Managing Complexity in Manufacturing Changeovers: A Sustainable Manufacturing-Oriented Approach and the Application Case Study

2016 ◽  
Author(s):  
Khalid Mustafa ◽  
Kai Cheng
Keyword(s):  
Manufacturing Systems ◽  
Manufacturing Industry ◽  
Business Models ◽  
Sustainable Manufacturing ◽  
Lead Times ◽  
Manufacturing Companies ◽  
Factors Affecting ◽  
Manufacturing Complexity ◽  
Oriented Approach

Increasing manufacturing complexity continues to be one of the most significant challenges facing the manufacturing industry today. Due to these rapid changes in manufacturing systems, one of the most important factors affecting production is recognized as the frequent production setup or changeovers, consequently affecting the overall production lead times and competitiveness of the company. Developing responsive production setup and process capability is increasingly important as product ranges and varieties in manufacturing companies are growing rapidly and, at the same time, production business models are operating more towards being customer-oriented. Furthermore, although different conventional methods have been used to manage complexity in production changeovers, sustainability and competitiveness development in a manufacturing company needs to be scientifically addressed by managing manufacturing complexity. In this paper, a sustainable manufacturing-oriented approach is presented in mind of managing manufacturing changeover complexities. A case study is carried out specifically concerning changeover complexity in a pharmaceutical company, aiming at minimizing complexities in production changeover and waste, increasing plant flexibility and productivity, and ultimately the sustainable competitiveness of the company in managing manufacturing changes.

Comparison of Different Scenarios Using Computer Simulation to Improve the Manufacturing System Productivity: Case Study

2013 ◽  
Vol 845 ◽  
pp. 770-774 ◽  
Author(s):  
Seyed Mojib Zahraee ◽  
Milad Hatami ◽  
J.M. Rohani ◽  
H. Mihanzadeh ◽  
Mohammadreza Haghighi
Keyword(s):  
Computer Simulation ◽  
Production Line ◽  
Manufacturing Systems ◽  
Manufacturing Industry ◽  
Manufacturing System ◽  
Waiting Times ◽  
Manufacturing Companies ◽  
System Productivity ◽  
High Resource

In the manufacturing industry, managers and engineers are seeking to find methods in order to eliminate the common problems in manufacturing systems such as bottlenecks and waiting times. This is because that all of these kinds of problems impose extra cost to the companies. In addition, manufacturing companies are striving to sustain their competitiveness by improving productivity, efficiency and quality of manufacturing industry for instance high throughput and high resource utilization. The paper concentrates on the application of computer simulation to analysis manufacturing system in order to improve the productivity. Therefore, this study introduces a color manufacturing line as a case study and the basic application of arena 13.9 software. The goal of this paper is to improve the productivity and efficiency of the production line by using computer simulation. To achieve this goal, first the basic model of the current situation of production line was simulated. Second, three different alternatives were simulated and modified to find the best scenario based on the maximum productivity and minimum total cost.

scholarly journals Applying the PDCA Cycle to Reduce the Defects in the Manufacturing Industry. A Case Study

2018 ◽  
Author(s):  
Arturo Realyvásquez-Vargas ◽  
Karina Cecilia Arredondo-Soto ◽  
Teresa Carrillo ◽  
Gustavo Ravelo
Keyword(s):  
Lean Manufacturing ◽  
Manufacturing Systems ◽  
Manufacturing Industry ◽  
Welding Process ◽  
Manufacturing Companies ◽  
Delivery Times ◽  
Pdca Cycle ◽  
Increasing Demand ◽  
Quality Of Products

Defects are considered one of the wastes in manufacturing systems that negatively affect the delivery times, cost and quality of products leading to manufacturing companies facing a critical situation with the customers and to not comply with the IPC-A-610E standard for the acceptability of electronic components. This is the case is a manufacturing company located in Tijuana, Mexico. Due to an increasing demand on the products manufactured by this company, several defects have been detected in the welding process of electronic boards, as well as in the components named Thru-Holes. It is for this reason that this paper presents a lean manufacturing application case study. The objective of this research is to reduce at least 20% the defects generated during the welding process. In addition, it is intended to increase 20% the capacity of 3 double production lines where electronic boards are processed. As method, the PDCA cycle, is applied. The Pareto charts and the flowchart are used as support tools. As results, defects decreased 65%, 79% and 77% in three analyzed product models. As conclusion, the PDCA cycle, the Pareto charts, and the flowchart are excellent quality tools that help decrease the number of defective components.

scholarly journals Applying the Plan-Do-Check-Act (PDCA) Cycle to Reduce the Defects in the Manufacturing Industry. A Case Study

2018 ◽  
Vol 8 (11) ◽  
pp. 2181 ◽  
Author(s):  
Arturo Realyvásquez-Vargas ◽  
Karina Arredondo-Soto ◽  
Teresa Carrillo-Gutiérrez ◽  
Gustavo Ravelo
Keyword(s):  
Lean Manufacturing ◽  
Manufacturing Systems ◽  
Manufacturing Industry ◽  
Welding Process ◽  
Manufacturing Companies ◽  
Delivery Times ◽  
Pdca Cycle ◽  
Increasing Demand ◽  
Quality Of Products

Defects are considered as one of the wastes in manufacturing systems that negatively affect the delivery times, cost and quality of products leading to manufacturing companies facing a critical situation with the customers and to not comply with the IPC-A-610E standard for the acceptability of electronic components. This is the case is a manufacturing company located in Tijuana, Mexico. Due to an increasing demand on the products manufactured by this company, several defects have been detected in the welding process of electronic boards, as well as in the components named Thru-Holes. It is for this reason that this paper presents a lean manufacturing application case study. The objective of this research is to reduce at least 20% the defects that are generated during the welding process. In addition, it is intended to increase 20% the capacity of three double production lines where electronic boards are processed. As method, the Plan-Do-Check-Act (PDCA) cycle, is applied. The Pareto charts and the flowchart are used as support tools. As results, defects decreased 65%, 79%, and 77% in three analyzed product models. As conclusion, the PDCA cycle, the Pareto charts, and the flowchart are excellent quality tools that help to decrease the number of defective components.

scholarly journals Managing Manufacturing Complexity Drivers on Performance – An Initial Study

2018 ◽  
Vol 2 (1) ◽  
pp. 45-50
Author(s):  
Keyword(s):  
Strong Correlation ◽  
Manufacturing Systems ◽  
Manufacturing Industry ◽  
Initial Study ◽  
Efficient Production ◽  
Product Management ◽  
Nonlinear Behaviour ◽  
Manufacturing Companies ◽  
Manufacturing Performance ◽  
Manufacturing Productivity

Manufacturing systems, in pursuit of cost, time and flexibility optimisation are becoming more and more complex, exhibiting a dynamic and nonlinear behaviour. Unpredictability is a distinct characteristic of such behaviour and effects production planning significantly. Complexity continues to be a challenge in manufacturing systems, resulting in ever-inflating costs, operational issues and increased lead times to product realisation. This challenge must be met with appropriate decision-making by manufacturing companies to secure competitive advantage without compromising sustainability. Assessing complexity realises the reduction and management of complexity sources which contribute to lowering associated engineering costs and time, improves productivity and increases profitability. Therefore, this study was undertaken to investigate the priority level and current achievement of manufacturing performance in Malaysia’s manufacturing industry and the complexity drivers on manufacturing productivity performance. The results showed that Malaysia’s manufacturing industry prioritised product quality and they managed achieved a good on-time delivery performance. However, for other manufacturing performance, there was a difference where the current achievement of manufacturing performances in Malaysia’s manufacturing industry is slightly lower than the priority given to them. The strong correlation of significant value for priority status was observed between efficient production levelling (finished goods) and finish product management while the strong correlation of significant value for current achievement was minimised the number of workstation and factory transportation system. This indicates that complexity drivers have an impact towards manufacturing performance. Consequently, it is necessary to identify complexity drivers to achieve well manufacturing performance.

scholarly journals Dynamics of Business Models in Industry-Wide Collaborative Networks for Circularity

2022 ◽  
Vol 8 (1) ◽  
pp. 3
Author(s):  
Aleš Krmela ◽  
Iveta Šimberová ◽  
Viktorija Babiča
Keyword(s):  
Manufacturing Industry ◽  
Business Models ◽  
Research Strategy ◽  
Collaborative Networks ◽  
Abstract Concept ◽  
Manufacturing Companies ◽  
Legitimacy Theory ◽  
Dynamic Changes ◽  
Financial Reports ◽  
Quantitative Content

Incumbent B2B manufacturing companies join forces and form collaborative networks, called consortia, aiming to increase the circularity of their products. Our research interest lies in the understanding of how the business models (BM) of the companies and the industry are affected by such collaborations in the collaborative networks of the circular economy (CE). Given the exploratory nature of our empirical research, we applied a mixed research strategy of an inductively deductive nature. We carried out case studies in a manufacturing industry field and combined them with quantitative content analyses of the companies’ financial and non-financial reports. Drawing on the assumptions of the Attention-Based View Theory and Legitimacy Theory, we defined and found verbally communicated identifiers of BM elements, CE strategies, and collaborative networks, quantified their occurrences, and transformed them into variables. Using correlation analyses, we determined the tightness and the changes in relationships between the BMs’ elements and CE strategies. We examined the dynamic changes in the structure of BMs and their elements occurring within the implementation of selected CE strategies. Our findings suggest that collaborative networks for CE support an adaptation of the industry’s BMs. The higher-level CE strategies impact the BM more than the lower-level ones. The contribution of our research is in the suggested method of quantification and concretization of an abstract concept of BMs’ elements and their interrelations. This enables an assessment and a direct comparison of BMs, as well as of implemented CE strategies across companies and across industries. Our results also shed more light on the way the companies and industries adapt their BMs towards reaching circularity, as well as on how collaborative networks support such a transition.

Selection of lean manufacturing systems using the PROMETHEE

2008 ◽  
Vol 3 (1) ◽  
pp. 40-70 ◽  
Author(s):  
G. Anand ◽  
Rambabu Kodali
Keyword(s):  
Decision Making ◽  
Lean Manufacturing ◽  
Manufacturing Systems ◽  
Strategic Decision ◽  
Computer Integrated Manufacturing ◽  
Preference Ranking ◽  
Manufacturing Strategy ◽  
Manufacturing Companies ◽  
Content Type

PurposeIn recent years, many manufacturing companies are attempting to implement lean manufacturing systems (LMS) as an effective manufacturing strategy to survive in a highly competitive market. Such a process of selecting a suitable manufacturing system is highly complex and strategic in nature. The paper aims to how companies make a strategic decision of selecting LMS as part of their manufacturing strategy, and on what basis such strategic decisions are made by the managers.Design/methodology/approachA case study of a small‐ and medium‐sized enterprise is presented, in which the managers are contemplating on implementing either computer integrated manufacturing systems (CIMS) or LMS. To supplement the decision‐making process, a multi‐criteria decision making (MCDM) model, namely, the preference ranking organisation method for enrichment evaluations (PROMETHEE) is used to analyse how it will impact the stakeholders of the organisation, and the benefits gained.FindingsAn extensive analysis of PROMETHEE model revealed that LMS was the best for the given circumstances of the case.Research limitations/implicationsThe same problem can be extended by incorporating the constraints (such as financial, technical, social) of the organisation by utilising an extended version of PROMETHEE called the PROMETHEE V. Since, a single case study approach has been utilised, the findings cannot be generalized for any other industry.Practical limitations/implicationsThe methodology of PROMETHEE and its algorithm has been demonstrated in a detailed way and it is believed that it will be useful for managers to apply such MCDM tools to supplement their decision‐making efforts.Originality/valueAccording to the authors’ knowledge there is no paper in the literature, which discusses the application of PROMETHEE in making a strategic decision of implementing LMS as a part of an organisation's manufacturing strategy.

Reshoring drivers and barriers in the Swedish manufacturing industry

2018 ◽  
Vol 11 (2) ◽  
pp. 174-201 ◽  
Author(s):  
Gabriella Engström ◽  
Kristina Sollander ◽  
Per Hilletofth ◽  
David Eriksson
Keyword(s):  
Manufacturing Industry ◽  
Future Research ◽  
Location Decisions ◽  
Location Decision ◽  
Manufacturing Companies ◽  
Content Type ◽  
Manufacturing Location ◽  
Practical Implications ◽  
Insight Into

PurposeThe purpose of this study is to explore reshoring drivers and barriers from a Swedish manufacturing perspective.Design/methodology/approachThis paper is a case study, including four Swedish manufacturing companies, with focus on drivers and barriers from the context of the Swedish manufacturing industry. A literature review of previously established drivers and barriers is used to map out the empirical findings and thereby identify potential gaps between the current body of literature and drivers and barriers from a Swedish manufacturing context.FindingsThe findings of the study suggest that quality issues continue to be one of the strongest reshoring drivers. Except for product quality, quality is also connected to host country’s infrastructure, communication and service. The supply chain perspective is a source of several drivers and is identified as a perspective often overlooked in offshoring decisions. Barriers related to firm specifics were more elaborately discussed by the companies, especially concerning calculation of location decision and the need to invest in resources, which allows for a higher level of capacity at the home country facility.Research limitations/implicationsThe study develops a structured table of reshoring drivers and barriers which can serve as a base for future research. Future research on the calculation of location decisions is deemed as a crucial step to further understand reshoring and aid companies in the decision-making process.Practical implicationsThe drivers and barriers identified in the study can give practitioners insight into reshoring from the perspective of the Swedish manufacturing industry and thus aid in future manufacturing location decisions. The table of drivers and barriers can also be important to understand how Sweden can strengthen its competitive advantage and motivate more companies to reshore manufacturing.Originality/valueThis is one of only few papers from the Nordic countries and also one of few case studies examining reshoring in manufacturing companies.

scholarly journals Challenges in developing modular services in manufacturing companies: A multiple case study in Danish manufacturing industry

Procedia CIRP ◽  
2019 ◽  
Vol 81 ◽  
pp. 399-404 ◽  
Author(s):  
Maria Stoettrup Schioenning Larsen ◽  
Ann-Louise Andersen ◽  
Kjeld Nielsen ◽  
Thomas Ditlev Brunoe
Keyword(s):  
Manufacturing Industry ◽  
Multiple Case Study ◽  
Manufacturing Companies ◽  
Multiple Case

scholarly journals Analyzing the Status of Sustainable Development in the Manufacturing Sector Using Multi-Expert Multi-Criteria Fuzzy Decision-Making and Integrated Triple Bottom Lines

2020 ◽  
Vol 17 (11) ◽  
pp. 3800 ◽  
Author(s):  
Sepehr Hendiani ◽  
Huchang Liao ◽  
Morteza Bagherpour ◽  
Manuela Tvaronavičienė ◽  
Audrius Banaitis ◽  
...  
Keyword(s):  
Performance Management ◽  
Social Relations ◽  
Manufacturing Systems ◽  
Sustainable Manufacturing ◽  
Economic Benefits ◽  
Fuzzy Decision Making ◽  
Technological Advancement ◽  
Manufacturing Companies ◽  
The Status ◽  
New Framework

A sustainable manufacturing company depends on the developments in three aspects in order to minimize harmful impacts on the environment, improve the social relations, and simultaneously maximize the economic benefits. Despite the increasing types of investigations that researchers have carried out in environmental and economic aspects, the minimum attention has been paid to social relations. In response to this deficiency, this paper proposes a new framework to obtain the overall sustainability index in manufacturing companies by encapsulating the sustainability criteria/sub-criteria. This article collected 33 sub-criteria for five pillars of sustainability as social, environment, economic, technological advancement, and performance management. The key contributions of this paper are highlighted as the hierarchical method that obtains the status of sustainability in uncertain conditions, the ability to identify the weak points, and a new framework for gathering the data about sustainability performance in manufacturing companies. The findings of this paper will aid both policymakers and decision-makers to assess the sustainability status of manufacturing systems and improve the performances of them.

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