Search results

The concept of virtual cellular manufacturing systems (VCMS) is finding acceptance among researchers and practitioners as an extension to group technology. This paper is related to a research work which resulted in designing and developing VCMS, which by virtue of its abilities proves to be attractive to manufacturing organisations fitting into the category of SMEs. VCMS consists of enterprise modeller (EM), cell design manager (CDM), cell operation manager (COM), simulator (SIM), performance evaluator (PE) and report generator (REP). The “cell design manager” is a very important constituent of the VCMS, as this module helps to generate a number of cell configurations using different algorithms. A new algorithm styled as “Better alternative to ROC (BETROC)”, which possesses many distinct features to generate a number of alternative solutions, has been developed and reported in this paper.

Existing conceptual, empirical and case studies evidence suggests that manufacturing industries find the joint implementation of Kaizen philosophy initiatives. However, the existing practices rarely demonstrated in a single framework and implementation procedure in a structure nature. This paper, therefore, aims to develop, validate and practically test a framework and implementation procedure for the implementation of integrated Kaizen in manufacturing industries to attain long-term improvement of operational, innovation, business (financial and marketing) processes, performance and competitiveness.

The study primarily described the problem, extensively reviewed the current state-of-the-art literature and then identified a gap. Based on it, generic and comprehensive integrated framework and implementation procedure is developed. Besides, the study used managers, consultants and academics from various fields to validate a framework and implementation procedure for addressing business concerns. In this case, the primary data was collected through self-administered questionnaire, and 244 valid questionnaires were received and were analyzed. Furthermore, the research verified the practicability of the framework by empirically exploring the current scenario of selected manufacturing companies.

The research discovered innovative framework and six-phase implementation procedure to fill the existing conceptual gap. Furthermore, the survey-based and exploratory empirical analysis of the research demonstrated that the practice of the proposed framework based on structured procedure is valued and companies attain the middling improvements of productivity, delivery time, quality, 5S practice, waste and accident rate by 61.03, 44, 52.53, 95.19, 80.12, and 70.55% respectively. Additionally, the companies saved a total of 14933446 ETH Birr and 5,658 M² free spaces. Even though, the practices and improvements vary from company to company, and even companies unable to practice some of the unique techniques of the identified CI initiatives considered in the proposed framework.

All data collected in the survey came from professionals working for Ethiopian manufacturing companies, universities and government. It is important to highlight that n = 244 is high sample size, which is adequate for a preliminary survey but reinforcing still needs further survey in terms of generalization of the results since there are hundreds of manufacturing companies, consultants and academicians implementing and consulting Kaizen. Therefore, a further study on a wider Ethiopian manufacturing companies, consultants and academic scale would be informative.

This work is very important for Kaizen professionals in the manufacturing industry, academic and government but in particular for senior management and leadership teams. Aside from the main findings on framework development, there is some strong evidence that practice of Kaizen resulted in achieving quantitative (monetary and non-monetary) and qualitative results. Thus, senior management teams should use this research out to practice and analyze the effect of Kaizen on their own organizations. Within the academic community, this study is one of the first focusing on development, validating and practically testing and should aid further study, research and understanding of Kaizen in manufacturing industries.

So far, it is rare to find preceding studies proposed, validated and practically test an integrated Kaizen framework with the context of manufacturing industries. Thus, authors understand that this is the very first research focused on the development of the framework for manufacturing industries continuously to be competitive and could help managers, institutions, practitioners and academicians in Kaizen practice.

The purpose of this paper is to address the gap between definition and practical aspects of production efficiency in mass customization (MC). The paper summarizes all major issues impacting efficiency in MC. Also, the paper reviews metrics, relationship between various parameters and provides a best practices benchmark toolkit to achieve higher machine efficiencies.

The paper identified and categorized multiple challenges impacting machine efficiency in MC through a literature review spanning over three decades, and also ranked the identified issue-based parameters. Top issues were found varying across different types of industries identified through the review. Metrics pertaining to efficiency and degree of MC are reviewed in the paper. A chronological review of issues is presented, and a chain diagram is built in the paper. Toolkit of best practices created with solution strategies and tools are summarized through the review.

The paper found that MC reasonably impacts machine efficiency which needs to be addressed. Major issues through literature review-based ranking are uncovered, and worldwide research trend and comparison are presented. Active research in this area is observed to be at its peak since 2010. The extensive use of strategies and benchmark toolkit for improving efficiency are summarized.

Ranking of issues has been done through a literature review; hence, there can be skewness depending on the frequency of issues researched by various authors in various areas of industries.

This paper is useful for manufacturing managers and companies willing to increase the size of their product portfolio and choices within their available resources without compromising machine efficiencies and, thereby, the cost. The identified issues help in providing a comprehensive issue list to the academia.

This paper describes what is believed to be the first study that explicitly examines the issues faced in achieving machine efficiency while manufacturing in an MC environment.

The purpose of this research is to discover equipment losses and assess the accomplishment of overall equipment effectiveness (OEE) values.

Industries specialized in die shops often have issues regarding their efficiencies, conferring to statistics further production line department procedure for various machines frequently suffered restrictions owing to excessive downtime and speed losses in machines thus, reducing their effectiveness and efficiency. OEE is a means of determining how effective a piece of equipment is when in working condition. Calculation of OEE finds the heart of the issue and the root cause for the underlying problem.

The dimensional outcomes suggest that the average machine effectiveness has not attained the norm of >85%, but there is still room for progression.

One recommended procedure to reduce losses is to keep the actual pace of operation and downtime of equipment constant. Many such suggestions are provided to reduce the losses.

The purpose of this research paper is to discuss cellular manufacturing is discussed under conditions of changing product demand. Traditional cell formation procedures ignore any changes in demand over time from product redesign and other factors. However given that in today's business environment, product life cycles are short, a framework is proposed that creates a multi‐period cellular layout plan including cell redesign where appropriate.

The framework is illustrated using a two‐stage procedure based on the generalized machine assignment problem and dynamic programming. This framework is conceptually compared to virtual cell manufacturing, which is useful when there is uncertainty in demand rather than anticipated changes in demand. A case study is used to explain how the concept would work in practice.

One major characteristic of the proposed method is that it is flexible enough to incorporate existing cell formation procedures. It is shown through an example problem that the proposed two‐stage method is better than undergoing ad hoc layout changes or ignoring the demand changes when shifting or cell rearrangement costs exist. It also sheds some insight into cellular manufacturing under dynamic conditions.

This paper should be useful to both researchers and practitioners who deal with demand changes in cellular manufacturing.

The practice of lean management (LM) principles has given firms, from a variety of sectors, quantum jumps in productivity and performance. India is at the cusp of a major leap in economic growth, and adoption of LM is a must for ramping up the rate of growth of the GDP speedily, if the government is really intent on achieving its objective of becoming the third or fourth largest economy soon. This paper aims to study the status of implementation of LM in the LM Leaders (LML’s) in the Indian industry, to understand if they are ready to accept the challenges ahead.

This is an exploratory research study. To study the level of maturity of LM in Indian industry, the authors selected the LM Leaders in the Indian industry (LMLII). By using a well-known survey instrument – the Lean Self -Assessment Tool (LESAT), Version 2.0 – designed and developed by MIT, the authors conducted a longitudinal survey over the period 2013 to 2016, a four-year duration. Surveys were conducted every year.

Survey results show an improvement in the overall average of “current state” scores between the years 2013 and 2016, indicating that LMLII’s have improved upon their LM adoption during these years. However, there is a striking gap between “where the industry wants to be” and “where it currently is”. This could drive future improvements. Based on the survey results, this paper draws lessons and proposes action points on how to improve the adoption and diffusion of LM principles and practices in the LMLII. Factors which need to be addressed to reinvigorate the practice of LM have been identified and classified as urgent, immediate and short term.

While many “snapshot” studies have been done to study LM in Indian industry, a longitudinal study has not been done. Moreover, previous studies administer questionnaires to one company (case study method) or a group of companies in a sector of the industry. Thus, there was a research gap. A longitudinal study will help us take a holistic approach. In addition, studying LMLII will provide data from the most serious adopters of LM. Both these will add value to the current research on LM in Indian industry. The results will also help the LMLII’s to further improve the practice of LM in a systematic and rigorous way. However, as the study is limited to the LMLII, it would not be possible to apply the knowledge to the Indian industry as a whole. For doing so, one would need a larger, more representative sample.

Using this paper, LMLII’s can develop practices which will improve customer satisfaction and reduce waste in manufacturing. They can ramp up LM intensity to make further quantum jumps in performance.

LM, in addition to improving the output/input ratio (producing more for less), also emphasises waste reduction, customer satisfaction and efficient operations. All these three factors are essential for sustainable and happy society.

The work is original. This is the first longitudinal survey of lean practices in the Indian industry to study cross-sectional practices, and the results will propel the Indian industry to intensify the practice of LM.

This study aims to address Industry 4.0 (I4.0) technologies that can improve the research and implementation of lean supply chain management (LSCM) and the enhanced LSCM subfields in I4.0 technologies.

The authors conducted a systematic literature review to detect, categorize and assess recent data, highlighting patterns and providing suggestions for potential research in this field, to investigate I4.0 literature and its effect on LSCM. The authors examined 79 published types of research from the Scopus database that were published between 2010 and 2021 and classified them into four LSCM fields: logistics, production, supply chain and marketing.

The authors can emphasize the fact that the literature on this topic is in progress, from early German academic research to the current creation of new effects around the world. The majority of the potential effects investigated were discovered to improve specific areas that ultimately enhance the practices of the four LSCM domains as well as performance outcomes. The authors were also able to assess the extent to which present and upcoming I4.0 technologies can improve LSCM research and implementation.

To the best of the authors’ knowledge, this is the first study of its kind. Although some research looked into various areas of I4.0 and LSCM topics, there has been no research specifically looking into the impact of I4.0 on LSCM. The originality of this study lies in the treatment of the main fields and sub-fields of LSCM, which can benefit from the technologies of I4.0. Academic scholars interested in the research topics may benefit from the findings of this study. Organizations in various industrial sectors, particularly manufacturing, where lean thinking is used, business professionals specialized in lean operations and supply chain management, along with anyone else who wants to learn more about the interrelationships between I4.0 and LSCM.

The purpose of this paper is to assess the impact of a maintenance philosophy, Total Productive Maintenance (TPM), on the operational performance of the Portuguese industry, identifying how it enables the systematic reduction of waste in maintenance.

A structured questionnaire was constructed and sent to 472 Portuguese enterprises, having obtained a sample constituted of 84 valid answers. With a five-point Likert scale, it was possible to assess the impact of the TPM on five operational performance dimensions, being them: quality, flexibility, productivity, safety and costs.

It was found that the planned maintenance, together with education and training are the practices with the highest degree of implementation in the Portuguese industry, exceeding 70% for both. The productivity is the dimension with a higher degree of impact from the implementation of TPM and costs the dimension that suffered a lesser impact.

This paper shows and analyses the current state of TPM implementation in the Portuguese industry and it will be useful for maintenance professionals, researchers and others concerned with maintenance, in order to understand the effects of TPM implementation on the operational performance of the Portuguese industries.

The findings from this paper will be valuable for professionals who desire and are looking forward to implement an effective maintenance approach in the maintenance management system, in order to achieve the excellence in maintenance.

The purpose of this paper is to evaluate the contributions of synergic implementation of total quality management (TQM) and total productive maintenance (TPM) paradigms towards improving business performance in the Indian manufacturing industry.

In this study, a large number of manufacturing organisations have been extensively surveyed, to ascertain contributions made by TQM‐TPM paradigms in the Indian manufacturing organisations towards realizing business performance improvements. The correlations between various organisational initiatives towards TQM‐TPM implementation and business performance improvements have been evaluated and validated by employing various statistical tools.

The research focuses upon the significant contributions of TQM‐TPM organisational initiatives like quality related queries; top level support and level of total employee involvement; culture of continuous improvement; TQM and TPM core strategies; and transfusion of TQM and TPM, towards affecting improvements in business performance. The inter‐relationships between various TQM‐TPM organisational initiatives with the business performance improvement parameters have been evaluated, to efficiently manage the synergic TQM‐TPM paradigms to realize organisational objectives of growth and sustainability.

The study establishes that focused TQM‐TPM implementation over a reasonable time period can strategically contribute towards realization of significant manufacturing performance enhancements.

The study stresses upon the need for improving the synergy between maintenance and quality functions in the organisations for meeting the challenges of highly competitive environments. The study highlights that significant achievements in manufacturing performance can be achieved through strategic synergic TQM‐TPM implementation over a considerable period of time.

The analysis of initiatives adopted by Indian entrepreneurs towards TQM‐TPM implementation has been presented in the study to demonstrate the commitment for quality and maintenance aspects of organisations to realize manufacturing excellence through TQM‐TPM paradigms.

The study highlights the strong potential of synergic TQM‐TPM implementation initiatives in affecting business performance improvements. The achievements of Indian manufacturing organisations through proactive TQM‐TPM initiatives have been evaluated and critical TPM success factors identified for enhancing the effectiveness of TQM‐TPM implementation programs in the Indian context.

Quality 4.0 is being presented as the new stage of quality development. However, its overlying concept and rationale are still hard to define. To better understand what different authors and studies advocate being Quality 4.0, a systematic literature review was undertaken on the topic. This paper presents the results of such review, providing some avenues for further research on quality management.

The documents for the systematic literature review have been searched on the Scopus database, using the search equation: [TITLE-ABS-KEY (“Quality 4.0”) OR TITLE-ABS-KEY (Quality Management” AND (“Industry 4.0” OR “Fourth Industr*” OR i4.0))]. Documents were filtered by language and by type. Of the 367 documents identified, 146 were submitted to exploratory content analysis.

The analyzed documents essentially provide theoretical discussions on what Quality 4.0 is or should be. Five categories have emerged from the content analysis undertaken: Industry 4.0 and the Rise of a New Approach to Quality; Motivations, Readiness Factors and Barriers to a Quality 4.0 Approach; Digital Quality Management Systems; Combination of Quality Tools and Lean Methodologies and Quality 4.0 Professionals.

It was hard to find studies reporting how quality is actually being managed in organizations that already operate in the Industry 4.0 paradigm. Answers could not be found to questions regarding actual practices, methodologies and tools being used in Quality 4.0 approaches. However, the research undertaken allowed to identify in the literature different ways of conceptualizing and analyzing Quality 4.0, opening up avenues for further research on quality management in the Industry 4.0 era.

This paper offers a broad look at how quality management is changing in response to the affirmation of the Industry 4.0 paradigm.