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Article
Publication date: 12 May 2023

Marcello Braglia, Mosè Gallo, Leonardo Marrazzini and Liberatina Carmela Santillo

This paper proposes a new metric, named Operational Space Efficiency (OpSE), intended to diagnose and quantify the inefficient use of floor space for stocking materials in…

Abstract

Purpose

This paper proposes a new metric, named Operational Space Efficiency (OpSE), intended to diagnose and quantify the inefficient use of floor space for stocking materials in industrial workstations. OpSE presents a formulation analogous to the well-known Overall Equipment Effectiveness and can be obtained as the product of three distinct indicators: Standard Compliance Effectiveness, Standards Selection Effectiveness and Design Space-usage Effectiveness.

Design/methodology/approach

This indicator scrutinizes how usefully floor space in workstations is used to temporarily stock materials in the form of raw materials, semi-finished products, parts and components. It is suited for analyzing fixed-position layouts as well as product layouts typical of repetitive manufacturing settings, such as assembly lines in the automotive sector. The proposed indicator leverages an appropriate loss structure that features those factors affecting floor space utilization in workstations with regard to supplying and stocking materials.

Findings

An Italian manufacturer in the field of electro-technology was used as an industrial case study for the application of the methodology. The application shows how the three indicators work in practice, the effectiveness of OpSE and the methodology as a whole, in diagnosing floor space usage inefficiencies and in properly addressing improvement actions of the internal logistics in industrial settings.

Originality/value

The paper scrutinizes some important Key Performance Indicators (KPIs) dealing with space usage efficiency and identifies some significant drawbacks. Then it suggests a new, inclusive structure of losses and a KPI that not only measures efficiency but also allows to identify viable countermeasures.

Details

International Journal of Productivity and Performance Management, vol. 73 no. 4
Type: Research Article
ISSN: 1741-0401

Keywords

Open Access
Article
Publication date: 15 January 2024

Marcello Braglia, Francesco Di Paco, Roberto Gabbrielli and Leonardo Marrazzini

This paper presents a new and well-structured framework that aims to assess the current environmental impact from a Greenhouse Gas (GHG) emissions perspective. This tool includes…

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Abstract

Purpose

This paper presents a new and well-structured framework that aims to assess the current environmental impact from a Greenhouse Gas (GHG) emissions perspective. This tool includes a new set of Lean Key Performance Indicators (KPIs), which translates the well-known logic of Overall Equipment Effectiveness in the field of GHG emissions, that can progressively detect industrial losses that cause GHG emissions and support decision-making for implementing improvements.

Design/methodology/approach

The new metrics are presented with reference to two different perspectives: (1) to highlight the deviation of the current value of emissions from the target; (2) to adopt a diagnostic orientation not only to provide an assessment of current performance but also to search for the main causes of inefficiencies and to direct improvement implementations.

Findings

The proposed framework was applied to a major company operating in the plywood production sector. It identified emission-related losses at each stage of the production process, providing an overall performance evaluation of 53.1%. The industrial application shows how the indicators work in practice, and the framework as a whole, to assess GHG emissions related to industrial losses and to proper address improvement actions.

Originality/value

This paper scrutinizes a new set of Lean KPIs to assess the industrial losses causing GHG emissions and identifies some significant drawbacks. Then it proposes a new structure of losses and KPIs that not only quantify efficiency but also allow to identify viable countermeasures.

Details

International Journal of Productivity and Performance Management, vol. 73 no. 11
Type: Research Article
ISSN: 1741-0401

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.

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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. 73 no. 11
Type: Research Article
ISSN: 1741-0401

Keywords

Article
Publication date: 19 March 2024

Rouhollah Khakpour, Ahmad Ebrahimi and Seyed-Mohammad Seyed-Hosseini

This paper recommends a method entitled “SMED 4.0” as a development of conventional single minute exchange of die (SMED) to avoid defect occurrence during production and improve…

Abstract

Purpose

This paper recommends a method entitled “SMED 4.0” as a development of conventional single minute exchange of die (SMED) to avoid defect occurrence during production and improve sustainability, besides reducing setup time.

Design/methodology/approach

The method builds upon an extensive literature review and in-depth explorative research in SMED and zero defect manufacturing (ZDM). SMED 4.0 incorporates an evolutionary stage that employs predict-prevent strategies using Industry 4.0 technologies including the Internet of Things (IoT) and machine learning (ML) algorithms.

Findings

It presents the applicability of the proposed approach in (1) identifying the triple bottom line (TBL) criteria, which are affected by defects; (2) predicting the time of defect occurrence if any; (3) preventing defective products by performing online setting on machines during production as needed; (4) maintaining the desired quality of the product during the production and (5) improving TBL sustainability in manufacturing processes.

Originality/value

The extended view of SMED 4.0 in this research, as well as its analytical approach, helps practitioners develop their SMED approaches in a more holistic way. The practical application of SMED 4.0 is illustrated by implementing it in a real-life manufacturing case.

Details

Journal of Manufacturing Technology Management, vol. 35 no. 3
Type: Research Article
ISSN: 1741-038X

Keywords

Article
Publication date: 17 July 2023

Kunwar Saraf, Karthik Bajar, Aaditya Jain and Akhilesh Barve

This study aims to determine the barriers hindering the incorporation of blockchain technology (BCT) in two key service industries – hotel and health care – as well as to assess…

Abstract

Purpose

This study aims to determine the barriers hindering the incorporation of blockchain technology (BCT) in two key service industries – hotel and health care – as well as to assess their readiness for implementing BCT after overcoming the barriers.

Design/methodology/approach

The barriers of this study are determined through two phases: a review of prior literature and obtaining expert opinions, which are then analyzed to identify specific barriers that are impeding the incorporation of BCT. Moreover, to generate a blockchain implementation reluctance index (BIRI), this study presents an interval-valued intuitionistic fuzzy set (IVIFS) that uses graph theory and matrix approach (GTMA). The permanent function in the GTMA approach is computed using the PERMAN algorithm. Finally, to compare the readiness of the hotel and health-care industries to adopt BCT, the BIRI values are plotted and evaluated.

Findings

The barriers identified by this study are listed under five major headings, namely, financial, operational, behavioral, technical and legal. This study revealed that the operational and technical barriers of BCT are critically hindering its widespread integration in hotel and health-care industries. Furthermore, on comparing the BIRI values of both industries, the result suggested that the hotel industry needs to work more on these barriers to effectively incorporate BCT. Besides the comparison, the BIRI values clearly indicate that both industries have to put a lot of effort into the mitigation of the barriers found by this study to successfully integrate BCT.

Research limitations/implications

The experts’ opinions are used to evaluate the identified barriers, which raises the chance that the opinions are prejudiced based on the experts’ perspectives and ideologies. The sensitivity of decision-maker loads toward preference outcomes is not analyzed in this manuscript. Therefore, any recent sensitivity analysis may be considered a prospective field for future research. This study applies a multicriteria decision-making (MCDM) approach, IVIFS–GTMA, which limits the evaluation of the influence caused by individual barriers on the integration of BCT in the hotel and health-care industries. Henceforth, in future investigations, alternative MCDM methods may be used to analyze individual barriers.

Practical implications

According to the findings, if the hotel or health-care industry aims to incorporate BCT in its supply chain operations, it is recommended to emphasize more on the operational barriers along with the technical and behavioral barriers. The barriers mentioned in this manuscript can be used as guidance for developers in their development activities, such as scalability concerns, establishment costs, the 51% attack and the inefficient nature of BCT. Furthermore, they may address the potential users’ negative perceptions about security, privacy, trust and risk avoidance through creatively developed blockchain solutions to promote BCT implementation.

Originality/value

To the best of the author’s knowledge, this is the first study that identifies barriers toward BCT incorporation in the major service industries, i.e. hotel and health care. Moreover, this is the first study that compares the preparedness of the hotel and health-care industries to determine the industry that requires more work to implement BCT.

Article
Publication date: 30 October 2023

Vikas and Akanksha Mishra

The aim of this paper states that total productive maintenance (TPM) is an improvement tool which employs the effective utilization of employees in order to enhance the…

Abstract

Purpose

The aim of this paper states that total productive maintenance (TPM) is an improvement tool which employs the effective utilization of employees in order to enhance the reliability of the equipment in consideration.

Design/methodology/approach

This paper identifies and evaluates the factors accountable for the adoption of TPM methodology in manufacturing organizations. Twenty-four factors affecting the TPM implementation are explored and categorized into five significant categories. Afterwards, these identified TPM factors have been evaluated by using a most popular Multi-criteria decision-making (MCDM) approach namely fuzzy pivot pairwise relative criteria importance assessment (F-PIPRECIA).

Findings

In this paper, through application of F-PIPRECIA, “Behavioural factor” is ranked first while “Financial factor” the last. Considering the sub-factors, “Top management support and commitment” is ranked first while “Effective use of performance indices” is ranked the last. A further sensitivity analysis indicates the factors that need higher level of attention.

Practical implications

The result of current research work may be exploited by the top administration of manufacturing enterprises for assessing their TPM adoption status and to recognize the frail links of TPM application and improve accordingly. Moreover, significant factors of TPM can be identified and deploy them successfully in their implementation procedure.

Originality/value

The conclusion obtained from this research enables the management to clearly understand the significance of each considered factor on the adoption of TPM in the organization and hence, provides effective utilization of resources.

Details

Journal of Quality in Maintenance Engineering, vol. 30 no. 1
Type: Research Article
ISSN: 1355-2511

Keywords

Article
Publication date: 4 January 2024

Nishant Kulshrestha, Saurabh Agrawal and Deep Shree

Spare Parts Management (SPM) and Industry 4.0 has proven their importance. However, employment of Industry 4.0 solutions for SPM is at emerging stage. To address the issue, this…

Abstract

Purpose

Spare Parts Management (SPM) and Industry 4.0 has proven their importance. However, employment of Industry 4.0 solutions for SPM is at emerging stage. To address the issue, this article is aimed toward a systematic literature review on SPM in Industry 4.0 era and identification of research gaps in the field with prospects.

Design/methodology/approach

Research articles were reviewed and analyzed through a content-based analysis using four step process model. The proposed framework consists of five categories such as Inventory Management, Types of Spares, Circularity based on 6Rs, Performance Indicators and Strategic and Operational. Based on these categories, a total of 118 research articles published between 1998 and 2022 were reviewed.

Findings

The technological solutions of Industry 4.0 concepts have provided numerous opportunities for SPM. Industry 4.0 hi-tech solutions can enhance agility, operational efficiency, quality of product and service, customer satisfaction, sustainability and profitability.

Research limitations/implications

The review of articles provides an integrated framework which recognizes implementation issues and challenges in the field. The proposed framework will support academia and practitioners toward implementation of technological solutions of Industry 4.0 in SPM. Implementation of Industry 4.0 in SPM may help in improving the triple bottom line aspect of sustainability which can make significant contribution to academia, practitioners and society.

Originality/value

The examination uncovered a scarcity of research in the intersection of SPM and Industry 4.0 concepts, suggesting a significant opportunity for additional investigative efforts.

Details

Journal of Quality in Maintenance Engineering, vol. 30 no. 1
Type: Research Article
ISSN: 1355-2511

Keywords

Article
Publication date: 27 March 2024

Temesgen Agazhie and Shalemu Sharew Hailemariam

This study aims to quantify and prioritize the main causes of lean wastes and to apply reduction methods by employing better waste cause identification methodologies.

Abstract

Purpose

This study aims to quantify and prioritize the main causes of lean wastes and to apply reduction methods by employing better waste cause identification methodologies.

Design/methodology/approach

We employed fuzzy techniques for order preference by similarity to the ideal solution (FTOPSIS), fuzzy analytical hierarchy process (FAHP), and failure mode effect analysis (FMEA) to determine the causes of defects. To determine the current defect cause identification procedures, time studies, checklists, and process flow charts were employed. The study focuses on the sewing department of a clothing industry in Addis Ababa, Ethiopia.

Findings

These techniques outperform conventional techniques and offer a better solution for challenging decision-making situations. Each lean waste’s FMEA criteria, such as severity, occurrence, and detectability, were examined. A pairwise comparison revealed that defect has a larger effect than other lean wastes. Defects were mostly caused by inadequate operator training. To minimize lean waste, prioritizing their causes is crucial.

Research limitations/implications

The research focuses on a case company and the result could not be generalized for the whole industry.

Practical implications

The study used quantitative approaches to quantify and prioritize the causes of lean waste in the garment industry and provides insight for industrialists to focus on the waste causes to improve their quality performance.

Originality/value

The methodology of integrating FMEA with FAHP and FTOPSIS was the new contribution to have a better solution to decision variables by considering the severity, occurrence, and detectability of the causes of wastes. The data collection approach was based on experts’ focus group discussion to rate the main causes of defects which could provide optimal values of defect cause prioritization.

Details

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

Keywords

Article
Publication date: 7 April 2023

Xinbo Sun, Zhiwei He and Yu Qian

The purpose of this paper is to explore what organizational adaptability means in the digitized context and to discuss how manufacturing companies achieve organizational…

Abstract

Purpose

The purpose of this paper is to explore what organizational adaptability means in the digitized context and to discuss how manufacturing companies achieve organizational adaptability during the digital transformation process.

Design/methodology/approach

By conducting semi-structured interviews and acquiring archive data from a typical Chinese manufacturing company, this paper gathers extensive data. Based on this, a single-case study methodology is used to investigate organizational adaptability in digital transformation.

Findings

This study identifies the process by which companies achieve organizational adaptability during digital transformation and deconstructs organizational adaptability into three dimensions: structural adaptability, operational adaptability and governance adaptability. This study also explores how organizational adaptability is affected by digital capabilities.

Originality/value

This study proposes a process model to demonstrate how organizational adaptability may be attained during digital transformation and redefines organizational adaptability in the context of digitization.

Details

Chinese Management Studies, vol. 18 no. 2
Type: Research Article
ISSN: 1750-614X

Keywords

Article
Publication date: 23 February 2024

Xinnan Liu, Jiani Meng, Jiayi Wang and Yingbo Ji

This study adopts the perspective of dynamic capabilities to investigate influencing factors and proposes improvement strategies of supply chain resilience of prefabricated…

Abstract

Purpose

This study adopts the perspective of dynamic capabilities to investigate influencing factors and proposes improvement strategies of supply chain resilience of prefabricated construction.

Design/methodology/approach

The structural equation model (SEM) is used to identify and verify the relationship between factors influencing supply chain resilience of prefabricated construction from the perspective of dynamic capabilities. The system dynamics (SD) model is constructed to dynamically simulate the specific effects of different influencing factors.

Findings

Results indicate that: (1) An evaluation index system for supply chain resilience of prefabricated construction containing five first-level indicators and 36 second-level indicators is constructed; (2) Ability to anticipate, ability to respond, ability to adapt, ability to recover and ability to learn are positively correlated with the supply chain resilience of prefabricated construction and (3) ANT3 (information system), RES1 (quick response), ADA3 (buffer stock) and LEA4 (trust) are the most leading factors influencing supply chain resilience of prefabricated construction over time.

Originality/value

This study fulfills the need for an in-depth exploration of the various influencing factors on supply chain resilience of prefabricated construction from the perspective of dynamic capabilities. Furthermore, this study provides improvement strategies to enhance supply chain resilience of prefabricated construction in China.

Details

Engineering, Construction and Architectural Management, vol. ahead-of-print no. ahead-of-print
Type: Research Article
ISSN: 0969-9988

Keywords

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