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Innovative startups have begun a trend using laser sintering (LS) technology patents expiration, namely, by introducing LS additive manufacturing (AM) machines that can overcome utilization barriers, such as the costliness of machines and productivity limitation. The recent rise of this trend has led the authors to investigate this new class of machines in novel settings, including hub configuration. There are various supply chain configurations to supply spare parts in industrial operations. This paper aims to explore the promise of a production configuration that combines the benefits of centralized production with the flexibility of local manufacturing without the huge costs related to it.

This study quantitatively examines the feasibility of different AM-enabled spare parts supply chain configurations. Using cost data extracted from a case study, three scenarios per AM machine technology are modeled and compared.

Results suggest that hub production configuration depending on the utilized AM machines can provide economic efficiency and effectiveness to reduce equipment downtime. While previous studies have suggested the need for AM machines with efficiency for single part production for a distributed supply chain, the findings in this research illustrate the positive relationship between multi-part production capability and the feasibility of a hub manufacturing configuration establishment.

This study explores the promise of a production configuration that combines the benefits of centralized production with the flexibility of local manufacturing without the huge costs related to it. Although the existing body of knowledge contains research on production decentralization, research on various levels of decentralization is lacking. Using a real-world case study, this study aims to compare the feasibility of different levels of decentralization for AM-enabled spare parts supply chains.

This paper aims to provide a method and decision support tool to enhance swift reconfiguration of Plug&Produce (P&P) systems in the presence of continuously changing production orders.

The paper reviews different production scenarios and system design and configuration methods and more particularly specifies the need of decision support tools for P&P systems that integrate configuration and planning activities. This problem is then addressed by proposing a method that helps reduce the solution space of the reconfiguration problem and allows the timely selection of the most promising reconfiguration alternative.

The proposed method was found to be helpful in reducing the reconfiguration alternatives that need to be considered and in selecting the most promising one for different orders. The advantages and limitations of this method are identified, and an illustrative test case of the approach is presented, corroborating the method applicability in the absence of large queues in the system.

This paper addresses a less explored domain within the P&P systems research field, which is the system reconfiguration. It proposed a method to support system validation and reconfiguration jointly with an illustrative test case. This represents an original contribution to the P&P research field, and it can have impact in improving agility and decreasing the complexity of reconfiguration activities to cope with constantly changing production orders.

The purpose of this paper is twofold. In view of the importance of process platform‐based production configuration (PPbPC) in sustaining product family production efficiency, it is to study the underlying logic for configuring production processes for a product family based on a process platform. Second, it is to apply the Petri nets (PNs) techniques to model PPbPC, in attempting to shed light on the underlying logic.

The authors first identify the fundamental issues in PPbPC, including variety handling, process variation accommodation, configuration at different abstraction levels, and constraint satisfaction. To accommodate the corresponding modelling difficulties, the authors develop a formalism of hierarchical colored timed PNs (HCTPNs) based on the principles of hierarchical PNs, timed PNs, and colored PNs. In the formalism, three types of nets together with a system of HCTPNs are defined to address the modelling of PPbPC.

Applying HCTPNs to vibration motors' case has revealed the logic of specifying complete production processes of final products at different levels of abstraction to achieve production configuration. The preliminary results also further demonstrate the feasibility of modelling PPbPC based on HCTPNs.

Traditional approaches to planning production processes for individual products may limit production performance improvement when companies need to timely produce a high variety of customized products. Systematic methods should be developed to plan production processes for product families so as to achieve production efficiency while utilizing the existing manufacturing resources.

By integrating the advantages of existing PN techniques, the HCTPNs formalism is developed to shed light on planning production processes for product families. The resulting production configuration model can facilitate practitioners to achieve production efficiency in producing large numbers of customized products.

Technology and market pressures are encouraging localized and small-series production in customer-driven industries. The purpose of this paper is to explore and understand the supply chain-, product- and process-design factors for small-series production in EU’s textile and apparel industry, to understand configuration decisions, priorities and challenges.

An interview study was undertaken with ten companies that represent diverse small-series production models and value chain roles. Interview data was analysed to identify supply network configuration characteristics, decision priorities and challenges.

Three small-series production models emerged from the analysis, differing with respect to adoption of process postponement and customization. The findings confirm and extend past research regarding diverse decision priorities and product, process, supply chain structure/relationship configurations. Challenges identified relate to planning (priorities) and implementation (configuration). Whereas competence availability and digital technology challenges are common, several difficulties are linked to production model like tensions related to priorities and small volumes, which are not found with customization.

Future research can make comparisons with other industry and location contexts; adopt dynamic approaches to distinguish between design and reconfiguration processes; and address indicated paradoxical-tensions.

The study findings can provide guidance for companies regarding identification of priorities and management of (planning/implementation) challenges impacting small-series production in T&A.

The paper brings a configuration perspective at the supply chain level to the problem of small-series production implementation, which demands holistic and context-specific understanding.

The emergence of distributed manufacturing (DM) is examined as a new form of localised production, distinct from previous manifestations of multi-domestic and indigenous production.

Supply network (SN) configuration and infrastructural provisioning perspectives were used to examine the literature on established localised production models as well as DM. A multiple case study was then undertaken to describe and explore the DM model further. A maximum variation sampling procedure was used to select five exemplar cases.

Three main contributions emerge from this study. First, the research uniquely brings together two bodies of literature, namely SN configuration and infrastructure provisioning to explore the DM context. Second, the research applies these theoretical lenses to establish the distinctive nature of DM across seven dimensions of analysis. Third, emerging DM design rules are identified and compared with the more established models of localised production, drawing on both literature and DM case evidence.

This study provides a rich SN configuration and infrastructural provisioning view on DM leading to a set of design rules for DM adoption, thus supporting practitioners in their efforts to develop viable DM implementation plans.

The authors contribute to the intra- and inter-organisational requirements for the emerging DM context by providing new perspectives through the combined lenses of SN configuration and infrastructural provisioning approaches.

The purpose of this paper is to eliminate the wastes and inefficient procedures in the maintenance organization of aircraft so as to reduce its downtime and increase mission availability.

Customized lean Six Sigma (LSS) was applied at the task level and servicing cycle level to reduce the task content, cycle length and resources in servicing. The loading of the servicing facility was simulated through a simulation program developed from a statistical analysis of historical data for validating/simulating/determining optimum loading of servicing facility with refined tasks, reduced cycle length and resources. In simulation, the optimum combination of manpower, resources and infrastructure at the facility level was determined through sensitive analysis and design of experiments (DoE).

Optimization at the task level and its re-organization at the servicing cycle level reduced the cycle length by 55-68 per cent and manpower resources by 26 per cent. This further reduced facility-level manpower by 25 to 40 per cent, capacity requirements by more than 33 per cent and annual aircraft downtime by 78 per cent. The approach reduced the average number of aircraft undergoing servicing at each airbase at any time from 2.35 to just 0.76 and increased the mission availability to 20 per cent.

The hallmark of the paper has been the design of LSS approach from structured historical data and its validation through innovative simulation. The multi-pronged bottom-up approach practically bundles all wastes resident in the maintenance organization. The paper provides cursory approach to lean practitioners in the elimination of wastes in the maintenance of capital assets like aircraft.

A robust description of the material transformation system is fundamental for understanding its capabilities and thus for communicating, prioritising and changing the system. Deploying a previously developed configuration model the purpose of this paper is to test the industrial usability of the model as an instrument to gain a better understanding of the material transformation system through externalising the generic production capabilities of the system.

In a multiple case study approach and using a prior conceptual configuration model of the material transformation system in the process industries as a research instrument, company-generic production capabilities were investigated in three companies representing the mineral, food and steel industries.

The empirical results supported the utility of the model as an instrument in providing a coherent set of elements that define operations and thus serve as a platform to model company-generic production capabilities and serve as input to strategizing though implicating needed change to the material transformation system. The theoretical contribution was mainly the empirical validation of the previously developed conceptual model as a tool in knowledge formation of the capabilities of the system and to outline the concept of “production capabilities configuration”.

Three sectors of the process industries were studied but it is recommended that the results should be replicated in complementary case studies or a survey of larger samples from the process industries. Those studies should not only be limited to increase the empirical knowledge base, but possibly to identify additional new variables, further refine the set of variables in the present model and investigate their relationships.

It is argued that the model can already be used as a tool to support both horizontal and vertical communication on production capabilities, thus facilitating, e.g. manufacturing strategy development.

The validated conceptual model supported by the empirical evidence is new knowledge to be used in the analysis of company-generic production capabilities in the process industries.

The purpose of this paper is to introduce a methodological approach to develop customized products which offer true customer value and achieve superior competitive advantage.

An integrated framework is presented where both front‐ and back‐end features of product development activities are illustrated. Detailed explanations of the framework participants are discussed with their specifications and view points that illustrate the value of the framework. This framework communicates between citarasa and do‐it‐yourself‐design configurators at the upstream, and available to promise, agile supply and demand network, advanced planning and scheduling systems in the downstream, in order to visualize the complete production scenarios and to maintain the flow of custom tailored product development.

It is hoped that the illustrated framework will bridge the gap between manufacturers, and customers in order to produce customer satisfied products that fulfill the business target in terms of earning more revenues.

This research work is based on a theoretical hypothesis. Although the proposed framework is implemented in a truck manufacturing company, it requires application in more industrial organizations in order to generalize its effectiveness, suitability, and consistency in the manufacturing arena.

This paper outlines the configuration principle, along with different tools and methodologies, which support manufacturing firms in the customization of products in both upstream and downstream activities in a profitable way. These tools or methodologies can help product developers to improve their due‐date promising, exploitation of bottlenecks, and the visualization of their capability to produce the customers' specific products.

While localized small-series production is a significant opportunity, various tensions challenge implementation in high-cost contexts. This paper explores how managers view and respond to different tensions in small-series production implementation by adopting a paradox-based perspective.

The paper presents a multiple case study addressing small-series production within EU's apparel industry, as key context to address managerial awareness, and responses to tensions regarding location and supply network configuration decisions. Seven cases were selected for variation in customization and implementation (early/established), ownership, location and company size, to identity commonalities.

The study highlights performing tensions related to sustainability, and risk, in addition to confirming traditional goal-related tensions predominantly impacting small volume production. With on-demand/custom production, tensions include costs in conflict with process scale, and several process-related tensions (flexibility, expansion/development, risk management). Identified multidimensional responses do not include location or structural decisions, instead focusing on synthesis, through product-operations efficiency, knowledge development and process innovation and supply chain collaboration. Temporal separation is found with customization, including reducing product/process complexity short-term with enhancing process development, which suggests latent learning tensions and limited awareness.

Future research should address the extent to which tensions can be resolved or remain paradoxical, as well as dynamic decision-making and latent tensions.

The paper shows how paradox theory facilitates a deeper understanding of complex network configuration decisions, including reshoring/localization. The findings identify organizing tensions/elements and elaborate upon performing/performing-organizing tensions suggested with small-series production, location decisions and supply chain management.

The study examines the remote integration process of advanced manufacturing technology (AMT) into the production system and identifies key challenges and mitigating actions for a smoother introduction and integration process.

The study adopts a case study approach to a cyber-physical production system at an industrial technology center using a mobile robot as an AMT.

By applying the plug-and-produce concept, the study exemplifies an AMT's remote integration process into a cyber-physical production system in nine steps. Eleven key challenges and twelve mitigation actions for remote integration are described based on technology–organization–environment theory. Finally, a remote integration framework is proposed to facilitate AMT integration into production systems.

The study presents results purely from a practical perspective, which could reduce dilemmas in early decision-making related to smart production. The proposed framework can improve flexibility and decrease the time needed to configure new AMTs in existing production systems.

The area of remote integration for AMT has not been addressed in depth before. The consequences of lacking in-depth studies for remote integration imply that current implementation processes do not match the needs and the existing situation in the industry and often underestimate the complexity of considering both technological and organizational issues. The new integrated framework can already be deployed by industry professionals in their efforts to integrate new technologies with shorter time to volume and increased quality but also as a means for training employees in critical competencies required for remote integration.