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Article
Publication date: 25 December 2023

Zihan Dang and Naiming Xie

Assembly line is a common production form and has been effectively used in many industries, but the imprecise processing time of each process makes production line balancing and…

Abstract

Purpose

Assembly line is a common production form and has been effectively used in many industries, but the imprecise processing time of each process makes production line balancing and capacity forecasting the most troublesome problems for production managers. In this paper, uncertain man-hours are represented as interval grey numbers, and the optimization problem of production line balance in the case of interval grey man-hours is studied to better evaluate the production line capacity.

Design/methodology/approach

First, this paper constructs the basic model of assembly line balance optimization for the single-product scenario, and on this basis constructs an assembly line balance optimization model under the multi-product scenario with the objective function of maximizing the weighted greyscale production line balance rate, second, this paper designs a simulated annealing algorithm to solve problem. A neighborhood search strategy is proposed, based on assembly line balance optimization, an assembly line capacity evaluation method with interval grey man-hour characteristics is designed.

Findings

This paper provides a production line balance optimization scheme with uncertain processing time for multi-product scenarios and designs a capacity evaluation method to provide managers with scientific management strategies so that decision-makers can scientifically solve the problems that the company's design production line is quite different from the actual production situation.

Originality/value

There are few literary studies on combining interval grey number with assembly line balance optimization. Therefore, this paper makes an important contribution in this regard.

Details

Grey Systems: Theory and Application, vol. 14 no. 2
Type: Research Article
ISSN: 2043-9377

Keywords

Article
Publication date: 4 April 2024

Emma Welch, David Gligor and Sıddık Bozkurt

This paper aims to address how perceived social media agility can promulgate co-creation processes, such as co-production and value-in-use, and how it impacts brand-related…

Abstract

Purpose

This paper aims to address how perceived social media agility can promulgate co-creation processes, such as co-production and value-in-use, and how it impacts brand-related outcomes. This study also addresses calls for marketing scholars to investigate the types of personality traits that affect these potential relationships by accounting for the impact of technology reflectiveness.

Design/methodology/approach

This paper conducted an online survey with 321 adult subjects. The direct, indirect and conditional (moderation) effects were assessed using multivariate regression, various PROCESS models and the Johnson–Neyman technique (to probe the interaction terms). Additional supplemental analyses were conducted via PROCESS models.

Findings

The results show that perceived social media agility directly and indirectly (through co-production and value-in-use) positively influences brand attachment and that the order of these two processes matters (co-production followed by value-in-use). Results also show that the positive impact of perceived social media agility on co-production and value-in-use deviates for customers high in technology reflectiveness but can be manipulated according to which process comes first.

Originality/value

This paper expounds on the new construct of perceived social media agility by uniquely linking perceived social media agility to two distinct value co-creation processes (co-production and value-in-use) and brand-related outcomes while highlighting how consumer-specific traits can affect this relationship in a social media setting.

Details

Journal of Product & Brand Management, vol. 33 no. 3
Type: Research Article
ISSN: 1061-0421

Keywords

Book part
Publication date: 20 November 2023

Esmir Demaj and Denis Mehillaj

Lean manufacturing, a philosophy that revolutionized the manufacturing industry, is often linked to the Toyota Production System (TPS). At the core of a lean company, one can…

Abstract

Lean manufacturing, a philosophy that revolutionized the manufacturing industry, is often linked to the Toyota Production System (TPS). At the core of a lean company, one can observe proper implementation of lean manufacturing tools and practices such as just-in-time, work teams, cellular manufacturing, lean layout, etc. The goal of lean production is to minimize the waste producing activities while offering the same or enhanced quality to customers.

The aim of this research is to investigate the implementation degree of lean manufacturing and its tools and practices focusing on the case of an SME in Albania as a concrete example. Higher attention is given to some of the pillars of lean manufacturing such as just-in-time and cellular manufacturing.

In this case study, researchers observed a variety of features of lean production. Just-in-time was implemented to a certain extent and cellular manufacturing at a more surprising level, which was facilitated especially by the U-shaped facility layout designs observed during the site visits. The value stream mapping showed a proper group technology in place and the management displayed signs of engagement and future advancement desire regarding this philosophy.

Details

Digitalization, Sustainable Development, and Industry 5.0
Type: Book
ISBN: 978-1-83753-191-2

Keywords

Open Access
Article
Publication date: 20 January 2023

Anas Fattouh, Koteshwar Chirumalla, Mats Ahlskog, Moris Behnam, Leo Hatvani and Jessica Bruch

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…

1357

Abstract

Purpose

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.

Design/methodology/approach

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.

Findings

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.

Practical implications

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.

Originality/value

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.

Article
Publication date: 1 September 2023

Diego Augusto de Jesus Pacheco and Thomas Schougaard

This study aims to investigate how to identify and address production levelling problems in assembly lines utilising an intensive manual workforce when higher productivity levels…

Abstract

Purpose

This study aims to investigate how to identify and address production levelling problems in assembly lines utilising an intensive manual workforce when higher productivity levels are urgently requested to meet market demands.

Design/methodology/approach

A mixed-methods approach was used in the research design, integrating case study analysis, interviews and qualitative/quantitative data collection and analysis. The methodology implemented also introduces to the literature on operational performance a novel combination of data analysis methods by introducing the use of the Natural Language Understanding (NLU) methods.

Findings

First, the findings unveil the impacts on operational performance that transportation, limited documentation and waiting times play in assembly lines composed of an intensive workforce. Second, the paper unveils the understanding of the role that a limited understanding of how the assembly line functions play in productivity. Finally, the authors provide actionable insights into the levelling problems in manual assembly lines.

Practical implications

This research supports industries operating assembly lines with intensive utilisation of manual workforce to improve operational performance. The paper also proposed a novel conceptual model prescriptively guiding quick and long-term improvements in intensive manual workforce assembly lines. The article assists industrial decision-makers with subsequent turnaround strategies to ensure higher efficiency levels requested by the market.

Originality/value

The paper offers actionable findings relevant to other manual assembly lines utilising an intensive workforce looking to improve operational performance. Some of the methods and strategies examined in this study to improve productivity require minimal capital investments. Lastly, the study contributes to the empirical literature by identifying production levelling problems in a real context.

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: 3 February 2022

Juan Du, Yan Xue, Vijayan Sugumaran, Min Hu and Peng Dong

For prefabricated building construction, improper handling of the production scheduling for prefabricated components is one of the main reasons that affect project performance…

Abstract

Purpose

For prefabricated building construction, improper handling of the production scheduling for prefabricated components is one of the main reasons that affect project performance, which causes overspending, schedule overdue and quality issues. Prior research on prefabricated components production schedule has shown that optimizing the flow shop scheduling problem (FSSP) is the basis for solving this issue. However, some key resources and the behavior of the participants in the context of actual prefabricated components production are not considered comprehensively.

Design/methodology/approach

This paper characterizes the production scheduling of the prefabricated components problem into a permutation flow shop scheduling problem (PFSSP) with multi-optimization objectives, and limitation on mold and buffers size. The lean construction principles of value-based management (VBM) and just-in-time (JIT) are incorporated into the production process of precast components. Furthermore, this paper applies biogeography-based optimization (BBO) to the production scheduling problem of prefabricated components combined with some improvement measures.

Findings

This paper focuses on two specific scenarios: production planning and production rescheduling. In the production planning stage, based on the production factor, this study establishes a multi-constrained and multi-objective prefabricated component production scheduling mathematical model and uses the improved BBO for prefabricated component production scheduling. In the production rescheduling stage, the proposed model allows real-time production plan adjustments based on uncertain events. An actual case has been used to verify the effectiveness of the proposed model and the improved BBO.

Research limitations/implications

With respect to limitations, only linear weighted transformations are used for objective optimization. In regards to research implications, this paper considers the production of prefabricated components in an environment where all parties in the supply chain of prefabricated components participate to solve the production scheduling problem. In addition, this paper creatively applies the improved BBO to the production scheduling problem of prefabricated components. Compared to other algorithms, the results show that the improved BBO show optimized result.

Practical implications

The proposed approach helps prefabricated component manufacturers consider complex requirements which could be used to formulate a more scientific and reasonable production plan. The proposed plan could ensure the construction project schedule and balance the reasonable requirements of all parties. In addition, improving the ability of prefabricated component production enterprises to deal with uncertain events. According to actual production conditions (such as the occupation of mold resources and storage resources of completed components), prefabricated component manufacturers could adjust production plans to reduce the cost and improve the efficiency of the whole prefabricated construction project.

Originality/value

The value of this article is to provide details of the procedures and resource constraints from the perspective of the precast components supply chain, which is closer to the actual production process of prefabricated components. In addition, developing the production scheduling for lean production will be in line with the concept of sustainable development. The proposed lean production scheduling could establish relationships between prefabricated component factory manufacturers, transportation companies, on-site contractors and production workers to reduce the adverse effects of emergencies on the prefabricated component production process, and promote the smooth and efficient operation of construction projects.

Details

Engineering, Construction and Architectural Management, vol. 30 no. 4
Type: Research Article
ISSN: 0969-9988

Keywords

Article
Publication date: 19 May 2023

Panagiotis Tsarouhas and Niki Sidiropoulou

In a packaging olives manufacturing system, the drained weight of the product plays a decisive role in customer’s satisfaction as well as in financial saving for the organization…

Abstract

Purpose

In a packaging olives manufacturing system, the drained weight of the product plays a decisive role in customer’s satisfaction as well as in financial saving for the organization. The purpose of this study is to minimize the variation of the drained weight of olives in the production system to avoid the negative consequences.

Design/methodology/approach

The research develops a practical implementation step-by-step of Six Sigma define, measure, analyze, improve and control (DMAIC) in reducing the variation of the drained weight of olives.

Findings

Data analysis was used at various phases of the project to identify the root causes of rejection and rework. As a result of the necessary interventions and actions to optimize the manufacturing process, the standard deviation of drained weight was significantly reduced by 51.02%, with a 99.97% decrease in the number of parts per million defectives. Thus, the yield of the production process was improved by 8.24%. The estimated annual savings from this project were US$ 228,000 resulting from reduced rejection and rework.

Practical implications

This research may be used in packaging olives production systems as a tool for managers and engineers planning to increase productivity and efficiency while also improving product quality. The study also provided the organization with helpful actions that will be used to guide future Six Sigma operations management on the system. Thus, practical guidelines and solutions are provided.

Originality/value

In this project, for the first time, the Six Sigma methodology has been applied to solve a real-world problem in the packaging olives manufacturing system and to show that the DMAIC approach may assist to improve the efficiency of their operations and hence contribute to their quest toward continuous improvement.

Details

International Journal of Lean Six Sigma, vol. 15 no. 2
Type: Research Article
ISSN: 2040-4166

Keywords

Article
Publication date: 30 March 2023

Rafael Diaz and Ali Ardalan

Motivated by recent research indicating that the operational performance of an enterprise can be enhanced by building a supporting data-driven environment in which to operate…

Abstract

Purpose

Motivated by recent research indicating that the operational performance of an enterprise can be enhanced by building a supporting data-driven environment in which to operate, this paper presents a simulation framework that enables an examination of the effects of applying smart manufacturing principles to conventional production systems, intending to transition to digital platforms.

Design/methodology/approach

To investigate the extent to which conventional production systems can be transformed into novel data-driven environments, the well-known constant work-in-process (CONWIP) production systems and considered production sequencing assignments in flowshops were studied. As a result, a novel data-driven priority heuristic, Net-CONWIP was designed and studied, based on the ability to collect real-time information about customer demand and work-in-process inventory, which was applied as part of a distributed and decentralised production sequencing analysis. Application of heuristics like the Net-CONWIP is only possible through the ability to collect and use real-time data offered by a data-driven system. A four-stage application framework to assist practitioners in applying the proposed model was created.

Findings

To assess the robustness of the Net-CONWIP heuristic under the simultaneous effects of different levels of demand, its different levels of variability and the presence of bottlenecks, the performance of Net-CONWIP with conventional CONWIP systems that use first come, first served priority rule was compared. The results show that the Net-CONWIP priority rule significantly reduced customer wait time in all cases relative to FCFS.

Originality/value

Previous research suggests there is considerable value in creating data-driven environments. This study provides a simulation framework that guides the construction of a digital transformation environment. The suggested framework facilitates the inclusion and analysis of relevant smart manufacturing principles in production systems and enables the design and testing of new heuristics that employ real-time data to improve operational performance. An approach that can guide the structuring of data-driven environments in production systems is currently lacking. This paper bridges this gap by proposing a framework to facilitate the design of digital transformation activities, explore their impact on production systems and improve their operational performance.

Details

Industrial Management & Data Systems, vol. 123 no. 5
Type: Research Article
ISSN: 0263-5577

Keywords

Article
Publication date: 31 August 2023

Lucia Espinosa-Brisset, Caroline Pénicaud, Isabelle Souchon and Anne Saint-Eve

The purpose of this paper is to better understand consumer's familiarity with fruit processing as well as how fruit production conditions (organic and conventional farming)…

Abstract

Purpose

The purpose of this paper is to better understand consumer's familiarity with fruit processing as well as how fruit production conditions (organic and conventional farming), processing conditions (homemade, artisanal and industrial) and the type of processing (e.g. applesauce, apple cider and apple sorbet) influence consumer perceptions of processed fruits.

Design/methodology/approach

An online survey questionnaire was applied to 1,000 people living in France. The people represented different genders, ages (18–60+) and sociodemographic categories. Participants were categorized based on their produce purchasing habits (conventional, local, organic, local-organic). The questionnaire contained multiple choice and five point Likert scale questions. Data were analyzed using non-parametric tests.

Findings

The authors found that participants saw year-round availability, fruit preservation and food waste reduction as processing advantages. Locally sourced products were preferred to organic products. The perceived disadvantages to processing were additive usage, nutrient loss and packaging. For consumers, these disadvantages drove highly differentiated perceptions of industrial versus artisanal/homemade apple products. Processing conditions appeared to matter far more than production conditions (organic vs. conventional). In general, consumers weren't familiar with processing operations, awareness was greater for consumers of local and/or organic produce than conventional consumers.

Social implications

There must be a societal transition toward healthier diets, and food technologies. Informed consumers, might be better equipped to make healthy, informed choices if the consumers are given quality information about food production and processing at different levels.

Originality/value

Research has shown that consumers view fresh organic fruit positively, but only few studies have looked at perceptions of processed fruit products and their familiarity with processing operations. Results of this study demonstrate that consumers could make better choices if the consumers are given quality information about fruit production and processing.

Details

British Food Journal, vol. 125 no. 11
Type: Research Article
ISSN: 0007-070X

Keywords

Article
Publication date: 1 April 2024

Mohammad Hani Al-Rifai

The purpose of this paper is twofold: first, a case study on applying lean principles in manufacturing operations to redesign and optimize an electronic device assembly process…

Abstract

Purpose

The purpose of this paper is twofold: first, a case study on applying lean principles in manufacturing operations to redesign and optimize an electronic device assembly process and its impact on performance and second, introducing cardboard prototyping as a Kaizen tool offering a novel approach to testing and simulating improvement scenarios.

Design/methodology/approach

The study employs value stream mapping, root cause analysis, and brainstorming tools to identify root causes of poor performance, followed by deploying a Kaizen event to redesign and optimize an electronic device assembly process. Using physical models, bottlenecks and opportunities for improvement were identified by the Kaizen approach at the workstations and assembly lines, enabling the testing of various scenarios and ideas. Changes in lead times, throughput, work in process inventory and assembly performance were analyzed and documented.

Findings

Pre- and post-improvement measures are provided to demonstrate the impact of the Kaizen event on the performance of the assembly cell. The study reveals that implementing lean tools and techniques reduced costs and increased throughput by reducing assembly cycle times, manufacturing lead time, space utilization, labor overtime and work-in-process inventory requirements.

Originality/value

This paper adds a new dimension to applying the Kaizen methodology in manufacturing processes by introducing cardboard prototyping, which offers a novel way of testing and simulating different scenarios for improvement. The paper describes the process implementation in detail, including the techniques and data utilized to improve the process.

Details

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

Keywords

1 – 10 of over 16000