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.     

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.     

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’.     

Optimal Policies for Selling New and Remanufactured Products

Because of environmental and economic reasons, an increasing number of original equipment manufacturers (OEMs) nowadays sell both new and remanufactured products. When both products are available, customers will buy the one that gives them a higher (and non‐negative) utility. Thus, if the firm does not price the products properly, then product cannibalization may arise and its revenue may be adversely impacted. In this paper, we study the pricing problem of a firm that sells both new and remanufactured products over a finite planning horizon. Customer demand processes for both new and remanufactured products are random and price‐sensitive, and product returns (also called cores) are random and remanufactured upon receipt. We characterize the optimal pricing and manufacturing policies that maximize the expected total discounted profit. If new products are made‐to‐order (MTO), we show that when the inventory level of remanufactured product increases, the optimal price of remanufactured product decreases while the price difference between new and remanufactured products increases; however, the optimal selling price of new product may increase or decrease. If new products are made to stock (MTS), then the optimal manufacturing policy is of a base‐stock policy with the base‐stock level decreasing in the remanufactured product inventory level. To understand the potential benefit in implementing an MTO system, we study the difference between the value functions of the MTO and MTS systems, and develop lower and upper bounds for it. Finally, we study several extensions of the base model and show that most of our results extend to those more general settings.     

An optimal product-reconfiguration policy due to order changes

Abstract

It is not an uncommon problem that a finished product cannot be delivered to its customer due to order change. In many real-life applications, such as rack-mounted computer products, it is possible to reconfigure a product by altering the combination of its components. Therefore, an inventory item, resulting from a cancelled order, can be handled in one of two ways: (1) keep the product in storage for a future order; or (2) send the product back to the manufacturing Door for reconfiguration in accordance with a new order A wise decision can be made by evaluating the trade-off between the inventory cost and the conversion cost. This paper presents an optimization procedure for achieving the minimum-cost solution. The problem is formulated by a quadratic programming model. Under a fairly general condition, the problem can be converted into a standard capacitated transportation problem and, therefore, can be solved efficiently. The cost structure, problem formulation, and solution technique arc discussed.     

The Global Food Industry and “Creative Capitalism”: The Partners in Food Solutions Sustainable Business Model

Rising global food prices have driven 44 million additional people into extreme poverty—and malnutrition—in developing countries since June 2010. Partners in Food Solutions (PFS), a nonprofit social enterprise affiliated with General Mills, is proposed as the conduit for food industry managers, engineers, and scientists to initially advise small‐ and medium‐sized African mills and food processors—and later other developing countries—on improving supply chain management by addressing manufacturing problems, developing products, improving packaging, extending product shelf, and finding new product markets. In this article, the “creative capitalism” model of sustainability and social and environmental responsibility is applied to the food manufacturing industry's efforts supporting PFS. Furthermore, the evolution of the sustainable business model developed by PFS is thoroughly described, explained, and analyzed as a generic model of social enterprise to be “scaled up” by the global food manufacturing industry. A summary of salient points conclude the article.     

Cloud platforms for remote monitoring system: a comparative case study

Abstract

Currently, industrial companies are increasingly introducing services to extend their tangible products. Remote monitoring solutions are one of the most implemented services by machine builders to manage their relationship with customers and also improve their business performance in the digital manufacturing era. However, the conventional method of remote monitoring cannot fulfill distributed business environments. Therefore, new solutions are needed to enable remote connection in manufacturing. By reviewing recent literature and proposing new features for software which can be used for remote service and operations, this research paper introduces a remote monitoring system connecting into a central cloud-based system with edge computing network architecture, namely Cloud-based Remote Monitoring (CloudRM). This proposed CloudRM also has been implemented in two different case companies for analysis and evaluation from a value proposition and technical implementation point of view. It shows significant improvement in production management and measurement by using CloudRM.     

新产品开发网络资源与技术资源匹配关系:基于中国制造业企业的实证研究

新技术革命背景下新产品开发所需资源的广度和深度与日俱增,不同资源的匹配组合对于新产品开发成功具有直接决定性作用。本文结合资源基础理论与社会网络理论,深入研究了新产品开发中不同程度网络-技术资源组合对新产品开发市场绩效与风险的作用机理,并探究了产品多元化对网络-技术资源组合与新产品开发市场绩效、风险之间关系的调节效应。基于143家中国制造业企业实地调研数据,运用结构方程模型与分层回归分析方法进行实证,结果发现:网络资源广度-技术资源深度组合以及网络资源深度-技术资源广度组合对新产品开发市场绩效有正向影响,对新产品开发风险有负向作用;网络资源广度-技术资源广度组合以及网络资源深度-技术资源深度组合对新产品开发市场绩效有负向影响,对新产品开发风险有正向作用;产品多元化正向调节网络资源广度-技术资源深度组合与新产品开发风险之间的关系,以及网络资源广度-技术资源广度组合与新产品开发市场绩效、风险之间的关系。本文的研究为企业提高新产品开发资源配置效率、降低开发风险提供了决策支持与理论依据。     

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 simulation study comparing performance of CONWIP and bottleneck-based release rules

Many firms seeking production economies and quicker throughput times have adopted cellular manufacturing techniques. New product introductions, increased product variety and process changes all add elements of uncertainty to the cell, and dynamic management techniques are required to achieve the benefits expected. This paper considers the problem of managing the flow of material into a manufacturing cell in order to maximize the output rate for a given level of work-inprocess inventory. The manufacturing cell is patterned after an Intel facility that assembles and tests microprocessors for the computer industry. The cell is studied under conditions in which a single bottleneck arises and those under which there are multiple bottlenecks. Alternative procedures for releasing material into the cell are evaluated in order to determine which offer the greatest advantage to managers.     

Adaptive agent-based manufacturing control and its application to flow shop routing control

The manufacturing industry is currently facing unprecedented challenges from changes and disturbances. The sources of these changes and disturbances are of different scope and magnitude. They can be of a commercial nature, or linked to fast product development and design, or purely operational (e.g. rush order, machine breakdown, material shortage etc.). In order to meet these requirements it is increasingly important that a production operation be flexible and is able to adapt to new and more suitable ways of operating. This paper focuses on a new strategy for enabling manufacturing control systems to adapt to changing conditions both in terms of product variation and production system upgrades. The approach proposed is based on two key concepts: (1) An autonomous and distributed approach to manufacturing control based on multi-agent methods in which so called operational agents represent the key physical and logical elements in the production environment to be controlled – for example, products and machines and the control strategies that drive them and (2) An adaptation mechanism based around the evolutionary concept of replicator dynamics which updates the behaviour of newly formed operational agents based on historical performance records in order to be better suited to the production environment. An application of this approach for route selection of similar products in manufacturing flow shops is developed and is illustrated in this paper using an example based on the control of an automobile paint shop.     

Engineering change: A theoretical assessment and a case study

The competitive playground where nowadays firms struggle to survive has rapidly become unforeseeable: product life cycle has shrunk, becoming even shorter than in the past, and world-wide market is suffering for a strong customer differentiation which led to an increasingly wide product mix. In this industrial environment, the engineering change process is getting more and more attention throughout the branches of industry, as it appears as a critical process which seeps into the operations management core, thus influencing the overall firm's performances. A brief state-of-the-art in the area of engineering change is firstly presented. Then a proposal of classification and a new methodology for an effective engineering change process management are suggested. The new proposed methodology has been successfully applied to a real-life manufacturing system and the related case study is reported at the end of the paper.     

考虑服务流的产品服务供应链网络均衡模型

产品服务供应链在向客户制造高质量产品的同时，也提供了产品全生命周期的专业服务，服务的嵌入增加了供应链协调的复杂性。考虑产品服务的双重需求，在分析各主体的运作行为的基础上，构建了包括多个制造商和多个销售商的多主体供应链网络；运用变分不等式刻画了制造商层、销售服务集成商层和需求市场的最优运作行为及其达成均衡的条件；最后，通过修正投影算法对数值算例进行了仿真。研究结果表明：产品服务供应链网络中的产品与服务均衡流相互影响，其中，服务水平直接影响到了产品需求；降低产品的售价将有利于服务价格和效益的提升。研究结论进一步印证了在产品服务供应链网络中承载于产品的服务将逐渐成为价值创造的主体。     

Manufacturing network configuration in supply chains with product recovery

Efficient implementation of product recovery requires appropriate network structures. In this paper, we study the network design problem of a firm that manufactures new products and remanufactures returned products in its facilities. We examine the capacity decisions and expected performance of two alternative manufacturing network configurations when demand and return flows are both uncertain.     

Capturing the benefits of industry 4.0: a business network perspective

Abstract

This study uses a business network perspective to investigate the industry 4.0 context with the internet of things (IoT) as its enabling technology and product-use data as its core network resource. A three-stage qualitative methodology (interviews, focus group, Delphi-based inquiry) was used to examine the case of an emergent IoT-based business network in the UK road transport industry to examine: (i) how aspects of product use data influence the benefit opportunities the data provide to the different network actors; (ii) how capturing of the benefit opportunities in a network context is impacted by key barriers; and (iii) how network capabilities can overcome these barriers to capture benefits from product-use data. The study, thereby, contributes to an understanding of the industry 4.0 context from a resource dependency theory perspective and provides concrete recommendations for management operating in this context.     

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.     

The myth of aggregate planning

Abstract

Abstract. An empirical study explores the business environment, the nature of manufacturing, and the planning cycle, using a sample of enterprises with seasonally-biased sales profiles for their products. This enables both the principles and the practicalities of aggregate planning to stand comparison with the observed rubric of manufacturing management. The conclusion is that neither is germane to industry, and that, in general, practitioners develop an effective (broad) manufacturing strategy with an appropriate resources-acquisition programme. The master production schedule then strikes an acceptable balance between productivity, flexibility, and financial risk.     

To Preannounce or Not: New Product Development in a Competitive Duopoly Market

In this study, we consider the issue of preannouncing or not preannouncing the development of a new product. Our research is motivated by contrasting views in the literature and varying actions observed in practice. We develop and analyze a game theoretic model that examines the effect of a firm's preannouncement of its product development. Our model is based on a durable goods duopoly market with profit‐maximizing firms. The first firm is an innovator who initially begins developing the product; the second firm is an imitator that begins developing a competing product as soon as it becomes aware of the innovator's product. We assume that consumers are rationally expectant and purchase at most one unit of the product when they have maximum positive utility surplus that is determined by the characteristics of the product, the consumer's marginal utility, and the consumer's discounted utility for future expected products. The innovator firm can release information about its product when it begins developing the product or can guard information about its product until it introduces the product into the market. Our analysis and numerical tests show that, under some conditions, the innovator firm can benefit by preannouncing its product and giving the imitator firm additional time to differentiate its product. We discuss these conditions and their implications for new product development efforts.     

Aspects of manufacturing strategy

Abstract

It is becoming increasingly important for manufacturing organizations to articulate clear and coherent manufacturing strategies that support their long term business objectives. In particular, manufacturing strategy should take conscious account of the competitive posture adopted by the organization in each of the product/market segments in which it has decided to participate. This paper discusses the various ways in which a systemic manufacturing strategy can contribute to an organization's competitiveness, and the processes by which such a strategy can be developed. Some important and often neglected issues concerning the development of the individual components of a manufacturing strategy are examined and the problems and issues of strategy implementation are discussed.     

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.