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Open Access
Article
Publication date: 14 October 2021

Anton Wiberg, Johan Persson and Johan Ölvander

The purpose of this paper is to present a Design for Additive Manufacturing (DfAM) methodology that connects several methods, from geometrical design to post-process…

Abstract

Purpose

The purpose of this paper is to present a Design for Additive Manufacturing (DfAM) methodology that connects several methods, from geometrical design to post-process selection, into a common optimisation framework.

Design/methodology/approach

A design methodology is formulated and tested in a case study. The outcome of the case study is analysed by comparing the obtained results with alternative designs achieved by using other design methods. The design process in the case study and the potential of the method to be used in different settings are also discussed. Finally, the work is concluded by stating the main contribution of the paper and highlighting where further research is needed.

Findings

The proposed method is implemented in a novel framework which is applied to a physical component in the case study. The component is a structural aircraft part that was designed to minimise weight while respecting several static and fatigue structural load cases. An addition goal is to minimise the manufacturing cost. Designs optimised for manufacturing by two different AM machines (EOS M400 and Arcam Q20+), with and without post-processing (centrifugal finishing) are considered. The designs achieved in this study show a significant reduction in both weight and cost compared to one AM manufactured geometry designed using more conventional methods and one design milled in aluminium.

Originality/value

The method in this paper allows for the holistic design and optimisation of components while considering manufacturability, cost and component functionality. Within the same framework, designs optimised for different setups of AM machines and post-processing can be automatically evaluated without any additional manual work.

Details

Rapid Prototyping Journal, vol. 27 no. 11
Type: Research Article
ISSN: 1355-2546

Keywords

Book part
Publication date: 29 March 2016

Marc Wouters, Susana Morales, Sven Grollmuss and Michael Scheer

The paper provides an overview of research published in the innovation and operations management (IOM) literature on 15 methods for cost management in new product…

Abstract

Purpose

The paper provides an overview of research published in the innovation and operations management (IOM) literature on 15 methods for cost management in new product development, and it provides a comparison to an earlier review of the management accounting (MA) literature (Wouters & Morales, 2014).

Methodology/approach

This structured literature search covers papers published in 23 journals in IOM in the period 1990–2014.

Findings

The search yielded a sample of 208 unique papers with 275 results (one paper could refer to multiple cost management methods). The top 3 methods are modular design, component commonality, and product platforms, with 115 results (42%) together. In the MA literature, these three methods accounted for 29%, but target costing was the most researched cost management method by far (26%). Simulation is the most frequently used research method in the IOM literature, whereas this was averagely used in the MA literature; qualitative studies were the most frequently used research method in the MA literature, whereas this was averagely used in the IOM literature. We found a lot of papers presenting practical approaches or decision models as a further development of a particular cost management method, which is a clear difference from the MA literature.

Research limitations/implications

This review focused on the same cost management methods, and future research could also consider other cost management methods which are likely to be more important in the IOM literature compared to the MA literature. Future research could also investigate innovative cost management practices in more detail through longitudinal case studies.

Originality/value

This review of research on methods for cost management published outside the MA literature provides an overview for MA researchers. It highlights key differences between both literatures in their research of the same cost management methods.

Article
Publication date: 21 February 2020

Saumyaranjan Sahoo

The purpose of this paper is to investigate the status of lean manufacturing in Indian automotive sector, component manufacturing industries in terms of lean adoption…

1491

Abstract

Purpose

The purpose of this paper is to investigate the status of lean manufacturing in Indian automotive sector, component manufacturing industries in terms of lean adoption, benefits, motivation, and challenges of implementing lean manufacturing practices.

Design/methodology/approach

The research objectives were achieved by conducting a qualitative multicase study approach. Fourteen Indian automotive component manufacturing small and medium-sized enterprises (SMEs) were chosen based on their different product offerings as well as differing approaches to the introduction and implementation of lean initiatives. Data were collected through in-depth, semistructured interviews supported by shop-floor observations.

Findings

The findings from the present study suggest that some of the participating automotive component manufacturing SMEs have a relatively good understanding of lean concepts and philosophy. However, there is room for further improvement for most SMEs. Major top five lean practices being implemented were found to be cellular manufacturing, total productive maintenance, 5S, work standardization, and quality management practices. Also, leadership and organizational culture were found to be crucial factors for the success of lean manufacturing.

Research limitations/implications

The fact that the data collected for the research study is based on subjective business evidence obtained from company representatives comprises the main limitation of the present study. So, the results should be considered with caution, as far as the lean adoption in Indian automotive component manufacturing sector is concerned.

Practical implications

Based on the present study, suggestions can be made regarding the successful adoption of lean principles, not only for the participating SMEs but also for the whole of the automotive component manufacturing sector. More specifically, by determining the strength and weakness of automotive component manufacturing SME's effort to adopt lean, suitable managerial initiatives can be undertaken by these companies as well as the whole sector to fully adopt lean and derive the respective benefits.

Originality/value

This paper explores the status of lean adoption in Indian automotive component manufacturing SMEs. Considering the unique characteristics of the automotive component manufacturing industry, the present research would be helpful for making strategies to implement lean in automotive component manufacturing industry setups.

Details

Benchmarking: An International Journal, vol. 27 no. 3
Type: Research Article
ISSN: 1463-5771

Keywords

Book part
Publication date: 23 September 2014

Marc Wouters and Susana Morales

To provide an overview of research published in the management accounting literature on methods for cost management in new product development, such as a target costing…

Abstract

Purpose

To provide an overview of research published in the management accounting literature on methods for cost management in new product development, such as a target costing, life cycle costing, component commonality, and modular design.

Methodology/approach

The structured literature search covered papers about 15 different cost management methods published in 40 journals in the period 1990–2013.

Findings

The search yielded a sample of 113 different papers. Many contained information about more than one method, and this yielded 149 references to specific methods. The number of references varied strongly per cost management method and per journal. Target costing has received by far the most attention in the publications in our sample; modular design, component commonality, and life cycle costing were ranked second and joint third. Most references were published in Management Science; Management Accounting Research; and Accounting, Organizations and Society. The results were strongly influenced by Management Science and Decision Science, because cost management methods with an engineering background were published above average in these two journals (design for manufacturing, component commonality, modular design, and product platforms) while other topics were published below average in these two journals.

Research Limitations/Implications

The scope of this review is accounting research. Future work could review the research on cost management methods in new product development published outside accounting.

Originality/value

The paper centers on methods for cost management, which complements reviews that focused on theoretical constructs of management accounting information and its use.

Article
Publication date: 1 August 2016

Vikas Swarnakar and S. Vinodh

This paper aims to deploy Lean Six Sigma (LSS) framework to facilitate defect reduction and enhance bottom line results of an automotive component manufacturing organization.

2409

Abstract

Purpose

This paper aims to deploy Lean Six Sigma (LSS) framework to facilitate defect reduction and enhance bottom line results of an automotive component manufacturing organization.

Design/methodology/approach

LSS is a business process improvement strategy widely used in the manufacturing field for enhancing manufacturing organization performance. The integration of Lean and Six Sigma will enable the attainment of defects reduction by eliminating non-value-adding activities from production line. LSS framework has been developed with the integration of define–measure–analysis–improve–control (DMAIC) tools and techniques.

Findings

The finding of this study is that the LSS framework has been successfully implemented in automotive component manufacturing organization, and non-value-adding activities and defects from assembly line have been reduced. The proposed LSS framework applies lean tools within Six Sigma DMAIC approach to facilitate waste elimination and defect reduction. The developed framework with linkage of DMAIC tools and techniques reduces defects and non-value-adding activities with enhanced bottom line results. The implementation of proposed LSS framework shows effective improvement in key metrics.

Research limitations/implications

The developed framework has been test implemented in an automotive component manufacturing organization. In future, more number of studies could be conducted. Further, advanced lean tools and techniques could be included in the framework for increasing the effectiveness of production line.

Practical implications

The proposed LSS framework with linkage of DMAIC tools and techniques has been successfully implemented in an assembly line of automotive component manufacturing organization. This method is presently applied for an automotive component manufacturing organization; in future, the approach could be applied in different industrial sectors with addition of new tools and techniques for improving its effectiveness.

Originality/value

LSS framework has been designed and test implemented in an assembly line of an automotive component manufacturing organization. Hence, the inferences are practical and key results of the study.

Details

International Journal of Lean Six Sigma, vol. 7 no. 3
Type: Research Article
ISSN: 2040-4166

Keywords

Article
Publication date: 4 October 2019

Swee Kuik and Li Diong

The purpose of this paper is to present the model-driven decision support system (DSS) for small and medium manufacturing enterprises (SMMEs) that actively participates in…

Abstract

Purpose

The purpose of this paper is to present the model-driven decision support system (DSS) for small and medium manufacturing enterprises (SMMEs) that actively participates in collaborative activities and manages the planned obsolescence in production. In dealing with the complexity of such demand and supply scenario, the optimisation models are also developed to evaluate the performance of operations practices.

Design/methodology/approach

The model-driven DSS for SMMEs, which uses the optimisation models for managing and coordinating planned obsolescence, is developed to determine the optimal manufacturing plan and minimise operating costs. A case application with the planned obsolescence and production scenario is also provided to demonstrate the approach and practical insights of DSS.

Findings

Assessing planned obsolescence in production is a challenge for manufacturing managers. A DSS for SMMEs can enable the computerised support in decision making and understand the planned obsolescence scenarios. The causal relationship of different time-varying component obsolescence and availability in production are also examined, which may have an impact on the overall operating costs for producing manufactured products.

Research limitations/implications

DSS can resolve and handle the complexity of production and planned obsolescence scenarios in manufacturing industry. The optimisation models used in the DSS excludes the variability in component wear-out life and technology cycle. In the future study, the optimisation models in DSS will be extended by taking into the uncertainty of different component wear-out life and technology cycle considerations.

Originality/value

This paper demonstrates the flexibility of DSS that facilitates the optimisation models for collaborative manufacturing in planned obsolescence and achieves cost effectiveness.

Details

Industrial Management & Data Systems, vol. 119 no. 9
Type: Research Article
ISSN: 0263-5577

Keywords

Article
Publication date: 20 July 2022

Kashif Ishfaq, Muhammad Asad, Muhammad Arif Mahmood, Mirza Abdullah and Catalin Pruncu

The purpose of this study is to explore the applications of 3D printing in space sectors. The authors have highlighted the potential research gap that can be explored in…

230

Abstract

Purpose

The purpose of this study is to explore the applications of 3D printing in space sectors. The authors have highlighted the potential research gap that can be explored in the current field of study. Three-dimensional (3D) printing is an additive manufacturing technique that uses metallic powder, ceramic or polymers to build simple/complex parts. The parts produced possess good strength, low weight and excellent mechanical properties and are cost-effective. Therefore, efforts have been made to make the adoption of 3D printing successful in space so that complex parts can be manufactured in space. This saves a considerable amount of both time and carrying cost. Thereof the challenges and opportunities that the space sector holds for additive manufacturing is worth reviewing to provide a better insight into further developments and prospects for this technology.

Design/methodology/approach

The potentiality of 3D printing for the manufacturing of various components under space conditions has been explained. Here, the authors have reviewed the details of manufactured parts used for zero-gravity missions, subjected to onboard international space station conditions and with those manufactured on earth. Followed by the major opportunities in 3D printing in space which include component repair, material characterization, process improvement and process development along with the new designs. The challenges like space conditions, availability of power in space, the infrastructure requirements and the quality control or testing of the items that are being built in space are explained along with their possible mitigation strategies.

Findings

These components are well comparable with those prepared on earth which enables a massive cost saving. Other than the onboard manufacturing process, numerous other components as well as a complete robot/satellite for outer space applications were manufactured by additive manufacturing. Moreover, these components can be recycled onboard to produce feedstock for the next materials. The parts produced in space are bought back and compared with those built on earth. There is a difference in their nature, i.e. the flight specimen showed a brittle nature, and the ground specimen showed a denser nature.

Originality/value

This review discusses the advancements of 3D printing in space and provides numerous examples of the applications of 3D printing in space and space applications. This paper is solely dedicated to 3D printing in space. It provides a breakthrough in the literature as a limited amount of literature is available on this topic. This paper aims at highlighting all the challenges that additive manufacturing faces in the space sector and also the future opportunities that await development.

Details

Rapid Prototyping Journal, vol. 28 no. 10
Type: Research Article
ISSN: 1355-2546

Keywords

Article
Publication date: 20 April 2015

Suryakumar Simhambhatla and K.P. Karunakaran

– This paper aims to develop build strategies for rapid manufacturing of components of varying complexity with the help of illustration.

1025

Abstract

Purpose

This paper aims to develop build strategies for rapid manufacturing of components of varying complexity with the help of illustration.

Design/methodology/approach

The build strategies are developed using a hybrid layered manufacturing (HLM) setup. HLM, an automatic layered manufacturing process for metallic objects, combines the best features of two well-known and economical processes, viz., arc weld-deposition and milling. Depending on the geometric complexity of the object, the deposition and/or finish machining may involve fixed (3-axis) or variable axis (5-axis) kinematics.

Findings

Fixed axis (3-axis) kinematics is sufficient to produce components free of undercuts and overhanging features. Manufacture of components with undercuts can be categorized into three methods, viz., those that exploit the inherent overhanging ability, those that involve blinding of the undercuts in the material deposition stage and those that involve variable axis kinematics for aligning the overhang with the deposition direction.

Research limitations/implications

Although developed using the HLM setup, these generic concepts can be used in a variety of metal deposition processes.

Originality/value

This paper describes the methodology for realizing undercut features of varying complexity and also chalks out the procedure for their manufacture with the help of case studies for each approach.

Details

Rapid Prototyping Journal, vol. 21 no. 3
Type: Research Article
ISSN: 1355-2546

Keywords

Open Access
Article
Publication date: 6 August 2019

Anton Wiberg, Johan Persson and Johan Ölvander

This paper aims to review recent research in design for additive manufacturing (DfAM), including additive manufacturing (AM) terminology, trends, methods, classification…

12297

Abstract

Purpose

This paper aims to review recent research in design for additive manufacturing (DfAM), including additive manufacturing (AM) terminology, trends, methods, classification of DfAM methods and software. The focus is on the design engineer’s role in the DfAM process and includes which design methods and tools exist to aid the design process. This includes methods, guidelines and software to achieve design optimization and in further steps to increase the level of design automation for metal AM techniques. The research has a special interest in structural optimization and the coupling between topology optimization and AM.

Design/methodology/approach

The method used in the review consists of six rounds in which literature was sequentially collected, sorted and removed. Full presentation of the method used could be found in the paper.

Findings

Existing DfAM research has been divided into three main groups – component, part and process design – and based on the review of existing DfAM methods, a proposal for a DfAM process has been compiled. Design support suitable for use by design engineers is linked to each step in the compiled DfAM process. Finally, the review suggests a possible new DfAM process that allows a higher degree of design automation than today’s process. Furthermore, research areas that need to be further developed to achieve this framework are pointed out.

Originality/value

The review maps existing research in design for additive manufacturing and compiles a proposed design method. For each step in the proposed method, existing methods and software are coupled. This type of overall methodology with connecting methods and software did not exist before. The work also contributes with a discussion regarding future design process and automation.

Details

Rapid Prototyping Journal, vol. 25 no. 6
Type: Research Article
ISSN: 1355-2546

Keywords

Article
Publication date: 18 May 2010

Axel Bindel, Paul Conway, Laura Justham and Andrew West

The purpose of this paper is to present an update of and the latest results from work on a project aimed at monitoring electronic products during the whole life cycle with…

Abstract

Purpose

The purpose of this paper is to present an update of and the latest results from work on a project aimed at monitoring electronic products during the whole life cycle with embedded wireless components.

Design/methodology/approach

Business processes of the electronic manufacturing supply chain were analysed. A business case and the system opportunities for life cycle monitoring, based on embedded wireless components system were developed. Radio frequency identification (RFID) assembly technology was adapted for the integration of components into a multi‐layer printed circuit board (PCB).

Findings

By storing product‐related information into electronic products, tracing of components, monitoring of processes, operations and costs, environmentally optimised recycling can be enhanced.

Research limitations/implications

The research undertaken so far relates to the embedding of RFID tags into PCBs. Wireless components with more processing power will be used in the next project phase.

Originality/value

The paper details how wireless components can be embedded into multi‐layer PCBs and how a business case for a life cycle monitoring system can be established.

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