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1 – 8 of 8Vinayambika S. Bhat, Thirunavukkarasu Indiran, Shanmuga Priya Selvanathan and Shreeranga Bhat
The purpose of this paper is to propose and validate a robust industrial control system. The aim is to design a Multivariable Proportional Integral controller that accommodates…
Abstract
Purpose
The purpose of this paper is to propose and validate a robust industrial control system. The aim is to design a Multivariable Proportional Integral controller that accommodates multiple responses while considering the process's control and noise parameters. In addition, this paper intended to develop a multidisciplinary approach by combining computational science, control engineering and statistical methodologies to ensure a resilient process with the best use of available resources.
Design/methodology/approach
Taguchi's robust design methodology and multi-response optimisation approaches are adopted to meet the research aims. Two-Input-Two-Output transfer function model of the distillation column system is investigated. In designing the control system, the Steady State Gain Matrix and process factors such as time constant (t) and time delay (?) are also used. The unique methodology is implemented and validated using the pilot plant's distillation column. To determine the robustness of the proposed control system, a simulation study, statistical analysis and real-time experimentation are conducted. In addition, the outcomes are compared to different control algorithms.
Findings
Research indicates that integral control parameters (Ki) affect outputs substantially more than proportional control parameters (Kp). The results of this paper show that control and noise parameters must be considered to make the control system robust. In addition, Taguchi's approach, in conjunction with multi-response optimisation, ensures robust controller design with optimal use of resources. Eventually, this research shows that the best outcomes for all the performance indices are achieved when Kp11 = 1.6859, Kp12 = −2.061, Kp21 = 3.1846, Kp22 = −1.2176, Ki11 = 1.0628, Ki12 = −1.2989, Ki21 = 2.454 and Ki22 = −0.7676.
Originality/value
This paper provides a step-by-step strategy for designing and validating a multi-response control system that accommodates controllable and uncontrollable parameters (noise parameters). The methodology can be used in any industrial Multi-Input-Multi-Output system to ensure process robustness. In addition, this paper proposes a multidisciplinary approach to industrial controller design that academics and industry can refine and improve.
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Maryam Zulfiqar, Michael Sony, Shreeranga Bhat, Jiju Antony, Willem Salentijn and Olivia McDermott
The integration of Lean Six Sigma (LSS) and Industry 4.0 (I4.0) is in the nascent stage and promises to achieve new optimums in operational excellence. This study aims to…
Abstract
Purpose
The integration of Lean Six Sigma (LSS) and Industry 4.0 (I4.0) is in the nascent stage and promises to achieve new optimums in operational excellence. This study aims to empirically examine the enablers, barriers, benefits and application of I4.0 technologies in LSS and I4.0 integration.
Design/methodology/approach
A pilot survey was chosen as an appropriate methodology, as LSS and I4.0 integration is still budding. The survey targeted senior quality management professionals, quality managers, team leaders, LSS Black Belts and operations managers to collect the relevant research data. The questionnaire was sent to 200 respondents and received 53 valid responses.
Findings
This study reveals that “top management support” is an essential enabler for LSS and I4.0 integration. The most significant barrier was “poor understanding of data analysis” and “lack of top management support”. The findings further illustrated that LSS and I4.0 integration resulted in greater efficiency, lower operational costs, improved productivity, improved customer satisfaction and improved quality. Regarding I4.0 technology integration at different phases of LSS, the authors noticed that big data analytics and artificial intelligence (AI) are the most prominent technologies used in all phases of LSS implementation.
Research limitations/implications
One of the limitations of this study is the sample size. LSS and I4.0 are emerging concepts; hence, obtaining a larger sample size is difficult. In addition, the study used non-parametric tests to analyse the data. Therefore, future studies should be conducted with large sample sizes across different continents and countries to understand differences in the key findings.
Practical implications
The outcomes of this study can be useful for organisational managers to understand the enablers and barriers before integrating LSS and I4.0 for adoption in their organisations. Secondly, it helps to convince top management and human resource personnel by providing a list of benefits of LSS and I4.0 integration. Finally, it can help decision-makers understand which I4.0 technologies can be used in different stages of LSS methodology.
Originality/value
LSS and I4.0 integration was studied at a conceptual level. This is the first empirical study targeted toward understanding the LSS and I4.0 integration. In addition, this study investigates the application of widely used I4.0 technologies in different phases of LSS.
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Jiju Antony, Michael Sony, Bart Lameijer, Shreeranga Bhat, Raja Jayaraman and Leopoldo Gutierrez
Design science research (DSR) is a structured approach for solving complex ill-structured problems in organizations through the development of an artefact followed by its…
Abstract
Purpose
Design science research (DSR) is a structured approach for solving complex ill-structured problems in organizations through the development of an artefact followed by its validation. This paper aims to evaluate existing DSR methodology and propose specific accents to promote DSR for environmental, social and governance (ESG)-oriented operational excellence (OPEX) initiatives within organizations.
Design/methodology/approach
This commentary paper is based on an abductive reasoning approach to evaluate and understand DSR and assess its effectiveness for developing solutions to typical ESG-oriented OPEX-based problems within organizations.
Findings
Existing literature on DSR is reviewed, after which it is evaluated on its ability to contribute to the implementation of sustainable solutions for ESG-oriented OPEX-based problems. Based on the review, specific DSR methodological accents are proposed for the development of ESG-oriented OPEX-based solutions in organizations.
Research limitations/implications
This conceptual paper contributes to the conceptual understanding of the applicability, limitations and contextual preconditions for applying DSR. This paper proposes an explicit and, in some ways, alternative view on DSR research for OPEX researchers to apply and further the body of knowledge on matters of sustainability (ESG) in operations management.
Practical implications
Currently, there is limited understanding and application of the DSR methodology for OPEX-based problem-solving initiatives, as appears in the scant literature on DSR applied for the implementation of OPEX based initiatives for ESG purposes. This paper aims to challenge and provide accents for DSR applied to OPEX-related problems by means of a DSR framework and thereby promotes intervention-based studies among researchers.
Originality/value
The proposed step-by-step methodology contains novel elements and is expected to be of help for OPEX-oriented academicians and practitioners in implementing DSR methodology for practical related problems which need research interventions from academics from Higher Education Institutions.
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Jiju Antony, Shreeranga Bhat, Anders Fundin, Michael Sony, Lars Sorqvist and Mariam Bader
The use of quality management (QM) to achieve the United Nations Sustainable Development Goals (UNSDGs) is a topic of growing interest in academia and industry. The IAQ…
Abstract
Purpose
The use of quality management (QM) to achieve the United Nations Sustainable Development Goals (UNSDGs) is a topic of growing interest in academia and industry. The IAQ (International Academy for Quality) established Quality Sustainability Award in 2020, a testament to this growing interest. This study aims to investigate how QM philosophies, methodologies and tools can be used to achieve sustainable development in organizations.
Design/methodology/approach
Five large manufacturing organizations – three from India and two from China – who reported their achievements about using QM in achieving Sustainable Development Goals (SDGs) were studied using multiple sources of data collection. A detailed within-case and cross-case analysis were conducted to unearth this linkage's practical and theoretical aspects.
Findings
The study finds that QM methodologies effectively met the five organizations' UNSDGs. These organizations successfully used OPEX (Operational Excellence) methodologies such as Lean, Kaizen and Six Sigma to meet UNSDGs 7, 11, 12 and 13. Moreover, UNSG 12 (Responsible Consumption and Production) is the most targeted goal across the case studies. A cross-case analysis revealed that the most frequently used quality tools were Design of Experiments (DoE), Measurement Systems Analysis (MSA), C&E analysis and Inferential statistics, among other essential tools.
Research limitations/implications
The study's sample size was limited to large-scale manufacturing organizations in the two most populous countries in the world. This may limit the study's generalizability to other countries, continents, or micro-, small- and medium-sized enterprises (SMEs). Additionally, the study's conclusions would be strengthened if tested as hypotheses in a follow-up survey.
Practical implications
This practical paper provides case studies on how to use QM to impact SDGs. It offers both descriptive and prescriptive solutions for practitioners. The study highlights the importance of using essential QM tools in a structured and systematic manner, with effective teams, to meet the SDGs of organizations.
Social implications
The study shows how QM can be used to impact UNSDGs, and this is very important because the UNSDGs are a set of global objectives that aim to address a wide range of social and environmental issues. This study could motivate organizations to achieve the UNSDGs using essential QM tools and make the world a better place for the present and future generations.
Originality/value
This case study is the first to investigate at a micro-level how QM can impact UNSDGs using live examples. It uses data from the IAQ to demonstrate how QM can be integrated into UNSDGs to ensure sustainable manufacturing.
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Surekha Nayak, Anjali Ganesh, Shreeranga Bhat and Roopesh Kumar
The present research focuses on improving the awareness related to soft total quality management (TQM) practices by looking from the viewpoint of strategic human resources (HR)…
Abstract
Purpose
The present research focuses on improving the awareness related to soft total quality management (TQM) practices by looking from the viewpoint of strategic human resources (HR). In addition, it is intended to reflect on the resulting soft TQM-HR outcomes and determine the mediating effect between soft TQM-HR strategies and organizational effectiveness (OE).
Design/methodology/approach
An exploratory research methodology with an online survey technique was adopted for the study. Three hundred and three managerial-level personnel from nine large Indian manufacturing organizations participated in the research. A theoretical model is projected and verified using correlation and mediation analysis.
Findings
The results show that commitment, reduced turnover intentions and satisfaction levels of employees mediate the relationship between resources, development and retention strategies and OE. However, the retention strategy has the strongest association with the OE of the three strategies. Also, of the three HR outcomes, satisfaction was strongly associated with OE. The analysis proved that the proposed model is an acceptable fit.
Practical implications
Implementing HR-related TQM strategies will likely impact OE since it elicits positive HR outcomes such as commitment, reduced turnover intention and satisfaction. Recognizing human resources as a unique strategic asset will help HR managers devise adequate resourcing, development and retention strategies instrumental in executing TQM.
Originality/value
The present micro study is unique in scrutinizing the influence of soft TQM-HR practices on organizational effectiveness by analysing the mediating effects of commitment, reduced turnover intention and satisfaction in Indian large-scale manufacturing organizations. The study is unique since no literature deciphers the linkages between HR strategies and organizational effectiveness in the Indian manufacturing sector.
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Jiju Antony, Shreeranga Bhat, Michael Sony, Anders Fundin, Lars Sorqvist and Raul Molteni
In a highly competitive and globalised era, agile organisations proactively steer towards sustainability. This situation persuaded the organisations to align Quality Management…
Abstract
Purpose
In a highly competitive and globalised era, agile organisations proactively steer towards sustainability. This situation persuaded the organisations to align Quality Management (QM) initiatives to achieve sustainable outcomes. This study aims to explore quality–sustainability linkage, explicitly focusing on attaining the prestigious IAQ Quality Sustainability Award. Further it investigates, the impact of QM as a strategy for promoting sustainability to meet sustainable development goals (SDGs).
Design/methodology/approach
Due to the lack of substantial literature connecting QM to sustainability, the current research adopted an explanatory multiple-case study. Six cases were purposively chosen for the study. Three cases of those who have achieved the prestigious IAQ Quality Sustainability Award and remaining have been selected that have fallen short of receiving the award. A detailed within-case and cross-case examinations involving six cases that reported their QM achievements aligned with SDGs.
Findings
The findings demonstrate the significant role of QM adoption in achieving positive results from the perspective of SDGs, such as reduced environmental impacts, improved operational efficiency and enhanced quality of life. Effective stakeholder collaboration, proficiency in analytical tools and strategic alignment with SDGs emerged as critical success factors. Conversely, weak linkage with sustainability and unclear approaches were crucial challenges in attaining the IAQ Quality Sustainability Award.
Research limitations/implications
This paper outlines essential commandments for organisations actively seeking to promote sustainability. It offers valuable insights for decision-makers, facilitating a profound understanding of the challenges and opportunities in pursuing sustainable performance.
Originality/value
The distinctive nature of this study lies in its dedicated exploration of the intricate relationship between QM deployment and its true impact on the achievement of the SDGs.
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Vikas Swarnakar, Olivia McDermott, Michael Sony, Shreeranga Bhat and Jiju Antony
This study investigates the challenges and opportunities that organisations face in implementing Quality 4.0 as an approach to quality management and investigate the current state…
Abstract
Purpose
This study investigates the challenges and opportunities that organisations face in implementing Quality 4.0 as an approach to quality management and investigate the current state of Quality 4.0 implementation.
Design/methodology/approach
This study uses a qualitative research methodology to interview senior managers from globally based manufacturing and service industries.
Findings
The study explicates that most organisations implemented Quality 4.0 to improve their flexibility, efficiency, transparency and productivity while focusing on improving service quality, customer satisfaction and reducing cost. In terms of sustainability of Quality 4.0 the key factors found were a consistent effort from the top management, continuous training to employees, building leadership quality and creating a habit of using Quality 4.0.
Practical implications
The findings of this study offer useful guidance to organisations desirous of implementing Quality 4.0. In addition, the findings have identified key sustainability factors, helping organisations ensure a successful implementation and long-term returns from Quality 4.0.
Originality/value
The findings of this study contribute to the body of knowledge related to Quality 4.0 and help organisations in their digital transformation journey. In addition, it is one of the first studies to investigate the key factors for Quality 4.0 sustainability.
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Ravikantha Prabhu, Sharun Mendonca, Pavana Kumara Bellairu, Rudolf Charles DSouza and Thirumaleshwara Bhat
This paper aims to report the effect of titanium oxide (TiO2) particles on the physical, mechanical, tribological and water resistance properties of 5% NaOH-treated bamboo…
Abstract
Purpose
This paper aims to report the effect of titanium oxide (TiO2) particles on the physical, mechanical, tribological and water resistance properties of 5% NaOH-treated bamboo fiber–reinforced composites.
Design/methodology/approach
In this research, the epoxy/bamboo/TiO2 hybrid composite filled with 0–8 Wt.% TiO2 particles has been fabricated using simple hand layup techniques, and testing of the developed composite was done in accordance with the American Society for Testing and Materials (ASTM) standard.
Findings
The results of this study indicate that the addition of TiO2 particles improved the mechanical properties of the developed epoxy/bamboo composites. Tensile properties were found to be maximum for 6 Wt.%, and impact strength was found to be maximum for 8 Wt.% TiO2 particles-filled composite. The highest flexural properties were found at a lower TiO2 fraction of 2 Wt.%. Adding TiO2 filler helped to reduce the water absorption rate. The studies related to the wear and friction behavior of the composite under dry and abrasive wear conditions reveal that TiO2 filler was beneficial in improving the wear performance of the composite.
Originality/value
This research paper attempts to include both TiO2 filler and bamboo fibers to develop a novel composite material. TiO2 micro and nanoparticles are promising filler materials; it helps to enhance the mechanical and tribological properties of the epoxy composites and in literature, there is not much work reported, where TiO2 is used as a filler material with bamboo fiber–reinforced epoxy composites.
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