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Rising energy costs and potential scarcity are driving energy reduction initiatives in manufacturing companies. The reduction in energy use is complementary to the classic lean production philosophy and the lean and green literature implies that reducing energy waste supports lean objectives. The purpose of this paper is to examine this perceived positive correlation and identify the impact level of energy reduction of lean product flow.

To achieve this, published case studies and practices from interview were gathered and categorised against a waste management hierarchy.

Energy reduction activities implicitly reduce waste which is compatible with the lean waste objective, however, when applying the waste hierarchy principle to energy efficiency practice, lean product flow is progressively constrained or compromised towards the lower levels of the hierarchy.

The hierarchical classification seeks to communicate how reported energy efficiency improvements will/will not impact on flow. The research focuses on the modification of existing discrete part production facilities towards greater energy efficiency and neglects alternative production technologies and new build. The results suggest that as manufacturers seeking to be more energy efficient move away from preventative actions to more reduce and reuse actions then production flexibility could become restricted and the design of production facilities make re-think the fast, linear and short flow of product.

Examples of industrial practices are provided to show the implications of energy reduction practice on production flow.

Categorises the relationship between classic lean and industrial low-energy initiatives to provide insight to how higher energy cost could impact on production.

The purpose of this paper is to introduce management historians to the long‐forgotten work of Frank George Woollard (1883‐1957), who in the mid‐1920s established flow production in the British motor industry, and its remarkable similarity to current‐day production principles and practices used by Toyota Motor Corporation, also known as lean production.

Overview of Frank Woollard's life and work obtained from newly discovered journal papers, his 1954 book, Principles of Mass and Flow Production, newly discovered archives, and new first‐hand testimony from a close friend and from a long‐time family friend.

Frank Woollard was a pioneer in the establishment of flow production in the British motor industry in the mid‐1920s and the principal developer of automatic transfer machinery. His accomplishments are comparable to Taiichi Ohno, regarded as the architect of Toyota's production system.

Woollard's accomplishments in flow production are a fruitful area for future research given the speed and completeness with which flow production was established at Morris Motors Ltd, Engines Branch. Newly discovered papers describing his flow production system have yet to be studied in detail by academics.

Woollard's application of flow production beginning in 1923 means that timelines for discoveries and attributions of key accomplishments in lean management must be reexamined and revised.

Woollard's work fills important gaps in the literature on the history of flow production generally and in the British motor industry in particular. His work constitutes an early application of current‐day lean principles and practices, and is therefore noteworthy and relevant to management historians and the operations and production management community. It is hoped that this paper will inspire management historians to study Woollard's work and place him in the context of other early twentieth‐century pioneers in industrial management and flow production.

In this case study, flow manufacturing implementation at Acme International, a toilet bowl and seat manufacturer, is described. Flow manufacturing, is a pull‐driven strategy; its main principle is that daily production rate can be synchronized with demand. Thus, customer service is improved while costs are reduced through improved quality, minimum or zero inventory, and elimination of non‐productive time by rearranging equipment and personnel. In the case of Acme, the lead time was reduced by 68 percent while at the same time the defect rate was reduced by 62.5 percent.

The study aims to test, measure and quantify the impacts of lean construction and BIM implementation on flow in construction projects.

Detailed control data from a set of 18 high-rise residential construction projects executed between years 2011 and 2020 were analyzed using the construction flow index (CFI), a measure of workflow quality. Seven comparable projects with a diverse range of LPS, BIM, VDC and 5S implementation were selected to compare the impacts of these innovations on flow.

Implementing BIM in the big room and applying the last planner system and other lean construction techniques increased the CFI from 4.31 to 8.12 (on a 10-point scale). Avoiding trades crossing one another's paths between tasks was the most significant aspect of improved flow. Moreover, the benefits of implementing lean practices with BIM or VDC were found to be measurably greater than when these approaches were implemented separately.

The primary limitation of the study is that the degree of confidence in the results is limited by the nature of the case study approach. Although 18 is a respectable number of case study projects, it cannot offer the degree of confidence that a broader, representative sample of projects could. Similarly, the case studies are all drawn from the same construction context (residential apartments) and the same geographic region, which necessarily limits confidence concerning the degree to which the findings can be generalized.

The research is the first of its kind to quantitatively assess the impacts of BIM and lean construction on flow. Use of the CFI to quantify flow quality also highlights the potential value of CFI in providing project managers and planners a clear view of the smoothness or irregularity of flow and of differences between subcontractors' production rates.

Presents some theoretical principles and empirical evidence relating to the new Swedish production systems for final assembly of motor vehicles. Contends that in these production systems it is possible simultaneously to enhance efficiency and quality of working life. Briefly sketches three production forms as they apply to the final assembly of automobiles and discusses the societal environments in which these different forms of production have evolved. Focuses on Volvo′s Swedish Uddevalla plant as one of the main examples so far of a reflective production system for final assembly of automobiles. Amplifies the analysis of different production flow patterns for final assembly and in particular addresses the issue of semi‐parallel mechanistic production flow and parallel organic production flow as alternatives to serial flow on a conventional line assembly.

In a mixed flow production environment, interactions between production planning and scheduling are critical for mixed flow distributed manufacturing management. The purpose of this paper is to assist manufacturers in achieving real-time ordering and obtaining integrated optimization of shop floor production planning and scheduling for mixed flow production systems.

A double decoupling postponement (DDP) approach is presented for production dispatch control, and an integrated model is designed under an assemble to order (ATO) environment. To generate “optimal” lots to fulfil real-time customer requests, constant work in progress (CONWIP) and days of inventory dispatching algorithms are embedded into the proposed DDP model, which can deal with real-time ordering and dynamic scheduling simultaneously. Subsequently, a case study is conducted, and experiments are carried out to verify the presented method.

The proposed DDP model is designed to upgrade a previous CONWIP method in the case study company, and the proposed model demonstrates better performance for the integration of production planning and scheduling in mixed flow manufacturing. As a result, the presented operation mechanism can reflect real-time ordering information to shop floor scheduling and obtain performance metrics in terms of reliability, availability and maintainability.

The presented model can be further proliferated to generic factory manufacturing with the proposed logic and architecture.

The DDP model can integrate real-time customer orders and work in process information, upon which manufacturers can make correct decisions for dispatch strategies and order selection within an integrated system.

This study aims to address the management of reverse flows in the context of service supply chains. The study builds on the characteristics of services production reported in literature to: identify diverse types of reverse flows in services supply chains, discuss key issues associated to the management of reverse service flows and suggest directions for research for developing the knowledge for management of reverse flows in service contexts.

This study first provides an overview of the theoretical background which supports the identification and the characterization of the flows, and the reverse flows, involved in service production. A short summary of each paper accepted in this special issue is also provided to give readers an overview of the various issues around reverse exchanges in service supply chains that authors have attempted to address.

In this study, the authors identify distinct types of reverse flows in services production building on the analysis of the characteristics of service production and delivery reported in the literature. Our discussion highlights the fact that service supply chains can be quite diverse in the type of exchanges of inputs and outputs that take place between customers and providers, showing that often there can be substantial flows of items to return. In particular, and differently from manufacturing contexts, the authors highlight that in service supply chains, providers might need to handle bi-directional reverse flows.

The lack of research on reverse service supply chains is, to a great extent, a consequence of dominant paradigms which often identify the absence of physical product flows as a key distinguishing feature of service supply chains, and therefore lead to the misbelief that in services there is nothing to return. This special issue therefore aims to clarify this misunderstanding through the limited selection of eight papers that address various issues around reverse exchanges in service supply chains.

While theoretical and empirical research in supply chain is abundant, management of reverse exchanges in service supply chain is sparse. In this special issue we aim to provide the first contribution to understand how the characteristics of service production raise new issues for the management of reverse flows in service supply chains, and to foster the development of adequate management strategies.

The purpose of this paper is to present a practical proposal for integrating production control (PC) and quality control (QC) at the shop floor level.

The proposed method is based on three principles which relate PC and QC at the shop floor level. The proposal is applied successfully at the world's largest pencil factory.

The results show that the proposed method contributes to improve four performance indicators related to PC and QC at the company studied: increase the average throughput in about 28.9 per cent; reduce the average value of work in process (WIP) in about 35.6 per cent, reduce the average lead time by about 45.4 per cent, and reduce the average defect rate by about 71.4 per cent.

The proposal (mainly because of principle III) is developed to be applied in repetitive production (RP) systems, i.e. environments characterized by low production volume and low product variety.

Some practical implications for industrial managers arises from this study: managers must consider the importance of integrated PC and QC functions in order to get better results concerning performance indicators such as throughput, WIP, lead time, and rejection rate; the materials flow simplification is a prerequisite for a lot of improvement initiatives at the shop floor level; the adequate choice of the production control system (PCS) is vital in order to get positive results regarding the performance indicators related to PC; the determination of the production pace (or rate) for a RP system must take account capacity restrictions and the influence of defect rate on production rate.

The paper is original in that it shows that the performance of the shop floor level can be improved by means of integrating PC and QC, by discussing and implementing a method which simplifies the material flow in the shop floor level, chooses the most adequate PCS and shows how the production rate influence on the rejection rate. Therefore, the paper is important for those which practice industrial management, more specifically on PC and QC functions.

This study aims to elucidate the role of curved walls in the presence of identical mass of porous bed with identical heating at a wall for two heating objectives: enhancement of heat transfer to fluid saturated porous beds and reduction of entropy production for thermal and flow irreversibilities.

Two heating configurations have been proposed: Case 1: isothermal heating at bottom straight wall with cold side curved walls and Case 2: isothermal heating at left straight wall with cold horizontal curved walls. Galerkin finite element method is used to obtain the streamfunctions and heatfunctions associated with local entropy generation terms.

The flow and thermal maps show significant variation from Case 1 to Case 2 arrangements. Case 1 configuration may be the optimal strategy as it offers larger heat transfer rates at larger values of Darcy number, Da_m. However, Case 2 may be the optimal strategy as it provides moderate heat transfer rates involving savings on entropy production at larger values of Da_m. On the other hand, at lower values of Da_m (Da_m ≤ 10⁻³), Case 1 or 2 exhibits almost similar heat transfer rates, while Case 1 is preferred for savings of entropy production.

The concave wall is found to be effective to enhance heat transfer rates to promote convection, while convex wall exhibits reduction of entropy production rate. Comparison between Case 1 and Case 2 heating strategies enlightens efficient heating strategies involving concave or convex walls for various values of Da_m.

Effective operations management systems (OMS) measurement remains a critical issue for theorists and practising managers (Neely, 2005; Bititci et al., 2012). Traditional labor efficiency measures sufficed when all that was made could be sold or when mass production systems filled warehouses with stock and the OMS had little relationship with “the consumer.” Modern manufacturing systems require a different form of flow optimization (beyond labor efficiency) measurement (Schmenner, 2015). The essential unit of measure for all OMS designs is the optimal use of time for process value adding and the flow of materials into and from the conversion process. Timely flow, therefore, satisfies the needs of multiple organizational stakeholders including cash flow (accounting), consumer reaction times (marketing) and the general steady state flow of materials (sales and supply chain). The purpose of this paper is to present the results of testing a new performance measure of operations flow effectiveness (OFE) with ten purposively selected cases.

The paper is theory building using ten, purposively selected, longitudinal case studies drawn from the UK high-value manufacturing (HVM) sector using a pluralist methodology of interviews, observation and secondary data.

The OFE measure provides a holistic view of material flow through the input-process-output cycles of a firm. The measure highlights OMS design weaknesses and flow inhibitors that reduce cash flow using a time-based approach to measuring OMS performance. The study validates the OFE measure and has identified six key design elements that enable high flow performance.

The paper tests a new process-focused flow performance measure. The measure supports a holistic approach to the manufacturing enterprise and allows different OMS designs to be evaluated so that organizational learning may be enacted to support performance improvement.