服务企业而言,制造企业的管理层更容易做出对降低市场不确定性有重大影响的初始规划.     

How smart cities transform operations models: a new research agenda for operations management in the digital economy

Abstract

The notion of smart cities is growing in prominence in the digital economy. The integration of urban infrastructures with information and communication technologies enables the development of new operations models. Digitised infrastructures offer opportunities for public and private organisations to design and deliver more customer-centric products or services, particularly for those that require geographical proximity with consumers in the online to offline (O2O) context. A framework is developed and used to analyse three case examples. These cases illustrate the emergence of new operations models and, demonstrate how smart cities are redefining the characteristics of operations models around their scalability, analytical output and connectivity. We also explore the feasibility, vulnerability and acceptability of each new operation. This paper contributes to our understanding of how smart cities can potentially transform operational models, and sets out a research agenda for operations management in smart cities in the digital economy.     

TAPAS: A modular framework to support reuse in scheduling software development

Industrial schedulers try to take into account more and more complex aspects of manufacturing and become, as a consequence, more difficult to use efficiently. We suggest a modular framework for scheduling in order to support the development of schedulers better adapted to the workshop they are used in. An extensive reuse of past developments is made possible by the definition of a powerful, yet generic, data model, together with a fully modular architecture and the use of standards, e.g. CORBA, MMS and STEP. Examples of the first schedulers developed within this framework in an industrial context are shown.