An industrial application for total productivity optimization

Abstract. This paper presents four strategies for total productivity optimization of a real-life manufacturing company. These strategies are developed to attain overall growth, cost reduction, upgrading of technical efficiency and management effectiveness. Such strategies have been modelled mathematically by using a nonlinear mathematical programming approach. The model base and the data base used in implementing the strategies can serve as decision support to management for optimizing total productivity.     

Rolling horizon master production schedule performance: A policy analysis

In this paper, a simulation experiment has been developed to examine the combined influence of the design, inventory and environmental factors on the cost performance of a rolling horizon master production schedule. Specifically, a 2 5 factorial design was used to examine the effects associated with three rolling schedule design policies, one inventory policy and one environmental condition of forecast error on MPS cost performance. The study was based on actual data from a paint company. Results suggest that the choice of appropriate lot-size and inventory policies have a significant influence on MPS costs and that there are indeed important interactions between these policies and other design factors of a rolling schedule.     

A decomposition technique for quantifying real process performance

A decomposition technique for quantifying the impacts of changes in product mix and process performance on aggregate process-related indicators is presented. Through application of the technique, the real performance of a process can be quantified. Changes in real performance over time can be monitored to provide useful information for process evaluation and production planning. Two case studies, one related to the aggregate defective rate for an assembly line of an integrated circuit fabrication plant and the other to the aggregate inventory turnover for a tyre distribution company, are presented to illustrate the application of the technique.     

Resource smoothing: A cost minimization approach

From the available literature, there seems to be no defined approach to resource smoothing exercise except those attempted by Weist (1967, Management Science, 13, B359-B377) and Burgess and Killebrew (1962, Journal of Industrial Engineering, 13, 76-83). The aim of the smoothing exercise is to achieve optimal resource usage by avoiding high peaks and deep valleys in the project resource profile. The general approach has always been to move some activities with floats in the high peak regions to be started at a later date, and as this is done, the valleys will be filled to smooth the resource profile subject of course to time constraint. If this approach is followed as it is, it would be difficult to determine optimality especially when many resources are involved. A cost minimization approach is envisaged in the present study with no limitation on the number of resource inputs. In a situation where the resources are assumed to have the same value, the cost assigned to each of them should be similar. The method follows the general concept but with a difference; cost of the activity in question is considered. The exercise is continued until all the floats are exhausted. The optimum result would then be the one with the minimum cost profile. From examples used for the evaluation, the results obtained are comparable to those of the above two researchers, and some with better results in the majority of cases.     

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.     

Judicious order acceptance and order release in make-to-order manufacturing systems

This paper explores a two-stage input control system for fixed capacity make-to-order manufacturing systems (with heavy job tardiness penalties), that selectively accepts incoming orders and holds the accepted ones in a pre-shop queue prior to releasing them to the shop floor. Single-stage input control systems that only allow orders to be delayed in a pre-shop queue (i.e. they do not allow some orders to be rejected) have been previously investigated and found to negatively impact overall due-date performance. The hypothesis motivating this research is that judiciously rejecting a subset of incoming orders can prevent the order release queue from being overloaded when a surge of demand occurs. The input control system is evaluated via experiments using a discrete-event simulation model of a fixed capacity manufacturing system. The experiments reported here suggest that holding orders in the pre-shop queue does not improve due date performance, and that judiciously rejecting orders on its own is a viable alternative mechanism of input control that can deliver improved performance.     

Green supply chain management practices in India: an empirical study

This paper presents an empirical study of green supply chain management (GSCM) practices in the Micro, small and medium enterprises (MSMEs) in India. Although the research in the area of GSCM has grown in recent times, the literature has yet to furnish an accepted explanation for why green practices are to be manifested in supply chain management given external and internal pressures. These MSMEs have been involved in such green supply chain practices only to the extent of their participation as suppliers, distributors and in other capacities as business partners. This study confirms and validates that Indian MSMEs face significant pressures from external stakeholders to adopt GSCM practices. Among internal pressures, on-the-job training forces MSMEs in India to adopt GSCM practices. It has been also established that external pressures and adoption of GSCM are fully mediated by internal pressures.     

Managing green productivity: Some strategic directions

The twentieth century has been the hallmark for managing total productivity, where the emphasis is towards maximization of outputs commensurate with the consumption of inputs. This is being challenged now to evolve the world class manufacturing strategy requiring a paradigm shift. This shift is towards green productivity, which looks forward to socially appropriate production and consumption aiming at value innovation and resource conservation. This paper is an attempt to outline the concepts and experiential learning about green productivity.     

The Competitive Impact of Targeted Television Advertisements Using DVR Technology

Digital video recorders (DVRs) are an emerging technology that is fundamentally changing the competitive landscape in industries that advertise on television. Perhaps the most familiar impact of DVR technology is that it enables consumers to avoid advertisements (ads) by fast forwarding through them. However, this “zipping” of ads is only one aspect of the impact of DVR technology. DVRs also collect a wealth of information at the consumer level that can be used by firms to target their ads more effectively. We examine how this targeting capability moderates the impact of ad avoidance in a competitive setting. Insights are provided on how best to manage this emerging technology in terms of the key managerial decisions of product pricing and advertising efforts, as well as its impact on profits in a competitive (duopoly) marketplace.     

Disaster and deritualization: A re-interpretation of findings from early disaster research

This study investigates how ritual practices are disrupted in disasters and the ways people deal with those situations. We employ structural ritualization theory to conduct this investigation focusing on deritualization, which refers to the breakdown or loss of ritualized activities that occur in daily life. The thesis of this paper is that ritual practices are disrupted in a disaster leading to the breakdown of action and meaning. Data were collected from 19 seminal sociological studies from the National Academy of Sciences published first under the name of the Committee on Disaster Studies (1951–1957) and then under the rubric of the Disaster Research Group (1957–1962). A content analysis of these studies revealed many instances of deritualization. Deritualization is manifested or most evident through its effects on action and meaning in rituals. Examples were categorized according to the loss of action, meaning, or a combination of both.