Search results

This study aims to provide a foundation for the development of subcontracts that suit takt production in construction.

This is a non-empiric conceptual study, which integrates takt production and general construction literature into new proposals for subcontract clauses suitable for takt production in construction. This study uses literature reviews, from which proposals regarding takt production viable subcontract clauses are conducted via logical reasoning.

A total of 13 proposals for takt production applicable subcontracts are provided in this study. The proposals emphasize detailed and collaborative planning, suitable payment methods and flexibility for takt plan modification.

Previous takt literature has not properly addressed the development of subcontracts for takt production, despite regular attempts to use subcontracting in takt production. This study aims to aid main contractors to create fair and suitable subcontracts, so that adhering to takt schedules could be more viable in practice. This study also acts as a foundation for further empirical studies regarding the subject.

Lean is a well‐established industrial paradigm and has proved to be of significant benefit in different sectors of the manufacturing industry (e.g. automotive and aerospace). This paper aims to report on the introduction of lean to a new sector – the “UK red meat industry”. It highlights the benefits of lean production in one specific manufacturing area, the “cutting room”, where meat is split down from a carcass into retail cuts of meat.

A multiple case study approach is adopted in this paper. As part of the Red Meat Industry Forum's Value Chain Analysis Initiative, five cutting plants are presented as case studies in this paper.

This paper identifies two “traditional” and three “advanced” cutting rooms and reports a typical 25 per cent productivity gap. The paper tentatively concludes this is due to the advanced cases practicing lean techniques, such as “Takt‐time” and “work standardization”.

The literature review identifies a gap in previous research on the applications of logistics and operations management concepts and practices into the red meat industry. Particularly, lean techniques have been overlooked in the red meat industry.

The aim of this research is to discuss the benefits of U-shaped layout for production cell operating in variable takt time. Different experiments were conducted using benchmarks to highlight the performance gap between a linear cell and a U-Cell.

The implementation of the production cell, either in a U-shaped or in a straight line layout, is optimized through linear programming based on the number of operators. The two corresponding programs, in Mosel language, use the same approach to not introduce bias in the comparison of results. The study used the authors’ own datasets and other well-known academic benchmarks.

A comparison was conducted between the obtained takt times, with equivalent operating conditions, in both U-Cell and linear cell. A significant increase of the production rate was observed. This increase has often exceeded 10 per cent, reaching 32 per cent. All the experiments show that, with the same number of operators, a cell in a U-shaped layout is always at least as efficient, in terms of attainable production rates, than an equivalent linear cell. Ninety-six per cent of the studied cases give an improvement of production rate. Moreover, the dispersion of the U-Cell results is weaker, which suggests that the U-shaped layout gives better performances in more robust manner.

Results were obtained through a study of various academic benchmarks. The results must be validated on industrial situations.

This paper will be very useful for researchers and practitioners to understand lean implementations and their derived benefits. This paper will allow them to evaluate and analyze the expected benefits of the implementation of the production cell in the U-shaped layout (operating in variable takt time).

U-Cells constitute an appropriate solution for a layout of any kind of production cells with a variable structure (variability of the number of operators, of the organization of the cell, of the takt time […]). When facing a significant variation in the demand, the response consists of adjusting the number of operators assigned to the cell. This study jointly addresses the problem of the U-shaped layout and the operation in variable takt time.

University research efforts have not been effective in developing lasting impacts on operations management in construction because of inadequate coordination between academia and industry. This study aims to describe the development of an industry–university (IU) relationship which has enabled the conduct of practically and scientifically relevant research.

Design science research was carried out between 2016 and 2019 to build a consortium between a university and 17 design, construction, technology and logistics companies for enabling process innovations in construction. The consortium conducted industry-funded research on various topics, such as takt production, lean design management, prefabrication, measurement of waste and business models supported by digitalisation. The academic and practical impacts of the consortium’s research projects were investigated through a survey and in-depth company interviews.

The paper presents a conceptual model for creating an IU relationship to support scientifically and practically relevant research. The model includes network architects who mobilised consortium development and a joint governance body that developed a shared long-term vision and selected research topics based on this vision. The results show that using the model’s approach, the consortium selected research topics that have led to both academic publications and process innovations in construction.

Using empirical data, this study describes how to create a win-win IU innovation relationship that enables the implementation of process innovations into the construction sector and, at the same time, the conduct of scientific research in construction management.

Significant transitions in firms (e.g. outsourcing) may impact the relative importance of production and inventory assets, affecting the hierarchical separation of planning decisions. The purpose of this paper is to contribute to planning literature by investigating how the production system and the planning environment influence the performance difference between hierarchical and monolithic planning. Further, it seeks to reduce the prevailing theory-practice gap in tactical planning.

Through an action research study, a monolithic model integrating tactical production planning decisions, subject to upstream supply chain constraints, with strategic investments decisions was developed, tested and implemented in a global OEM. Using the developed model and a measure of the capital cost of production assets relative to the cost of holding inventory, it is numerically examined how the production system and planning environment influence the performance of hierarchical and monolithic planning.

The research demonstrates the potential of integrating decisions and reveals significant performance differences between hierarchical and monolithic planning for firms with low capital cost relative to inventory holding cost.

The findings suggest a fit between planning processes, the production system and planning environment. Future research should empirically validate the findings and propositions.

The paper combine capital investments and production planning decisions, which usually transpire at different hierarchical levels and on different time-horizons, and investigates the consequences of hierarchical separation through a real-life validated case and numerical analysis.

Purpose – In this chapter, the potential of Milk Run logistics, a method for consolidating freight, is analysed. Milk Run logistics provides a host of possibilities for consolidating freight transport activities and thus using transport capacity efficiently. It utilizes one vehicle to conduct several pick-ups/deliveries in a round trip, which means that the pick-up/delivery points should be located in a limited area which can be covered in a one-day trip.

Findings – Milk Run logistics seems highly beneficial in congested urban environments in developed and developing countries although it may also work in other areas. Furthermore, it can be linked to long-distance logistics, by rail for example, in the national and world-wide network of large companies.

Application – Examples for three automotive companies are given: Toyota with its logistic concept for the Bangkok region, Webasto, a supplier of hardtops and other car parts, and Audi, a daughter company of Volkswagen. All of them have introduced green logistics concepts including Milk Runs, which help to reduce CO2, waste material and – last but not least – costs.

Implications – The chapter concludes with indicating the high potential of Milk Run logistics to China and its rapidly developing automotive industry.

The purpose of this paper is to address the following issues: first, the significance of the three independent variables (the chassis, trim, and assembly departments) on the three outputs (direct run loss first time capability, jobs per hour (JPH) lost, and injury rate); second, the optimal level of span of control based on the best achieved outputs; and third, whether increasing the span of control post 2009 improved manufacturing outputs in comparison with a span of control pre 2009.

The optimal level of span of control at the automotive Big Three (Chrysler LLC, Ford, General Motors) is investigated using design of experiments.

The analysis shows that the variables are significant for all outputs, except for chassis on injury. All three variables deteriorate as the span of control increases. The paper indicates that the lower the span of control the better the output variables.

Based on the recommendations given by the managers at the Big Three facilities visited, the top three variables that were utilized from the assembly facilities for this study are the span of control at the Chassis, Trim, and Assembly departments, and the outputs are Direct Run Loss First Time Capability, JPH Lost, and Injury Rate.

The purpose of this paper is to present a practical proposal for integrating production control (PC) and quality control (QC) at the shop floor level.

The proposed method is based on three principles which relate PC and QC at the shop floor level. The proposal is applied successfully at the world's largest pencil factory.

The results show that the proposed method contributes to improve four performance indicators related to PC and QC at the company studied: increase the average throughput in about 28.9 per cent; reduce the average value of work in process (WIP) in about 35.6 per cent, reduce the average lead time by about 45.4 per cent, and reduce the average defect rate by about 71.4 per cent.

The proposal (mainly because of principle III) is developed to be applied in repetitive production (RP) systems, i.e. environments characterized by low production volume and low product variety.

Some practical implications for industrial managers arises from this study: managers must consider the importance of integrated PC and QC functions in order to get better results concerning performance indicators such as throughput, WIP, lead time, and rejection rate; the materials flow simplification is a prerequisite for a lot of improvement initiatives at the shop floor level; the adequate choice of the production control system (PCS) is vital in order to get positive results regarding the performance indicators related to PC; the determination of the production pace (or rate) for a RP system must take account capacity restrictions and the influence of defect rate on production rate.

The paper is original in that it shows that the performance of the shop floor level can be improved by means of integrating PC and QC, by discussing and implementing a method which simplifies the material flow in the shop floor level, chooses the most adequate PCS and shows how the production rate influence on the rejection rate. Therefore, the paper is important for those which practice industrial management, more specifically on PC and QC functions.

This study aims to comparatively discuss the effect of lean manufacturing (LM) implementation in the manufacturing sectors of developing and developed countries.

An in-depth literature review focused on previous research published between 2015 and March 2020. The papers published by the databases such as Google Scholar, Scopus, ProQuest and Web of Science were used in the study. A total of 63 studies that focused on LM application in manufacturing industries in developing and developed countries were used in the research.

It was observed that LM improves operational performance for manufacturing organizations in developing and developed countries. Small and medium-sized enterprises in both developed and developing countries have difficulties transforming their organizations into lean organizations compared to large enterprises. Furthermore, the review also found that there seems to have been no paper had reported the negative impact of implementing LM in manufacturing industries in developing and developed countries from 2015 to March 2020.

The study used research papers written between January 2015 and March 2020 and only considered manufacturing organizations from developed and developing nations.

The study provides more insight into LM implementation in developing and developed countries. It gives the LM practices and the implications of applying these practices in manufacturing organizations for developing and developed countries.

A preliminary review of papers indicated that this seems to be the first paper that comparatively studies how LM implementation has affected manufacturing organizations in developed and developing countries. The study also assessed the LM practices commonly used by the manufacturing industries in developing and developed countries.

The purpose of this paper is to determine the efficacy of lean learning as experienced and demonstrated by a group of students who were exposed to a purpose built simulated working environment (SWE). The study expands on previous research aimed at establishing the student views of the new type of training by including the perceptions of the industry mentors.

An SWE was developed to allow students to experience an assembly line environment and practice lean tools. The students’ perceptions of the learning process and the perceptions of their industry mentors were then measured to gauge the success of the programme.

Groups of students indicated that they believed their grasp of the basic lean concepts had been significantly enhanced through exposure to the SWE teaching exercises. The outcome of this initial study was endorsed by the findings of the second study that measured the perceptions of their industry mentors after a six-month experiential learning period.

The research covered in this paper reflects only the findings of these two groups as they progressed from the SWE-type training to industry-based experiential learning. It is acknowledged that expanded research would be beneficial to not only verify initial findings but also to refine the lean learning experienced in the simulated work environment.

The paper describes a lean learning process that is more effective than current processes and could therefore be universally utilised to enhance the lean learning experience in higher education.