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Article
Publication date: 23 July 2020

Marcello Braglia, Davide Castellano, Marco Frosolini, Mosè Gallo and Leonardo Marrazzini

The paper proposes a new workforce effectiveness metric that is a sophisticated evolution of a pre-existing overall labour effectiveness (OLE) indicator. The KPI, named…

Abstract

Purpose

The paper proposes a new workforce effectiveness metric that is a sophisticated evolution of a pre-existing overall labour effectiveness (OLE) indicator. The KPI, named revised OLE (ROLE), provides a structured methodology to measure in a holistic way the losses relating to labour, maintaining some formal similitude to the overall equipment effectiveness (OEE)

Design/methodology/approach

A new structure of losses is proposed to overcome the drawbacks and the difficulties that usually affect the data collection stage, referring to directly measurable quantities or, when this is not the case, suggesting a viable method to quantify the loss. Besides, this approach facilitates the comprehension of labour-related issues, suggesting potential countermeasures. The novel ROLE indicator has been defined, based on this new structure, to evaluate the labour effectiveness in batch process industries. A real case study is provided, which explains the methodology and illustrates the capability of the corresponding KPI.

Findings

The present work analyses the labour performance indexes available in literature, with the aim of evidencing those aspects that can be properly observed and quantified and, at the same time, categorizing them to identify their possible drawbacks. A new structure of losses is derived, with respect to four different categories, which may help to measure the losses themselves more effectively

Originality/value

The paper investigates some important KPIs dealing with labour performance and individuates some significant drawbacks. Then it suggests a new, inclusive structure of losses and a modified KPI that not only measures effectiveness but also allows to identify viable countermeasures.

Details

International Journal of Productivity and Performance Management, vol. 70 no. 6
Type: Research Article
ISSN: 1741-0401

Keywords

Article
Publication date: 7 October 2013

Marcello Braglia, Davide Castellano and Marco Frosolini

The purpose of this paper is to present a reliability centered maintenance (RCM) embedded integer linear programming approach (suited to the budget monetary resources…

1268

Abstract

Purpose

The purpose of this paper is to present a reliability centered maintenance (RCM) embedded integer linear programming approach (suited to the budget monetary resources allocation task) to the maintenance strategies mix selection for an industrial plant equipment.

Design/methodology/approach

The developed approach allows to determine the optimal maintenance strategies mix for a set of equipment in a more quantitative way than the classic RCM approach. The proposed model takes into account, for each potential failure determined using the FMECA and for each admissible strategy, the costs and the potential risk priority number (RPN) reduction. Finally, an industrial case concerning an Italian paper-mill plant is reported to demonstrate the effectiveness of the approach presented.

Findings

The paper finds that the application of the proposed approach allows to optimally allocate the budget monetary resources, determining which suitable maintenance practice apply to each failure, taking into account the costs of each strategy and the potential reduction of the RPN.

Practical implications

The proposed model permits to assign (during the budget monetary resources allocation task) to each failure the optimal strategy, among a set of suitable maintenance practices, considering the costs and the estimated RPN reduction.

Originality/value

The paper proposes a completely new RCM embedded approach to the maintenance strategies selection, in order to optimally allocate the budget monetary resources. This model overcomes the limits of the traditional RCM approach, taking into account quantitative aspects, i.e. the compatibility constraint between failures and policies, the maintenance strategies costs, and the RPN estimated reduction.

Details

International Journal of Quality & Reliability Management, vol. 30 no. 9
Type: Research Article
ISSN: 0265-671X

Keywords

Article
Publication date: 11 September 2020

Alexander E. Ellinger, Frank G. Adams, George R. Franke, Gregory D. Herrin, Tyler E. deCoster and Karli E. Filips

Supply chain management (SCM) proficiency is generally associated with superior business performance. Yet, SCM research continues to focus predominantly on the performance…

Abstract

Purpose

Supply chain management (SCM) proficiency is generally associated with superior business performance. Yet, SCM research continues to focus predominantly on the performance of individual firms, rather than on the collective performance of multiple supply chain participants as espoused by the extended enterprise (EE) concept. In response to calls for quantitative studies that examine the collective performance of multiple supply chain participants, this research study compares the combined performance of triads comprising focal firms recognized for their relative SCM proficiency and their upstream (supplier) and downstream (customer) supply chain partners with that of their close industry competitors' triads.

Design/methodology/approach

The triadic, longitudinal examination of multiple supply chain participants' collective performance utilized archival financial data of the period 2007–2017 from the Compustat database and the supply chain (SPLC) function of Bloomberg.

Findings

Findings of this study indicated that supply chain triads that included focal firms recognized for their relative SCM proficiency experienced significantly lower sales and general administrative expenses and significantly higher productivity, return on assets and profitability over time than their close industry competitors' triads. However, contrary to expectations, the performance advantages identified did not extend to revenue growth.

Research limitations/implications

Supply chain triads cannot fully represent entire supply chains or EEs. However, this study’s triadic analysis can be viewed as a practically achievable proxy for further validating the EE concept. Moreover, based on assertions that triadic studies are suitable for SCM research and on empirical studies that consistently show individual firms recognized for their relative SCM proficiency outperform competitors, the authors contend that the study’s findings appropriately corroborate the value of the EE concept.

Practical implications

Because such empirical evidence is so rare, the consistent, collective performance advantages identified in this study should be highly significant to managers.

Originality/value

Robust, longitudinal evidence that supply chain triads which include focal firms recognized for relative SCM proficiency collectively outperform their close industry competitors' triads extends generally accepted associations between SCM proficiency and business performance, suggesting that the application of extended resource-based view (ERBV) in supply chain contexts warrants further examination and further substantiates the efficacy of the EE concept.

Details

International Journal of Physical Distribution & Logistics Management, vol. 50 no. 7/8
Type: Research Article
ISSN: 0960-0035

Keywords

Article
Publication date: 10 October 2016

V. Raja Sreedharan and R. Raju

The purpose of this paper is to review Lean Six Sigma (LSS) literature and report different definitions, demographics, methodologies and industries.

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Abstract

Purpose

The purpose of this paper is to review Lean Six Sigma (LSS) literature and report different definitions, demographics, methodologies and industries.

Design/methodology/approach

This paper highlights various definitions by different researchers and practitioners. A total of 235 research papers has been reviewed for the LSS theme, research methodology adopted, type of industry, author profile, country of research and year of publication.

Findings

From the review, four significant LSS classifications were identified that deal with the spread of LSS in different industries followed by observation for classification.

Practical implications

LSS is a strategy for success, but it did not examine its presence in various Industries. From this paper, readers can understand the quantum of its spread before implementing LSS. For academicians, it will be a comprehensive list of papers for research.

Originality/value

This paper reviews 235 research papers for their year, author profile, research methodology and type of industry. Various characteristics of LSS definitions and their theme are also reviewed.

Details

International Journal of Lean Six Sigma, vol. 7 no. 4
Type: Research Article
ISSN: 2040-4166

Keywords

Article
Publication date: 20 June 2022

Luis Alejandro Gólcher-Barguil, Simon Peter Nadeem, Jose Arturo Garza-Reyes, Ashutosh Samadhiya and Anil Kumar

Equipment performance helps the manufacturing sector achieve operational and financial improvements despite process variations. However, the literature lacks a clear index…

Abstract

Purpose

Equipment performance helps the manufacturing sector achieve operational and financial improvements despite process variations. However, the literature lacks a clear index or metric to quantify the monetary advantages of enhanced equipment performance. Thus, the paper presents two innovative monetary performance measures to estimate the financial advantages of enhancing equipment performance by isolating the effect of manufacturing fluctuations such as product mix price, direct and indirect characteristics, and cost changes.

Design/methodology/approach

The research provides two measures, ISB (Improvement Saving Benefits) and IEB (Improvement Earning Benefits), to assess equipment performance improvements. The effectiveness of the metrics is validated through a three stages approach, namely (1) experts' binary opinion, (2) sample, and (3) actual cases. The relevant data may be collected through accounting systems, purpose-built software, or electronic spreadsheets.

Findings

The findings suggest that both measures provide an effective cost–benefit analysis of equipment performance enhancement. The measure ISB indicates savings from performance increases when equipment capacity is greater than product demand. IEB is utilised when equipment capacity is less than product demand. Both measurements may replace the unitary cost variation, which is subject to manufacturing changes.

Practical implications

Manufacturing businesses may utilise the ISB and IEB metrics to conduct a systematic analysis of equipment performance and to appreciate the financial savings perspective in order to emphasise profitability in the short and long term.

Originality/value

The study introduces two novel financial equipment performance improvement indicators that distinguish the effects of manufacturing variations. Manufacturing variations cause cost advantages from operational improvements to be misrepresented. There is currently no approach for manufacturing organisations to calculate the financial advantages of enhancing equipment performance while isolating production irregularities.

Details

Benchmarking: An International Journal, vol. ahead-of-print no. ahead-of-print
Type: Research Article
ISSN: 1463-5771

Keywords

Open Access
Article
Publication date: 28 November 2022

Elena Stefana, Paola Cocca, Federico Fantori, Filippo Marciano and Alessandro Marini

This paper aims to overcome the inability of both comparing loss costs and accounting for production resource losses of Overall Equipment Effectiveness (OEE)-related approaches.

Abstract

Purpose

This paper aims to overcome the inability of both comparing loss costs and accounting for production resource losses of Overall Equipment Effectiveness (OEE)-related approaches.

Design/methodology/approach

The authors conducted a literature review about the studies focusing on approaches combining OEE with monetary units and/or resource issues. The authors developed an approach based on Overall Equipment Cost Loss (OECL), introducing a component for the production resource consumption of a machine. A real case study about a smart multicenter three-spindle machine is used to test the applicability of the approach.

Findings

The paper proposes Resource Overall Equipment Cost Loss (ROECL), i.e. a new KPI expressed in monetary units that represents the total cost of losses (including production resource ones) caused by inefficiencies and deviations of the machine or equipment from its optimal operating status occurring over a specific time period. ROECL enables to quantify the variation of the product cost occurring when a machine or equipment changes its health status and to determine the actual product cost for a given production order. In the analysed case study, the most critical production orders showed an actual production cost about 60% higher than the minimal cost possible under the most efficient operating conditions.

Originality/value

The proposed approach may support both production and cost accounting managers during the identification of areas requiring attention and representing opportunities for improvement in terms of availability, performance, quality, and resource losses.

Details

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

Keywords

Article
Publication date: 14 July 2020

Seyyed Habibollah Mirghafoori, Hossein Sayyadi Tooranloo and Sepideh Saghafi

In this way, the aim of this study is to expand and evelop the application of this technique in FMEA to rank failure modes of ESQ of academic libraries in an…

Abstract

Purpose

In this way, the aim of this study is to expand and evelop the application of this technique in FMEA to rank failure modes of ESQ of academic libraries in an intuitionistic fuzzy environment. Assessment of electronic service quality (ESQ) of libraries is significantly important according to their major roles. It should be noted that the ESQ has a significant impact on customer satisfaction, which improves organizational performance. Accordingly, low ESQ means waste of organizational resources and poor user satisfaction. So, there is a dire need to reflect reasons inducing failure modes in academic library ESQ. Thus, investigation of failure modes affecting academic library ESQ is highly important. One solution in this area is utilization of the intuitionistic fuzzy (IF) failure mode and effects analysis (FMEA) as one of the widely used methods for prediction and identification of failure modes.

Design/methodology/approach

The present study in terms of objective is applied and in terms of the type of method is descriptive-analytical. The research sample included four experts of Yazd academic Libraries (Iran). To collect data, three types of questionnaires were distributed among experts. The purpose of the first questionnaire was to identify and reach an agreement on e-library failure modes. Type II questionnaire was used to determine the importance of identified risk factors and Type III questionnaire was used to prioritize the factors.

Findings

Results indicate that the difficulty of using websites, lack of provided information feedback to users and lack of links on the website to users' are the main priorities for improving ESQ in the studied academic libraries.

Originality/value

In this approach, the Intuitionistic fuzzy Elimination Et Choix Traduisant la REalité and technique for order of preference by similarity to ideal solution method were used to rank failure modes in academic library ESQ within the FMEA framework.]

Article
Publication date: 10 December 2019

Narges Hemmati, Masoud Rahiminezhad Galankashi, D.M. Imani and Farimah Mokhatab Rafiei

The purpose of this paper is to select the best maintenance policy for different types of equipment of a manufacturer integrating the fuzzy analytic hierarchy process…

Abstract

Purpose

The purpose of this paper is to select the best maintenance policy for different types of equipment of a manufacturer integrating the fuzzy analytic hierarchy process (FAHP) and the technique for order of preference by similarity to ideal solution (TOPSIS) models.

Design/methodology/approach

The decision hierarchy of this research includes three levels. The first level aims to choose the best maintenance policy for different types of equipment of an acid manufacturer. These equipment pieces include molten sulfur ponds, boiler, absorption tower, cooling towers, converter, heat exchanger and sulfur fuel furnace. The second level includes decision criteria of added-value, risk level and the cost. Lastly, the third level comprises time-based maintenance (TBM), corrective maintenance (CM), shutdown maintenance and condition-based maintenance (CBM) as four maintenance policies.

Findings

The best maintenance policy for different types of equipment of a manufacturer is the main finding of this research. Based on the obtained results, CBM policy is suggested for absorption tower, boiler, cooling tower and molten sulfur ponds, TBM policy is suggested for converters and heat exchanger and CM policy is suggested for a sulfur fuel furnace.

Originality/value

This research develops a novel model by integrating FAHP and an interval TOPSIS with concurrent consideration of added-value, risk level and cost to select the best maintenance policy. According to the highlights of the previous studies conducted on maintenance policy selection and related tools and techniques, an operative integrated approach to combine risk, added-value and cost with integrated fuzzy models is not developed yet. The majority of the previous studies have considered classic fuzzy approaches such as FAHP, FANP, Fuzzy TOPSIS, etc., which are not completely capable to reflect the decision makers’ viewpoints.

Details

International Journal of Quality & Reliability Management, vol. 37 no. 9/10
Type: Research Article
ISSN: 0265-671X

Keywords

Article
Publication date: 2 January 2018

J. Saravanan and Jitesh J. Thakkar

The purpose of this paper is to investigate into the improvement strategies for lead time reduction of military aircraft major overhaul (enhance the overhaul task from…

Abstract

Purpose

The purpose of this paper is to investigate into the improvement strategies for lead time reduction of military aircraft major overhaul (enhance the overhaul task from present seven to nine-plus aircrafts as agreed to customer) for ABC Company.

Design/methodology/approach

This research has been conducted based on the available knowledge and extensive experience gained while working in the overhaul unit of the case organization for a long period of time. The research employs an integrated approach of multi-criteria decision method (in specific analytic hierarchy process (AHP)), theory of constraint (TOC) and simulation for M/M/1/K queuing environment for investigating the improvement strategies for lead time reduction in major overhaul of military aircraft. This has mainly included: Step 1: analysis of existing activity network using actual overhaul data; Step 2: ranking of constraint activities that most affects the lead time using AHP; Step 3: revised flow activity network using time buffers (TBs) concept of TOC; Step 4: mathematical model formulation for effective utilization of TB using single server finite queuing approach (M/M/1/K queuing environment); Step 5: discrete event simulation representing present overhaul conditions and revised overhaul conditions with different scenarios; and Step 6: sensitivity analysis and interpretation of results. The proposed methodology has been tested on an industrial case study dealing with an aircraft overhaul in India (namely ABC Company).

Findings

The proposed overhaul lead-time reduction plan points out the augmentation of resources in order to achieve more than 50 per cent reduction in lead time and waiting time under two scenarios – with overtime and without overtime.

Research limitations/implications

An integrated approach proposed has so far been applicable to the specific aircrafts (Jaguar/Mirage/Kiran) of the ABC Company overhaul division. However, the particular methodology can be proved potentially useful and highly practical when applying to other aircraft types.

Originality/value

The results indicate several problems with the current overhaul strategies that need focused process improvements and a need for capacity augmentation for achieving the enhanced overhaul task of nine+ aircrafts per year with reduced overhaul lead time. The proposed approach also provides the maintenance planners with a platform for decision analysis and support often ignored the capacity augmentation.

Details

International Journal of Quality & Reliability Management, vol. 35 no. 1
Type: Research Article
ISSN: 0265-671X

Keywords

Article
Publication date: 1 October 2018

Alessandro Brun and Matteo Mario Savino

Failure mode and effect analysis (FMEA) is an analysis technique for identifying and eliminating known and/or potential failures and problems from products, processes or…

Abstract

Purpose

Failure mode and effect analysis (FMEA) is an analysis technique for identifying and eliminating known and/or potential failures and problems from products, processes or systems. Notwithstanding its diffusion, traditional FMEA has several limitations. Lately, scientific research has been focused on improving said limitations, yet the process is still ongoing. The purpose of this paper is to support developments in this area.

Design/methodology/approach

The paper improves the conventional FMEA by using the method of pairwise comparison to establish the relative importance of the input factors in risk priority number calculation, and Markov chains to calculate risk distributions in the long term.

Findings

The functioning and usefulness of the proposed methodology is demonstrated through an application to the construction industry, one of the world’s biggest industrial sectors, dogged by a high rate of work-related injuries and casualties.

Originality/value

Having demonstrated the applicability of the novel methodology to a real domain, the paper contributes to the process of overcoming traditional FMEA limitations.

Details

International Journal of Quality & Reliability Management, vol. 35 no. 9
Type: Research Article
ISSN: 0265-671X

Keywords

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