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Output from the Irish Dairy Industry has grown rapidly since the abolition of quotas in 2015, with processors investing heavily in capacity expansion to deal with the extra milk volumes. Further capacity gains may be achieved by extending the processing season into the winter, a key enabler for which being the reduction of duration of the winter maintenance overhaul period. This paper aims to investigate if Lean Six Sigma tools and techniques can be used to enhance operational maintenance performance, thereby releasing additional processing capacity.

Combining the Six-Sigma Define, Measure, Analyse, Improve, Control (DMAIC) methodology and the structured approach of Turnaround Maintenance (TAM) widely used in process industries creates a novel hybrid model that promises substantial improvement in maintenance overhaul execution. This paper presents a case study applying the DMAIC/TAM model to Ireland’s largest dairy processing site to optimise the annual maintenance shutdown. The objective was to deliver a 30% reduction in the duration of the overhaul, enabling an extension of the processing season.

Application of the DMAIC/TAM hybrid resulted in process enhancements, employee engagement and a clear roadmap for the operations team. Project goals were delivered, and original objectives exceeded, resulting in €8.9m additional value to the business and a reduction of 36% in the duration of the overhaul.

The results demonstrate that the model provides a structure that promotes systematic working and a continuous improvement focus that can have substantial benefits for wider industry. Opportunities for further model refinement were identified and will enhance performance in subsequent overhauls.

To the best of the authors’ knowledge, this is the first time that the structure and tools of DMAIC and TAM have been combined into a hybrid methodology and applied in an Irish industrial setting.

The unstable labor productivity and periodic planning method cause barriers to improving construction logistics management. This paper aims to explore a demand-driven mechanism for efficient construction logistics planning to record the material consumption, report the real-time demand and trigger material replenishment from off-site to on-site, which is aided by Building Information Modeling (BIM) and the Kanban technique.

This paper follows the design science research (DSR) principles to propose a system of designing and applying Kanban batch with 4D BIM for construction logistics planning and monitoring. Prototype development with comparative simulation experiments of a river remediation project is conducted to analyze the conventional and Kanban-triggered supply. Two-staged industrial interviews are conducted to guide and evaluate the system design.

The proposed BIM-enabled Kanban system enables construction managers and suppliers to better set integrated on- and off-site targets, report real-time demands and conduct collaborative planning and monitoring. The simulation results present significant site storage and schedule savings applying the BIM-enabled Kanban system. Feedback and constructive suggestions from practitioners are collected via interviews and analyzed for further development.

This paper brings to the limelight the benefits of implementing BIM-enabled demand-driven replenishment to remove waste from the material flow. This paper combines lean production theory with advanced information technology to solve construction logistics management problems.

The article addresses the optimization of safety stock service levels for parts in a repair kit. The work was undertaken to assist a public transit entity that stores thousands of parts used to repair equipment acquired over many decades. Demand is intermittent, procurement lead times are long, and the total inventory investment is significant.

Demand exists for repair kits, and a repair cannot start until all required parts are available. The cost model includes holding cost to carry the part being modeled as well as shortage cost that consists of the holding cost to carry all other repair kit parts for the duration of the part’s lead time. The model combines deterministic and stochastic approaches by assuming a fixed ordering cycle with Poisson demand.

The results show that optimal service levels vary as a function of repair demand rate, part lead time, and cost of the part as a percentage of the total part cost for the repair kit. Optimal service levels are higher for inexpensive parts and lower for expensive parts, although the precise levels are impacted by repair demand and part lead time.

The proposed model can impact society by improving the operational performance and efficiency of public transit systems, by ensuring that home repair technicians will be prepared for repair tasks, and by reducing the environmental impact of electronic waste consistent with the right-to-repair movement.

The optimization model is unique because (1) it quantifies shortage cost as the cost of unnecessary holding other parts in the repair kit during the shortage time, and (2) it determines a unique service level for each part in a repair kit bases on its lead time, its unit cost, and the total cost of all parts in the repair kit. Results will be counter-intuitive for many inventory managers who would assume that more critical parts should have higher service levels.

Owing to the finite nature of the boundary of the line (BOL), the conventional method, involving the strong matching of single-variety parts with storage locations at the periphery of the line, proves insufficient for mixed-model assembly lines (MMAL). Consequently, this paper aims to introduce a material distribution scheduling problem considering the shared storage area (MDSPSSA). To address the inherent trade-off requirement of achieving both just-in-time efficiency and energy savings, a mathematical model is developed with the bi-objectives of minimizing line-side inventory and energy consumption.

A nondominated and multipopulation multiobjective grasshopper optimization algorithm (NM-MOGOA) is proposed to address the medium-to-large-scale problem associated with MDSPSSA. This algorithm combines elements from the grasshopper optimization algorithm and the nondominated sorting genetic algorithm-II. The multipopulation and coevolutionary strategy, chaotic mapping and two further optimization operators are used to enhance the overall solution quality.

Finally, the algorithm performance is evaluated by comparing NM-MOGOA with multi-objective grey wolf optimizer, multiobjective equilibrium optimizer and multi-objective atomic orbital search. The experimental findings substantiate the efficacy of NM-MOGOA, demonstrating its promise as a robust solution when confronted with the challenges posed by the MDSPSSA in MMALs.

The material distribution system devised in this paper takes into account the establishment of shared material storage areas between adjacent workstations. It permits the undifferentiated storage of various part types in fixed BOL areas. Concurrently, the innovative NM-MOGOA algorithm serves as the core of the system, supporting the formulation of scheduling plans.

This study explores the significance and implementation priorities for Digital Product Passports (DPP) in the context of building renovation projects. It aims to reveal bottlenecks and how a data-driven workflow bridges the DPP understanding/implementation gap, facilitating the transition towards practices aligned with the EU Green Deal goals.

A mixed-methods embedded design was employed for a real-case study exploration. Desk research and field observations ground the two-level analysis combining project documentation, namely the Bill of Quantities (BoQ), with different criteria in digitalisation and sustainability, such as economic ratio, 3D modelling, waste management, hazards, energy performance and facility management. All results were interpreted from the DPP lens.

The analysis revealed a system for identifying building products representing a significant part of the renovation budget. About 11 priority DPPs were found. Some are crucial for both the deconstruction and construction phases, highlighting the need for an incremental and strategic approach to DPP implementation.

The study is limited to a single case study. Constraints are minimised given the sample's archetype representativeness. The outcomes introduce the need for strategic thinking for incremental DPP implementation. Future research will explore additional criteria and cases.

The research has resulted in a classification framework for DPPs' significance and priority, which is provided with case results. The outcome of the framework provides views on concept alignment to make the implementation in construction more straightforward. Its practical use can be replicated in other projects, emphasizing the importance of data structure and management for the circular economy.

In this paper, we investigate the coevolution of the supply network and procurement strategies in the context of semiconductors and electronics for the automotive industry over 3 decades. We aim to explain how procurement strategy interrelates with changes in supply network structure and what the implications of a hub-centric structure network structure are for procurement in supply.

We collected in-depth primary and secondary data that stretched back to 1996 from a leading automotive European original equipment manufacturer (OEM) and its network. Using social network analysis (SNA), we identified OEMs’ procurement focus and mapped the evolution of the supply network, the links in the network, and the environmental forces impacting the strategies and the network.

Our findings describe the supply network for semiconductor and electronic components to the automotive industry. The findings suggest that a focus on cost can lead to a Tier 1-centric network structure with many tiers that can fail to assure supply or capture innovation when the external environment is marked by high uncertainty. In such situations, increasing complexity by creating more links in the network can improve transparency and contribute to supply assurance and innovation.

The findings indicate that managers should consider the role of the supply network in selecting their strategy to attain objectives of cost, innovation, and supply assurance.

This paper presents empirical-based insights into the automotive semiconductor and electronic component supply chain (SC), the unexpected implications of hub-centric supply networks, and the use of SNA in the SC in context.

President Trump's tenure was accompanied by a series of protectionist measures that intended to reinvigorate US-based production and make manufacturing supply chains more “local”. Amidst these increasing institutional pressures to localise, and the business uncertainty that ensued, this study investigates the extent to which manufacturers reconfigured their supply bases.

Bloomberg's Supply Chain Function (SPLC) is used to manually extract data about the direct suppliers of 30 of the largest American manufacturers in terms of market capitalisation. Overall, the raw data comprise 20,100 quantified buyer–supplier relationships that span seven years (2014–2020). The supply base dimensions of spatial complexity, spend concentration and buyer dependence are operationalised by applying appropriate aggregation functions on the raw data. The final dataset is a firm-year panel that is analysed using a random effect (RE) modelling approach and the conditional means of the three dimensions are plotted over time.

Over the studied timeframe, American manufacturers progressively reduced the spatial complexity of their supply bases and concentrated their purchase spend to fewer suppliers. Contrary to the aims of governmental policies, American manufacturers increased their dependence on foreign suppliers and reduced their dependence on local ones.

The research provides insights into the dynamics of manufacturing supply chains as they adapt to shifting institutional demands.

This study seeks to explore the strategies purchasing and supply managers can employ to navigate the challenges presented by low-probability-high-impact (LPHI) disruptions. The core aim is to create a process framework that provides a systematic, step-by-step method to help purchasing and supply managers effectively deal with the chaos triggered by LPHI events.

The study draws on qualitative data collected from eight firms operating within different industries (healthcare, fishing, food retail and manufacturing), where two firms represented each industry. The data underwent a thorough analytical process involving open coding, axial coding and aggregation of categories, resulting in the identification and formulation of overarching themes.

The analysis unveiled five primary challenges purchasing and supply management (PSM) encountered during the COVID-19 pandemic. These include supply shortages, supplier opportunism, the imperative to build a new supply base, price volatility and the need to make critical decisions based on limited information. It also identified contingent factors that influenced the magnitude of these challenges and approaches applied to address them. Additionally, it identified five responses to the challenges and two contingent factors that affected the responses.

This study extends the existing body of knowledge in purchasing and supply management by developing a process framework tailored to assist purchasing and supply managers in effectively addressing LPHI disruptions. To the best of our knowledge, this is one of the first studies to offer a structured, step-by-step approach that guides PSM professionals in navigating the chaos likely to be caused by such events.

This paper proposes a new metric, named Operational Space Efficiency (OpSE), intended to diagnose and quantify the inefficient use of floor space for stocking materials in industrial workstations. OpSE presents a formulation analogous to the well-known Overall Equipment Effectiveness and can be obtained as the product of three distinct indicators: Standard Compliance Effectiveness, Standards Selection Effectiveness and Design Space-usage Effectiveness.

This indicator scrutinizes how usefully floor space in workstations is used to temporarily stock materials in the form of raw materials, semi-finished products, parts and components. It is suited for analyzing fixed-position layouts as well as product layouts typical of repetitive manufacturing settings, such as assembly lines in the automotive sector. The proposed indicator leverages an appropriate loss structure that features those factors affecting floor space utilization in workstations with regard to supplying and stocking materials.

An Italian manufacturer in the field of electro-technology was used as an industrial case study for the application of the methodology. The application shows how the three indicators work in practice, the effectiveness of OpSE and the methodology as a whole, in diagnosing floor space usage inefficiencies and in properly addressing improvement actions of the internal logistics in industrial settings.

The paper scrutinizes some important Key Performance Indicators (KPIs) dealing with space usage efficiency and identifies some significant drawbacks. Then it suggests a new, inclusive structure of losses and a KPI that not only measures efficiency but also allows to identify viable countermeasures.

This study aims to explore and empirically test variables influencing material delivery schedule inaccuracies?

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.

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.

The findings provide guidelines for exploring and finding patterns in specific variables to improve material delivery schedule inaccuracies and input into predictive forecasting models.

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?