Search results

This paper proposes an efficient and effective BOM management scheme for small and medium manufacturing (SME) companies that produce automobile parts. Automobile part’s manufacturers produce very various products due to various automobile characteristics such as types, colors, and options of cars. These products are classified into product groups with common pars and like this product groups with commonality are regarded as product family. This paper proposes a BOM data model for product family structures and implements the practical EXCEL‐based BOM management system for real small and medium manufacturing (SME) companies that produces automobile parts.

The paper provides an overview of research published in the innovation and operations management (IOM) literature on 15 methods for cost management in new product development, and it provides a comparison to an earlier review of the management accounting (MA) literature (Wouters & Morales, 2014).

This structured literature search covers papers published in 23 journals in IOM in the period 1990–2014.

The search yielded a sample of 208 unique papers with 275 results (one paper could refer to multiple cost management methods). The top 3 methods are modular design, component commonality, and product platforms, with 115 results (42%) together. In the MA literature, these three methods accounted for 29%, but target costing was the most researched cost management method by far (26%). Simulation is the most frequently used research method in the IOM literature, whereas this was averagely used in the MA literature; qualitative studies were the most frequently used research method in the MA literature, whereas this was averagely used in the IOM literature. We found a lot of papers presenting practical approaches or decision models as a further development of a particular cost management method, which is a clear difference from the MA literature.

This review focused on the same cost management methods, and future research could also consider other cost management methods which are likely to be more important in the IOM literature compared to the MA literature. Future research could also investigate innovative cost management practices in more detail through longitudinal case studies.

This review of research on methods for cost management published outside the MA literature provides an overview for MA researchers. It highlights key differences between both literatures in their research of the same cost management methods.

This paper aims to focus on production ramp up modeling on built‐to‐order (BTO) manufacturers facing customized demand. The general purpose is to present a novel approach to managing collaboration, by considering information exchange between the manufacturer and the supplier.

The methodology applies feedback control mechanism to analyze supplier responsiveness and customer order decoupling point to represent the need for collaboration. A two‐stage game is applied ahead of control system application to optimize the capacity decision, with the ultimate goal being profit maximization.

The results show that a higher product commonality degree gives more opportunity for quick response BTO supply chains, which are managed by feedback control, and at the same time to possibly mitigate the bullwhip effect caused by demand information noise.

The analytical model here focused on one product family development, so the applicability of the proposed model to the whole product portfolio should be investigated in the future.

This paper helps the manufacturer to act optimally by considering the possibility of information exchange with the supplier and deciding on the product commonality degree, in taking into account the customer's lead time requirement.

A control system model of “BTO Supply Chain” is proposed by including product commonality and response analysis in the simulation model. Furthermore, a contribution to collaborative supply chains is shown by applying a synchronized supply model to represent supplier and manufacturer communication.

Recognizing the rationale of a product family architecture (PFA) with respect to design for mass customization (DFMC), this paper discusses the fundamental issues underlying a PFA, including product information modeling, structural implications of product families, functional variety versus technical variety, class‐member relationships inherent in variety, modularity and commonality, PFA design spaces, and PFA composition. The background research is reviewed in terms of product architecture and modularity, product platform and product families, and product modeling and design process models. To organize product varieties in DFMC, a PFA should be described from three different perspectives, namely the functional (as seen from customer, sales and marketing viewpoints), behavioral (as seen from the product technology or design engineer perspective) and structural (as seen from the fulfillment or manufacturing and logistic perspective). Meeting diverse customer requirements and achieving volume economy simultaneously can be best achieved by synchronizing these three perspectives. In fact, the mappings between PFA views manifest the cooperative effort among different business functions, whilst three PFA views facilitate the integration of different phases of product development.

Reconfigurable machines tools (RMTs) are gaining momentum as the new solutions to customised products in the manufacturing world. The driving force, among others, behind these machines is the part envelope and the part family of products that they can produce. The purpose of this paper is to propose a new class of RMT known as a reconfigurable guillotine shear and bending press machine (RGS&BPM). A part family of products that this machine can produce is developed using hierarchical clustering methodologies. The development of these part families is guided by the relationship of the parts in the family in terms of complexity and geometry.

Part families cannot be developed in isolation, but that process has to incorporate the machine modules used in the reconfiguration process for producing the parts. Literature was reviewed, and group technology principles explored, to develop a concept that can be used to develop the part families. Matrices were manipulated to generate part families, and this resulted in the development of a dendrogram of six possible part families. A software with a graphic user interface for manipulation was also developed to help generate part families and machine modules. The developed concept will assist in the development of a machine by first developing the part family of products and machine modules required in the variable production process.

The developed concepts assist in the development of a machine by first developing the part family of products and machine modules required in the variable production process. The development of part families for the RGS&BPM is key to developing the machine work envelope and modules to carry out the work. This work has been presented to demonstrate the importance of machine development in conjunction with a part family of products that the machine will produce. The paper develops an approach to manufacturing where part families of products are developed prior to developing the machine. The families of products are then used to develop modules that enable the manufacture of the parts and subsequently the size of the machine.

The research was limited to the development of part families for a new RGS&BPM, which is still under development.

The study reflects the development of reconfigurable machines as a solution to manufacturing challenges in terms of group technology approaches adopted in the design phase. It also highlights the significance of the concepts in the reconfigurable machine tool design. The part families define the machine work envelop and its reconfiguration capability.

The success of the research will usher an alternative to smaller players in sheet metal work. It will contribute to the easy development of the machine that will bridge the high cost of machine tools.

The study contributes to the new approach in sheet metal manufacturing where dedicated machines may be substituted by a highly flexible reconfigurable machine that has a dual operation, making the investment for small to medium enterprises affordable. It also contributes to the body of knowledge in reconfigurable machine development and the framework for such activities, especially in developing countries.

To investigate the impact of number of components (NC) and component commonality (CC) (i.e. product structure characteristics) on the effectiveness of component reservation methods and partial order releases (i.e. order review and evaluation (ORE) procedures).

Simulation experiments were conducted using a multistage production‐inventory system with MRP for planning. The results were analyzed using analysis of variance.

The results indicate that: in the presence of component availability problems, partial order release is a more effective ORE procedure than component reservation; product structure characteristics should be considered when selecting partial order release proportions; and high levels of shop congestion (SC) mitigate the influence of ORE procedures, regardless of product structure characteristics.

This study used fixed lot sizes and two factors to characterize product structures (NC and CC). Thus, studies that investigate the impact of alternative lot sizing strategies and a wider range of product structure factors could provide additional insight into the order release process.

The results provide a useful source of information for managers to consider when addressing problem orders related to material availability.

Although the literature on order review/release (ORR) recognizes the possibility of material availability problems, very little guidance is provided on how managers should react to the situation. This paper fulfils an identified information need by integrating and extending the research streams on product structure and ORE activities.

To identify and examine the origins of complexity in a mass customization system and to propose an effective application sequence of variety management strategies in order to cope with this complexity.

Through the application of Suh's complexity theory an understanding of the causes of complexity in the specific context of a mass customization environment is developed. This facilitates the identification of the strategies that are adequate to tackle the problems induced by complexity.

The mass customization system is a coupled system that cannot be mastered simply. It is definitely impossible to transform it to an uncoupled system with a low complexity level. However, the effective and targeted implementation of variety management strategies at the product and process levels enables the management of this complexity by making the system more decoupled.

Complexity can be decreased if managers ensure less dependency between the satisfaction of customer requirements and position of the decoupling point. It is also advantageous to reduce the coupling level between fast delivery requirement in mass customization and the decoupling point placement. Furthermore, an effective variety management calls for the implementation of the identified strategies in an ascending order of complexity reduction potential.

The article relates the complexity theory of Suh to mass customization system, provides a framework for the classification of variety management strategies and derives managerial recommendations so as to reduce the complexity in a mass customization environment.

The main purpose of this paper is to improve a web content management system (WCMS) product line for future implementations by identifying software commonalities in WCMS‐based web applications. WCMS plays a central role in modern web application development: most large public and internal web sites are based on a WCMS foundation. If we can improve the implementation process, the effectiveness and efficiency of web application development will increase significantly.

This research identifies reusable solutions from existing WCMS implementations using problem diagrams and structured goal modeling. From configurations were matched with atomic e‐business models by linking them to the strategic competencies through bottom‐up goal modeling. A designed method was constructed on how requirements can be elicited for WCMS implementations using goal modeling and problem frames.

The resulting method provides insight in relevant e‐business models and their relation to software product lines. Moreover, the approach is applied in a WCMS study which demonstrates its applicability.

The practical implications of this research is twofold: WCMS developers now have a method to improve their product line based on e‐business models; and requirements engineers implementing WCMS can use this model to apply reusable software and prioritize requirements. Both will potentially have a large impact on the effectiveness of implementations since most web applications are developed with WCMS.

The paper presents a novel approach for efficient and effective identification of software commonalities. This research is part of the web engineering method that focuses on development of web applications based on WCMSs.

This paper aims to investigate the factors enabling or hindering the simultaneous pursuit of volume flexibility and mix flexibility within a supply chain through the lens of a manufacturing plant seeking to implement a build‐to‐order (BTO) strategy.

To accomplish this empirical investigation, an in‐depth case study involving a manufacturing plant and its supply chain was designed. Prior to primary and secondary data collection, this research setting had already decided to implement a BTO strategy and had, moreover, carefully assessed several practices for BTO strategy implementation, as well as their interactions.

The studied case suggests that a number of approaches typically used to increase volume flexibility, actually negatively affect mix flexibility and vice versa. The existence of such trade‐offs may ultimately inhibit the implementation of a BTO strategy and this was the case in the studied company. Nevertheless, empirical evidence also suggests that, to some extent, volume flexibility and mix flexibility may be achieved synergistically, as initiatives such as component standardization or component‐process interface standardization would improve both volume flexibility and mix flexibility.

The pursuit of volume flexibility and mix flexibility in implementing a BTO strategy in a specific setting and from primarily an operations management perspective was investigated. As such, the findings can be complemented by viewing the case study results through the lens of other established general management theories or by replicating the study in different research settings.

While past research informs us about how manufacturing firms can successfully achieve mix flexibility or volume flexibility, there are few insights for understanding how volume flexibility and mix flexibility can both be simultaneously achieved within a manufacturing plant and its supply chain. This research fills this gap in the literature and contributes to the development of a theory of BTO strategy implementation, especially in terms of volume flexibility, mix flexibility and their interactions.

Success in manufacturing industries often depends on the ability of a firm to apply product platforms. In speeding up product development, platforms often enable companies to benefit from scale effects by reusing existing components in the development of new products. In the delivery of complex products and system (CoPS), however, platforms are frequently modified since components have to be changed within their life cycle to meet additional customer-specific engineering demands and evolving innovations in technology. In this article, it will be illustrated that intangible design elements can be used as platforms in firms that deliver CoPS. The paper aims to discuss these issues.

Through extensive fieldwork at a leading supplier of science-based lithography machinery, a modified platform concept was developed and tested that is labelled as the function-technology (FT) platform. The longitudinal data, collected on site, demonstrate positive effects of applying FT platforms.

The results show that an important explanation for firm's success in delivering lithography machinery with attractive performance is their ability to deliver variants that are specific in terms of physical modules, but common in terms of functions and technologies. Based on the results, it can be argued that establishing an FT platform will allow the efficient creation of variants within a family of CoPS.

The findings add considerable insight to the existing literature on operations management by explaining how intangible design elements, instigated during development, can be reused in the delivery of CoPS. Moreover, it enables development managers to more easily structure and reuse complex development tasks.