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Article

Astha Sharma, Neeraj Bhanot, Ajay Gupta and Rajeev Trehan

This study aims to utilize DMAIC methodology along with value stream mapping and other Lean Six Sigma tools in a major automobile light manufacturing industry to reduce…

Abstract

Purpose

This study aims to utilize DMAIC methodology along with value stream mapping and other Lean Six Sigma tools in a major automobile light manufacturing industry to reduce defect rates and increase production capacity in their manufacturing line. The study also proposes a modified framework based on lean principles and FlexSim to identify and reduce waste in the selected industry.

Design/methodology/approach

A Lean Six Sigma modified framework has been deployed with DMAIC to reduce the defect rate and increase the production rate. Various tools like value stream mapping, brainstorming, Pareto charts, 5S, kanban, etc. have been used at different phases of DMAIC targeting wastes and inventory in the production line. Also, a simulation model has been utilized for the automobile light manufacturing industry to improve the machine utilization time with varying batch sizes.

Findings

The results of the study indicated a 53% reduction in defect rates. Thus, there would be an expected improvement in sigma value from 3.78 to 3.89 and a reduction in defects per million opportunities (DPMO) from 11,244 to 8,493. Additionally, simulation model using FlexSim was developed, and the optimum ordering batch size of raw material was obtained. It was also analyzed that idle time for various stations could be reduced by up to 30%.

Practical implications

The utilized framework helps identify defects for managers to increase production efficiency. The workers, operators and supervisors on the production line also need to be trained regularly for identifying the areas of improvement.

Originality/value

The modified Lean Six Sigma framework used in this study includes FlexSim simulation to make the framework robust, which has not been used with LSS tools in the literature studied. Also, the LSS finds very less application in the manufacturing domain, considering which this study tends to add value in existing literature taking a case of an automobile light manufacturing industry.

Details

International Journal of Productivity and Performance Management, vol. ahead-of-print no. ahead-of-print
Type: Research Article
ISSN: 1741-0401

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Article

Nithya R.P. and Haridass M.

The purpose of this paper is to provide simulation modelling for bulk arrival bulk service queueing system involved in a textile industry and analyze the performance metrics.

Abstract

Purpose

The purpose of this paper is to provide simulation modelling for bulk arrival bulk service queueing system involved in a textile industry and analyze the performance metrics.

Design/methodology/approach

This paper describes the simulation modelling of a bulk queueing system with limited number of admissions and multiple vacations. The model is developed for the proposed queueing system using Flexsim 2017, and it is explained through an application observed in a textile industry involving the process of cone winding.

Findings

In this paper, the simulation model has been developed to study the behaviour of queues at different resources in a production system. Various performance measures such as average components, average waiting time, total number of inputs and outputs, processing time and idle time involved in a textile industry are evaluated using simulation and justified through numerical illustration.

Practical implications

The proposed simulation model may be used in various scenarios wherever a real time situation exists related to bulk queueing system. The results produced in this paper can be used by the manufacturing industries to enhance the need-based accuracy. It is worth pointing out that the findings are of direct practical relevance and can be successfully used for a number of industrial applications.

Originality/value

The approach suggested in this paper attempts to deal with the queueing system involved in a textile industry and provides numerical results in less time with less computer resources. It provides a reasonably good approximation for simple and complex queueing models where it is difficult to find closed form of theoretical results.

Details

Kybernetes, vol. 50 no. 2
Type: Research Article
ISSN: 0368-492X

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Article

Fei Jin Ying, Michael O’Sullivan and Ivo Adan

Materials supply is one of the important elements in construction operation and a major factor affecting the quality of construction projects. Many industries look to…

Abstract

Purpose

Materials supply is one of the important elements in construction operation and a major factor affecting the quality of construction projects. Many industries look to manage materials effectively by attempting to integrate logistics processes into logistics chains of suppliers and customers. Logistics processes, being crucial for successful completion of construction projects, but in fact, auxiliary, are often entrusted to external professionals specialised in logistic services, such as logistics centres. However, this tendency is yet to be developed in construction. The purpose of this paper is to develop a simulation framework for the examination of potential improvements of logistics performance using logistics centres.

Design/methodology/approach

A case study approach was adopted with computer simulation using Flexsim. Data of vehicle movements were collected during construction on-site from the start of construction to “hand-over” to the building owner.

Findings

The ideal location of a logistics centre is identified using vehicle movements data collected on the site. The potential improvements of the planned centre are then evaluated by simulating various scenarios of vehicle movements. The enclosed results from the simulations indicate that using a logistics centre will reduce waste for the construction project considered.

Originality/value

The paper emphasises that creating a logistics centre for a project can improve construction logistics performance, by consolidating and optimizing both off-site and on-site logistics, especially when the site condition is prohibitive (small footprint with limited loading bay area). Establishing logistics centres may help find ways of making the overall construction project more effective by improving the management of materials.

Details

Construction Innovation , vol. ahead-of-print no. ahead-of-print
Type: Research Article
ISSN: 1471-4175

Keywords

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Article

Adam Sadowski, Piotr Wojciechowski and Per Engelseth

In a volatile marketplace, warehouse management is fundamentally contingent of changes in its supply network environment. Flexibility is therefore a key logistics issue in…

Abstract

Purpose

In a volatile marketplace, warehouse management is fundamentally contingent of changes in its supply network environment. Flexibility is therefore a key logistics issue in distribution centre management. This study probes into the nature of warehouse flexibility in a supply network through simulation.

Design/methodology/approach

By using the FlexSim simulation tool the dynamic behaviour of the warehouse system are conceptualised, documented, simulated, analysed and evaluated.

Findings

Simulation revealed that external changes affect daily processes and the reorganisation of warehouse processes. Given the extensity of resource use, simulation also revealed that process reorganisation should not be a daily undertaking. This is because warehouse processes react in unpredictable and different manners to even the smallest disturbance from the environment. This reaction is not necessarily negative impending more long-term change of warehouse processes.

Originality/value

The warehouse is a complex system that self-adapts with limited need to calculate new optimised warehouse processes to counter changes in its environment. Rather than following deterministic optimisation procedures, the development of flexible resources is a key issue in warehouse management. The applied simulation model is generic and therefore applicable in other distribution centres pointing to how to monitor warehouse processes to in a pre-emptively develop warehouse flexibility through change of process context.

Details

International Journal of Productivity and Performance Management, vol. ahead-of-print no. ahead-of-print
Type: Research Article
ISSN: 1741-0401

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Article

Young‐Gyun Kim and Jaejoo Lim

In traditional point‐of‐sale (POS) systems, an in‐house database server processes all sales transactions it receives from local client computers. Such systems incur high…

Abstract

Purpose

In traditional point‐of‐sale (POS) systems, an in‐house database server processes all sales transactions it receives from local client computers. Such systems incur high costs because of operational requirements, such as professional maintenance, the sophisticated server hardware required, and scalability requirements. For small retailers that want to use POS systems but have relatively limited financial resources, these expensive operational requirements are big obstacles. Considering these issues, the purpose of this paper is to suggest a POS system that is adequate for small businesses.

Design/methodology/approach

Using a simulation method, the authors tested and compared the operational performance of POS systems in two different environments, i.e. the remote server‐client environment and the local server‐client environment.

Findings

One possible solution is for a group of small retailers to use a shared, remote database server, but such servers often have reliability and performance issues. To resolve these issues, the authors suggest a POS system that utilizes local data tables embedded in each client's computer. This system consists of a remote database server and a group of client POS computers with off‐line data‐handling capabilities. The results indicated that it is possible for small businesses to obtain significant benefits from an affordable POS system based on a remote client‐server model that utilizes a local data cache.

Practical implications

The results of this study indicated that small businesses may obtain significant benefit from the affordable POS systems based on a remote client‐server model that utilizes a local data cache.

Originality/value

The literature lacks studies on small businesses' accessibility to POS systems. The study fills this literature gap and shows a technological solution to provide affordable POS systems to small businesses, which have not been paid much attention by POS vendors.

Details

Management Research Review, vol. 34 no. 12
Type: Research Article
ISSN: 2040-8269

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Article

Jagdeep Singh, Harwinder Singh, Amandeep Singh and Jashanpreet Singh

The purpose of this paper is to cover the significance of lean thinking using value stream mapping and six sigma methodology in managing industrial operations.

Abstract

Purpose

The purpose of this paper is to cover the significance of lean thinking using value stream mapping and six sigma methodology in managing industrial operations.

Design/methodology/approach

Lean manufacturing is an efficient approach for identifying and eliminating waste through a continuous improvement via flow of the product/service at the pull of customer in chase of exactness. This study has been carried out in a manufacturing unit of Northern India that was suffering from high production lead time and work in progress (WIP) inventory.

Findings

The current state and future state maps for the critical product have been prepared. On comparison of both current and future state maps, it was observed that lead time has been reduced by 14.88 percent, processing time by 14.71 percent and wastage of material movement by 37.97 percent. As proposed in model, the WIP inventories have been reduced by 17.76 percent and workforce by 17.64 percent. Further it would lead to the profit of Rs161,800 per annum. Six sigma projects have been carried out to reduce rejections of the critical product P-19 under study. The total length of the product was undersize of the critical product. Root cause analysis technique has been used through strategic DMAIC implementation. Results of investigation demonstrated net savings of rupees 145,560 annually.

Originality/value

The paper demonstrates the practical application of lean thinking, showing how it can bring real breakthroughs in saving cost in the manufacturing industry.

Details

Management Decision, vol. 58 no. 6
Type: Research Article
ISSN: 0025-1747

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Article

Fentahun Moges Kasie and Glen Bright

This study aims to propose a decision support system (DSS) that performs a decision-based part-fixture assignment and fixture flow control in planned production periods.

Abstract

Purpose

This study aims to propose a decision support system (DSS) that performs a decision-based part-fixture assignment and fixture flow control in planned production periods.

Design/methodology/approach

The principal approaches were fuzzy case-based reasoning (FCBR) and discrete-event simulation (DES). Besides, the fuzzy analytic hierarchy process (FAHP), an object-oriented (OO) method and a fuzzy weighted Euclidean distance were used to support the decision-making process.

Findings

It shows that integrating FCBR and DES systems is a promising approach to address part-fixture planning problems. The FCBR subsystem proposed various stable numbers of fixtures as scenarios. The DES model analyzed the future performances of these scenarios and identified the best alternative.

Research limitations/implications

The DSS was tested in laboratory environments using a numerical analysis; however, it was not validated in industrial situations.

Originality/value

The synergy of integrating FCBR and DES systems was not exploited in the past in part-fixture assignment and fixture flow control problems.

Details

Journal of Modelling in Management, vol. 14 no. 2
Type: Research Article
ISSN: 1746-5664

Keywords

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Article

Fuli Zhou, Panpan Ma, Yandong He, Saurabh Pratap, Peng Yu and Biyu Yang

With an increasingly fierce competition of the shipbuilding industry, advanced technologies and excellent management philosophies in the manufacturing industry are…

Abstract

Purpose

With an increasingly fierce competition of the shipbuilding industry, advanced technologies and excellent management philosophies in the manufacturing industry are gradually introduced to domestic shipyards. The purpose of this study is to promote the lean management of Chinese ship outfitting plants by lean production strategy.

Design/methodology/approach

To promote the lean implementation of Chinese shipyards, the lean practice of ship-pipe part production is highlighted by lot-sizing optimization and strategic CONWIP (constant work-in-process) control. A nonlinear programming model is formulated to minimize the total cost of ship-pipe part manufacturing and the particle swarm optimization (PSO)-based algorithm is designed to resolve the established model. Besides, the pull-from-the-bottleneck (PFB) strategy is used to control ship-pipe part production, verified by Simulink simulation.

Findings

Results show that the proposed lean strategy of the programming model and strategic PFB control could assist Chinese ship outfitting plants to leverage competitive advantage by waste reduction and lean achievement. Specifically, the PFB double-loop control strategy shows better performance when there is high productivity and the PFB single-loop control outperforms at lower productivity scenarios.

Practical implications

To verify the effectiveness of the proposed lean strategy, a case study is performed to validate the formulated model. Also, simulation experiments realized by FlexSim software are conducted to testify results obtained by the constructed programming model.

Originality/value

Lean production management practice of the shipyard building industry is performed by the proposed lean production strategy through lot-sizing optimization and strategic PFB control in terms of ship-pipe part manufacturing.

Details

Kybernetes, vol. ahead-of-print no. ahead-of-print
Type: Research Article
ISSN: 0368-492X

Keywords

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Article

Jagmeet Singh and Harwinder Singh

This paper aims to apply lean manufacturing using value stream mapping (VSM) in the manufacturing organization (automotive suspension and fastening components section). To…

Abstract

Purpose

This paper aims to apply lean manufacturing using value stream mapping (VSM) in the manufacturing organization (automotive suspension and fastening components section). To validate the VSM approach, simulation has been done.

Design/methodology/approach

VSM approach has been used to implement lean stages in the U-bolt section. Current state map was prepared and future state map has been implemented. Further, simulation has been done to compare current state and future state maps.

Findings

It has been found that there is 87.59% reduction in cycle time (C/T), 76.47% reduction in work-in-process (WIP) inventory, 95.41% reduction in production lead time, 66.08% increase in value added (VA) ratio, 95.78% reduction in non-value added (NVA) time, 57.14% reduction in the number of operators and 70.67% reduction in change over (C/O) time for the U-bolt section. Simulated and VSM of current and future state has observed error of 5 s.

Research limitations/implications

This study is based on automotive manufacturing industry situated in northern part of India. The outcome of this study is applicable only to the selected product of the manufacturing company.

Originality/value

This paper deals with case study part which reflects the true picture of implementation of Lean manufacturing (LM) tools in the organization.

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Article

Zeeshan Aziz, Rana Muhammad Qasim and Sahawneh Wajdi

The purpose of this paper is to investigate the integration of discrete event simulation (DES) and value stream mapping (VSM) to enhance the productivity of road surfacing…

Abstract

Purpose

The purpose of this paper is to investigate the integration of discrete event simulation (DES) and value stream mapping (VSM) to enhance the productivity of road surfacing operations by achieving high production rates and minimum road closure times. Highway infrastructure is one of the most valuable assets owned by the public sector. The success of national and local economies as well as quality of life of the general public depend on the efficient operations of highways. Ensuring smooth traffic operations requires maintenance and improvements of the highest standard.

Design/methodology/approach

Research approach involved the use of primary data collected from direct observation, interviews, review of archival records and productivity databases. Based on this, process maps and value stream maps were developed which were subsequently used to produce discrete event simulation models for the exploration of different optimisation scenarios.

Findings

This research highlights the synergistic relationship between VSM and DES in driving innovation in construction processes. Identified factors that affect roadworks process productivity include machine, manpower, material, information, environment and method-related factors. A DES model is presented to optimise the process and increase the production rates. A hybrid DES-VSM approach ensures an integrated approach to process optimisation.

Research limitations/implications

This study is an application of hybrid version of previously published DES-VSM framework in the manufacturing sector. The present study has extended and tested its applicability within road surfacing operations. The different what-if scenarios presented in this paper might not be applicable to other parts of the world owing to various constraints. The study has focused on addressing the waste production inherent in pavement laying process. Even though external variables could possibly influence pavement process, those were ignored to allow for in-depth focus on the process under consideration.

Practical implications

Road users are one of the most important stakeholders that will benefit from the positive implications of this study. Private resurfacing companies and transport departments can optimise their overall process and style of working by comparing their end-to-end process and work plans with the ones mentioned in this paper. It will boost the productivity of equipment like planners, pavers and other machines used for resurfacing operations.

Originality/value

Existing approaches to process modelling such as VSM and process diagrams are constrained by their effectiveness in the analysis of dynamic and complex processes. This study presents a DES-based approach to validate targeted improvements of the current state of road surfacing processes and in exploration of different optimisation scenarios.

Details

Construction Innovation, vol. 17 no. 3
Type: Research Article
ISSN: 1471-4175

Keywords

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