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1 – 10 of 69Prasenjit Biswas, Deepak Patel, Archana Mallik and Sanjeev Das
The purpose of this paper is to develop a concept and design to cast Al alloys/metal matrix composites (MMCs) by continuous casting process. The various steps involved in the…
Abstract
Purpose
The purpose of this paper is to develop a concept and design to cast Al alloys/metal matrix composites (MMCs) by continuous casting process. The various steps involved in the evolution of the design have been reported and discussed in this study.
Design/methodology/approach
On the basis of developed design concept, initial prototype design has been prepared in this study. The casting process's melt flow pattern was studied via computer simulation, and the resulting changes were implemented in the original design. The single-phase fluid flow pattern through bottom feeding technique is studied. The equipment was fabricated based on computer simulation and water modelling studies. Finally, validation was performed for the preparation of Al alloys/ MMCs after parameter optimisation. The results were observed in the optical metallography to confirm the alloying and Al MMC preparation.
Findings
The developed continuous casting process with bottom feeding technique for the addition of constituent particles shows more efficiency in comparison to the existing batch processes. The final manufactured setup demonstrates effective Al alloy/MMC production as the basis for final fabrication has been accomplished by both computer simulation and water model test. In addition, the microstructure exhibits homogeneous distribution, validating the reliability of the setup.
Originality/value
Integrating continuous casting with continuous reinforcement or master alloy addition is novel in this area. The constraints that batch production had that have been rectified will also lower the contemporary cost of production.
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Elena Stefana, Paola Cocca, Federico Fantori, Filippo Marciano and Alessandro Marini
This paper aims to overcome the inability of both comparing loss costs and accounting for production resource losses of Overall Equipment Effectiveness (OEE)-related approaches.
Abstract
Purpose
This paper aims to overcome the inability of both comparing loss costs and accounting for production resource losses of Overall Equipment Effectiveness (OEE)-related approaches.
Design/methodology/approach
The authors conducted a literature review about the studies focusing on approaches combining OEE with monetary units and/or resource issues. The authors developed an approach based on Overall Equipment Cost Loss (OECL), introducing a component for the production resource consumption of a machine. A real case study about a smart multicenter three-spindle machine is used to test the applicability of the approach.
Findings
The paper proposes Resource Overall Equipment Cost Loss (ROECL), i.e. a new KPI expressed in monetary units that represents the total cost of losses (including production resource ones) caused by inefficiencies and deviations of the machine or equipment from its optimal operating status occurring over a specific time period. ROECL enables to quantify the variation of the product cost occurring when a machine or equipment changes its health status and to determine the actual product cost for a given production order. In the analysed case study, the most critical production orders showed an actual production cost about 60% higher than the minimal cost possible under the most efficient operating conditions.
Originality/value
The proposed approach may support both production and cost accounting managers during the identification of areas requiring attention and representing opportunities for improvement in terms of availability, performance, quality, and resource losses.
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The purpose of this paper is twofold: first, a case study on applying lean principles in manufacturing operations to redesign and optimize an electronic device assembly process…
Abstract
Purpose
The purpose of this paper is twofold: first, a case study on applying lean principles in manufacturing operations to redesign and optimize an electronic device assembly process and its impact on performance and second, introducing cardboard prototyping as a Kaizen tool offering a novel approach to testing and simulating improvement scenarios.
Design/methodology/approach
The study employs value stream mapping, root cause analysis, and brainstorming tools to identify root causes of poor performance, followed by deploying a Kaizen event to redesign and optimize an electronic device assembly process. Using physical models, bottlenecks and opportunities for improvement were identified by the Kaizen approach at the workstations and assembly lines, enabling the testing of various scenarios and ideas. Changes in lead times, throughput, work in process inventory and assembly performance were analyzed and documented.
Findings
Pre- and post-improvement measures are provided to demonstrate the impact of the Kaizen event on the performance of the assembly cell. The study reveals that implementing lean tools and techniques reduced costs and increased throughput by reducing assembly cycle times, manufacturing lead time, space utilization, labor overtime and work-in-process inventory requirements.
Originality/value
This paper adds a new dimension to applying the Kaizen methodology in manufacturing processes by introducing cardboard prototyping, which offers a novel way of testing and simulating different scenarios for improvement. The paper describes the process implementation in detail, including the techniques and data utilized to improve the process.
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Patrik Jonsson, Johan Öhlin, Hafez Shurrab, Johan Bystedt, Azam Sheikh Muhammad and Vilhelm Verendel
This study aims to explore and empirically test variables influencing material delivery schedule inaccuracies?
Abstract
Purpose
This study aims to explore and empirically test variables influencing material delivery schedule inaccuracies?
Design/methodology/approach
A mixed-method case approach is applied. Explanatory variables are identified from the literature and explored in a qualitative analysis at an automotive original equipment manufacturer. Using logistic regression and random forest classification models, quantitative data (historical schedule transactions and internal data) enables the testing of the predictive difference of variables under various planning horizons and inaccuracy levels.
Findings
The effects on delivery schedule inaccuracies are contingent on a decoupling point, and a variable may have a combined amplifying (complexity generating) and stabilizing (complexity absorbing) moderating effect. Product complexity variables are significant regardless of the time horizon, and the item’s order life cycle is a significant variable with predictive differences that vary. Decoupling management is identified as a mechanism for generating complexity absorption capabilities contributing to delivery schedule accuracy.
Practical implications
The findings provide guidelines for exploring and finding patterns in specific variables to improve material delivery schedule inaccuracies and input into predictive forecasting models.
Originality/value
The findings contribute to explaining material delivery schedule variations, identifying potential root causes and moderators, empirically testing and validating effects and conceptualizing features that cause and moderate inaccuracies in relation to decoupling management and complexity theory literature?
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Chao-chao Liu, Miao Wang, Zhanwen Niu and Xun Mo
The view that dynamic capabilities theory can help explain how lean organizations improve has been put forward by scholars. However, there is still a lack of research on the…
Abstract
Purpose
The view that dynamic capabilities theory can help explain how lean organizations improve has been put forward by scholars. However, there is still a lack of research on the matching relationship between the application of lean practice and the internal elements of enterprise organization from the perspective of dynamic capabilities. The purpose of this study is to validate the moderating effect of dynamic capabilities on the relationship between lean practices and operational performance.
Design/methodology/approach
This study used the method of survey and empirical research to collect sample data from 263 enterprises in China. Through literature review, this study put forward the moderating hypotheses around dynamic capabilities, lean practices and operation performance and used the method of regression analysis to validate these hypotheses.
Findings
The results showed that dynamic capabilities have a partially moderating effect on the application of lean practices. Specifically, dynamic capabilities have a significant moderating effect on the relationship between just-in-time, total quality management, total preventive maintenance and operational performance, while dynamic capabilities have no significant moderating effect on the relationship between human resource management and operational performance.
Originality/value
The research conclusion complements and enriches the lean practices literature from the perspective of dynamic capabilities. Existing studies mainly focus on the moderating role of external environmental factors, while there is a lack of empirical research on the role of dynamic capabilities in lean practices literature. The research results will help enterprises further understand the matching relationship between lean practices and dynamic capabilities and then improve the success of lean practices application.
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Zhenbao Wang, Zhen Yang, Mengyu Liu, Ziqin Meng, Xuecheng Sun, Huang Yong, Xun Sun and Xiang Lv
Microribbon with meander type based on giant magnetoimpedance (GMI) effect has become a research hot spot due to their higher sensitivity and spatial resolution. The purpose of…
Abstract
Purpose
Microribbon with meander type based on giant magnetoimpedance (GMI) effect has become a research hot spot due to their higher sensitivity and spatial resolution. The purpose of this paper is to further optimize the line spacing to improve the performance of meanders for sensor application.
Design/methodology/approach
The model of GMI effect of microribbon with meander type is established. The effect of line spacing (Ls) on GMI behavior in meanders is analyzed systematically.
Findings
Comparison of theory and experiment indicates that decreasing the line spacing increases the negative mutual inductance and a consequent increase in the GMI effect. The maximum value of the GMI ratio increases from 69% to 91.8% (simulation results) and 16.9% to 51.4% (experimental results) when the line spacing is reduced from 400 to 50 µm. The contribution of line spacing versus line width to the GMI ratio of microribbon with meander type was contrasted. This behavior of the GMI ratio is dominated by the overall negative contribution of the mutual inductance.
Originality/value
This paper explores the effect of line spacing on the GMI ratio of meander type by comparing the simulation results with the experimental results. The superior line spacing is found in the identical sensing area. The findings will contribute to the design of high-performance micropatterned ribbon with meander-type GMI sensors and the establishment of a ribbon-based magnetic-sensitive biosensing system.
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Oscar Y. Moreno Rocha, Paula Pinto, Maria C. Consuegra, Sebastian Cifuentes and Jorge H. Ulloa
This study aims to facilitate access to vascular disease screening for low-income individuals living in remote and conflict areas based on the results of a pilot trial in…
Abstract
Purpose
This study aims to facilitate access to vascular disease screening for low-income individuals living in remote and conflict areas based on the results of a pilot trial in Colombia. Also, to increase the amount of diagnosis training of vascular surgery (VS) in civilians.
Design/methodology/approach
The operation method includes five stages: strategy development and adjustment; translation of the strategy into a real-world setting; operation logistics planning; strategy analysis and adoption. The operation plan worked efficiently in this study’s sample. It demonstrated high sensibility, efficiency and safety in a real-world setting.
Findings
The authors developed and implemented a flow model operating plan for screening vascular pathologies in low-income patients pro bono without proper access to vascular health care. A total of 140 patients from rural areas in Colombia were recruited to a controlled screening session where they underwent serial noninvasive ultrasound assessments conducted by health professionals of different training stages in VS.
Research limitations/implications
The plan was designed to be implemented in remote, conflict areas with limited access to VS care. Vascular injuries are critically important and common among civilians and military forces in regions with active armed conflicts. As this strategy can be modified and adapted to different medical specialties and geographic areas, the authors recommend checking the related legislation and legal aspects of the intended areas where we will implement this tool.
Practical implications
Different sub-specialties can implement the described method to be translated into significant areas of medicine, as the authors can adjust the deployment and execution for the assessment in peripheral areas, conflict zones and other public health crises that require a faster response. This is necessary, as the amount of training to which VS trainees are exposed is low. A simulated exercise offers a novel opportunity to enhance their current diagnostic skills using ultrasound in a controlled environment.
Social implications
Evaluating and assessing patients with limited access to vascular medicine and other specialties can decrease the burden of vascular disease and related complications and increase the number of treatments available for remote communities.
Originality/value
It is essential to assess the most significant number of patients and treat them according to their triage designation. This management is similar to assessment in remote areas without access to a proper VS consult. The authors were able to determine, classify and redirect to therapeutic interventions the patients with positive findings in remote areas with a fast deployment methodology in VS.
Plain language summary
Access to health care is limited due to multiple barriers and the assessment and response, especially in peripheral areas that require a highly skilled team of medical professionals and related equipment. The authors tested a novel mobile assessment tool for remote and conflict areas in a rural zone of Colombia.
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Daniele dos Reis Pereira Maia, Fabiane Letícia Lizarelli and Lillian Do Nascimento Gambi
There is increasing interest in the connection between Industry 4.0 (I4.0) and operational excellence approaches; however, studies on the integration between Six Sigma (SS) and…
Abstract
Purpose
There is increasing interest in the connection between Industry 4.0 (I4.0) and operational excellence approaches; however, studies on the integration between Six Sigma (SS) and I4.0 have been absent from the literature. Integration with I4.0 technologies can maximize the positive effects of SS. The purpose of this study is to understand what types of relationships exist between SS and I4.0 and with I4.0's technologies, as well as the benefits derived from this integration and future directions for this field of study.
Design/methodology/approach
A Systematic Literature Review (SLR) was carried out to analyze studies about connections between I4.0 technologies and SS. SLR analyzed 59 articles from 2013 to 2021 extracted from the Web of Science and Scopus databases, including documents from journals and conferences.
Findings
The SLR identified relationships between SS and several I4.0 technologies, the most cited and with the greatest possibilities of relationships being Big Data/Big Data Analytics (BDA) and Internet of Things (IoT). Three main types of relationships were identified: (1) support of I4.0 technologies to SS; (2) assistance from the SS to the introduction of I4.0 technologies, and, to a lesser extent; (3) incompatibilities between SS and I4.0 technologies. The benefits are mainly related to availability of large data sets and real-time information, enabling better decision-making in less time.
Practical implications
In addition, the study can help managers to understand the integration relationships, which may encourage companies to adopt SS/Lean Six Sigma (LSS) in conjunction with I4.0 technologies. The results also drew attention to the incompatibilities between SS and I4.0 to anticipate potential barriers to implementation.
Originality/value
The study focuses on three previously unexplored subjects: the connection between SS and I4.0, the existing relationships with different technologies and the benefits resulting from the relationships. In addition, the study compiled and structured different types of relationships for SS and I4.0 and I4.0's technologies, identifying patterns and presenting evidence on how these relationships occur. Finally, exposes current trends and possible research directions.
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Assembly line is a common production form and has been effectively used in many industries, but the imprecise processing time of each process makes production line balancing and…
Abstract
Purpose
Assembly line is a common production form and has been effectively used in many industries, but the imprecise processing time of each process makes production line balancing and capacity forecasting the most troublesome problems for production managers. In this paper, uncertain man-hours are represented as interval grey numbers, and the optimization problem of production line balance in the case of interval grey man-hours is studied to better evaluate the production line capacity.
Design/methodology/approach
First, this paper constructs the basic model of assembly line balance optimization for the single-product scenario, and on this basis constructs an assembly line balance optimization model under the multi-product scenario with the objective function of maximizing the weighted greyscale production line balance rate, second, this paper designs a simulated annealing algorithm to solve problem. A neighborhood search strategy is proposed, based on assembly line balance optimization, an assembly line capacity evaluation method with interval grey man-hour characteristics is designed.
Findings
This paper provides a production line balance optimization scheme with uncertain processing time for multi-product scenarios and designs a capacity evaluation method to provide managers with scientific management strategies so that decision-makers can scientifically solve the problems that the company's design production line is quite different from the actual production situation.
Originality/value
There are few literary studies on combining interval grey number with assembly line balance optimization. Therefore, this paper makes an important contribution in this regard.
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Kai Rüdele, Matthias Wolf and Christian Ramsauer
Improving productivity and efficiency has always been crucial for industrial companies to remain competitive. In recent years, the topic of environmental impact has become…
Abstract
Purpose
Improving productivity and efficiency has always been crucial for industrial companies to remain competitive. In recent years, the topic of environmental impact has become increasingly important. Published research indicates that environmental and economic goals can enforce or rival each other. However, few papers have been published that address the interaction and integration of these two goals.
Design/methodology/approach
In this paper, we identify both, synergies and trade-offs based on a systematic review incorporating 66 publications issued between 1992 and 2021. We analyze, quantify and cluster examples of conjunctions of ecological and economic measures and thereby develop a framework for the combined improvement of performance and environmental compatibility.
Findings
Our findings indicate an increased significance of a combined consideration of these two dimensions of sustainability. We found that cases where enforcing synergies between economic and ecological effects were identified are by far more frequent than reports on trade-offs. For the individual categories, cost savings are uniformly considered as the most important economic aspect while, energy savings appear to be marginally more relevant than waste reduction in terms of environmental aspects.
Originality/value
No previous literature review provides a comparable graphical treatment of synergies and trade-offs between cost savings and ecological effects. For the first time, identified measures were classified in a 3 × 3 table considering type and principle.
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