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1 – 10 of 33Felipe Terra Mohad, Leonardo de Carvalho Gomes, Guilherme da Luz Tortorella and Fernando Henrique Lermen
Total productive maintenance consists of strategies and procedures that aim to guarantee the entire functioning of machines in a production process so that production is not…
Abstract
Purpose
Total productive maintenance consists of strategies and procedures that aim to guarantee the entire functioning of machines in a production process so that production is not interrupted and no loss of quality in the final product occurs. Planned maintenance is one of the eight pillars of total productive maintenance, a set of tools considered essential to ensure equipment reliability and availability, reduce unplanned stoppage and increase productivity. This study aims to analyze the influence of statistical reliability on the performance of such a pillar.
Design/methodology/approach
In this study, we utilized a multi-method approach to rigorously examine the impact of statistical reliability on the planned maintenance pillar within total productive maintenance. Our methodology combined a detailed statistical analysis of maintenance data with advanced reliability modeling, specifically employing Weibull distribution to analyze failure patterns. Additionally, we integrated qualitative insights gathered through semi-structured interviews with the maintenance team, enhancing the depth of our analysis. The case study, conducted in a fertilizer granulation plant, focused on a critical failure in the granulator pillow block bearing, providing a comprehensive perspective on the practical application of statistical reliability within total productive maintenance; and not presupposing statistical reliability is the solution over more effective methods for the case.
Findings
Our findings reveal that the integration of statistical reliability within the planned maintenance pillar significantly enhances predictive maintenance capabilities, leading to more accurate forecasts of equipment failure modes. The Weibull analysis of the granulator pillow block bearing indicated a mean time between failures of 191.3 days, providing support for optimizing maintenance schedules. Moreover, the qualitative insights from the maintenance team highlighted the operational benefits of our approach, such as improved resource allocation and the need for specialized training. These results demonstrate the practical impact of statistical reliability in preventing unplanned downtimes and informing strategic decisions in maintenance planning, thereby emphasizing the importance of your work in the field.
Originality/value
In terms of the originality and practicality of this study, we emphasize the significant findings that underscore the positive influence of using statistical reliability in conjunction with the planned maintenance pillar. This approach can be instrumental in designing and enhancing component preventive maintenance plans. Furthermore, it can effectively manage equipment failure modes and monitor their useful life, providing valuable insights for professionals in total productive maintenance.
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Ashutosh Samadhiya and Rajat Agrawal
Sustainability performances (SPs) are the most crucial performances for an organisation in today's world, and they can be measured by economic, social, and environmental metrics…
Abstract
Purpose
Sustainability performances (SPs) are the most crucial performances for an organisation in today's world, and they can be measured by economic, social, and environmental metrics. Previous research has not been clear on the role of total productive maintenance (TPM) in the context of sustainability, which motivates the authors to investigate the relationship between TPM and various SPs of the manufacturing firm. Therefore, current research investigates the relationship between TPM and the overall sustainability of the manufacturing firm from the perspective of resource-based view (RBV) theory.
Design/methodology/approach
The current study proposed, tested and validated a conceptual framework using partial least squares structural equation modelling (PLS-SEM). A total of 326 responses were received to validate the conceptual framework in smartsPLS 3.0 software.
Findings
The research outcomes indicate that TPM considerably impacts a manufacturing firm's economic, environmental and social performance.
Research limitations/implications
This research demonstrates that outstanding shop floor behaviour, such as TPM, can become an important asset to offer competitive advantages in a manufacturing firm. Similarly, TPM might serve as a roadmap for leveraging overall sustainability for manufacturing companies. The study indicates the establishment of a sustainability-oriented training protocol while practising TPM.
Originality/value
No past investigation indicates that a shop floor activity like TPM could be used as an input to offer sustainability in a single index for a manufacturing firm from the perception of RBV theory.
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Anna Trubetskaya, Alan Ryan, Daryl John Powell and Connor Moore
Output from the Irish Dairy Industry has grown rapidly since the abolition of quotas in 2015, with processors investing heavily in capacity expansion to deal with the extra milk…
Abstract
Purpose
Output from the Irish Dairy Industry has grown rapidly since the abolition of quotas in 2015, with processors investing heavily in capacity expansion to deal with the extra milk volumes. Further capacity gains may be achieved by extending the processing season into the winter, a key enabler for which being the reduction of duration of the winter maintenance overhaul period. This paper aims to investigate if Lean Six Sigma tools and techniques can be used to enhance operational maintenance performance, thereby releasing additional processing capacity.
Design/methodology/approach
Combining the Six-Sigma Define, Measure, Analyse, Improve, Control (DMAIC) methodology and the structured approach of Turnaround Maintenance (TAM) widely used in process industries creates a novel hybrid model that promises substantial improvement in maintenance overhaul execution. This paper presents a case study applying the DMAIC/TAM model to Ireland’s largest dairy processing site to optimise the annual maintenance shutdown. The objective was to deliver a 30% reduction in the duration of the overhaul, enabling an extension of the processing season.
Findings
Application of the DMAIC/TAM hybrid resulted in process enhancements, employee engagement and a clear roadmap for the operations team. Project goals were delivered, and original objectives exceeded, resulting in €8.9m additional value to the business and a reduction of 36% in the duration of the overhaul.
Practical implications
The results demonstrate that the model provides a structure that promotes systematic working and a continuous improvement focus that can have substantial benefits for wider industry. Opportunities for further model refinement were identified and will enhance performance in subsequent overhauls.
Originality/value
To the best of the authors’ knowledge, this is the first time that the structure and tools of DMAIC and TAM have been combined into a hybrid methodology and applied in an Irish industrial setting.
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Sameh M. Saad, Ramin Bahadori, Chandan Bhovar and Hongwei Zhang
This paper aims to analyse the current state of research to identify the link between Lean Manufacturing and Industry 4.0 (I4.0) technologies to map out different research themes…
Abstract
Purpose
This paper aims to analyse the current state of research to identify the link between Lean Manufacturing and Industry 4.0 (I4.0) technologies to map out different research themes, to uncover research gaps and propose key recommendations for future research, including lessons to be learnt from the integration of lean and I4.0.
Design/methodology/approach
A systematic literature review (SLR) is conducted to thematically analyse and synthesise existing literature on Lean Manufacturing–I4.0 integration. The review analysed 60 papers in peer-reviewed journals.
Findings
In total, five main research themes were identified, and a thematic map was created to explore the following: the relationship between Lean Manufacturing and I4.0; Lean Manufacturing and I4.0 implication on performance; Lean Manufacturing and I4.0 framework; Lean Manufacturing and I4.0 integration with other methodologies; and application of I4.0 technologies in Lean Manufacturing. Furthermore, various gaps in the literature were identified, and key recommendations for future directions were proposed.
Research limitations/implications
The integration of Lean Manufacturing and I4.0 will eventually bring many benefits and offers superior and long-term competitive advantages. This research reveals the need for more analysis to thoroughly examine how this can be achieved in real life and promote operational changes that ensure enterprises run more sustainably.
Originality/value
The development of Lean Manufacturing and I4.0 integration is still in its infancy, with most articles in this field published in the past two years. The five main research themes identified through thematic synthesis are provided in the original contribution. This provides scholars better insight into the existing literature related to Lean Manufacturing and I4.0, further contributing to defining clear topics for future research opportunities. It also has important implications for industrialists, who can develop more profound and richer knowledge than Lean and I4.0, which would, in turn, help them develop more effective deployment strategies and have a positive commercial impact.
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Mahadev Laxman Naik and Milind Shrikant Kirkire
Asset maintenance in manufacturing industries is a critical issue as organizations are highly sensitive towards maximizing asset uptime. In the advent of Industry 4.0, maintenance…
Abstract
Purpose
Asset maintenance in manufacturing industries is a critical issue as organizations are highly sensitive towards maximizing asset uptime. In the advent of Industry 4.0, maintenance is increasingly becoming technology driven and is being termed as Maintenance 4.0. Several barriers impede the implementation of Maintenance 4.0. This article aims at - exploring the barriers to implementation of Maintenance 4.0 in manufacturing industries, categorizing them, analysing them to prioritize and suggesting the digital technologies to overcome them.
Design/methodology/approach
Twenty barriers to the implementation of Maintenance 4.0 were identified through literature survey and discussion with the industry experts. The identified barriers were divided into five categories based on their source of occurrence and prioritized using fuzzy-technique for order preference by similarity to ideal solution (TOPSIS), sensitivity analysis was carried out to check the robustness of the solution.
Findings
“Data security issues” has been ranked as the most influencing barrier towards the implementation of Maintenance 4.0, whereas “lack of skilled engineers and data scientists” is the least influencing barrier that impacts the implementation of Maintenance 4.0 in the manufacwturing industries.
Practical implications
The outcomes of this research will help manufacturing industries, maintenance engineers/managers, policymakers, and industry professionals for detailed understanding of barriers and identify easy pickings while implementing Maintenance 4.0.
Originality/value
Manufacturing industries are witnessing a paradigm shift due to digitization and maintenance 4.0 forms the cornerstone. Little research has been carried in Maintenance 4.0 and its implementation; this article will help in bridging the gap. The prioritization of the barriers and digital course of actions to overcome those is a unique contribution of this article.
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Osamu Tsukada, Ugo Ibusuki, Shigeru Kuchii and Anderson Tadeu de Santi Barbosa de Almeida
The purpose of this study is to explore the relationship between Lean manufacturing and Industry 4.0 for small and medium size of enterprise in Japan and Brazil.
Abstract
Purpose
The purpose of this study is to explore the relationship between Lean manufacturing and Industry 4.0 for small and medium size of enterprise in Japan and Brazil.
Design/methodology/approach
The authors conducted a quantitative survey (20 companies in Japan and 30 companies in Brazil) combined with a qualitative interview (2 companies in Japan and 15 companies in Brazil).
Findings
According to the quantitative study, 90% of them practice Lean manufacturing and 40% of them practice Industry 4.0. In the qualitative study in Brazil, four managers responded that the Lean manufacturing is a prerequisite for Industry 4.0 since any production process with waste cannot be productive, even with sophisticated digitalization technology.
Originality/value
The authors explored further the relationship between “defensive Digital Transformation (DX),” which is based mainly on Lean manufacturing, and “offensive DX,” which relates to customer value creation through Industry 4.0. This study clarifies the relationship and plays as a roadmap to develop better the manufacturing from current status to the vision of Industry 4.0.
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Dan Bumblauskas, Russell P. Guay and Steve Forbes
Prisons can utilize effective business process, operations management and continuous improvement techniques to provide an opportunity to support the rehabilitation of inmates. The…
Abstract
Purpose
Prisons can utilize effective business process, operations management and continuous improvement techniques to provide an opportunity to support the rehabilitation of inmates. The purpose of this paper is to analyze the Iowa Prison Industries (IPI) work training program offered for incarcerated individuals under the supervision of the Iowa Department of Corrections (IDOC).
Design/methodology/approach
The IPI developed an Operational Excellence (OpEx) apprenticeship program that has worked with approximately 800 incarcerated “associates” to help them acquire skills necessary to obtain gainful employment upon release. This includes skills and belt level assessment in Lean Six Sigma as well as 6S/5S events and training. These techniques have been deployed by 22 teams at seven locations across the state of Iowa (USA). These sites have established objectives and goals and provided significant security-related benefits in the correctional industries environment.
Findings
Findings and success outcomes have been encouraging as those who completed the IPI apprenticeship program had lower recidivism, higher wages and more employability compared to the general prison population.
Social implications
The rehabilitation of incarcerated individuals is critical to society. This novel and unique case study reviews one approach to providing work and life skills (such as esteem-building professional and personal skill sets) to support this process within the prison system.
Originality/value
This OpEx program has provided numerous benefits to both IPI and the incarcerated individuals. We feel that these findings could be beneficial to other correctional institutions and better prepare more inmates for a successful return to the workforce and to society.
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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.
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Elena Stefana, Paola Cocca, Federico Fantori, Filippo Marciano and Alessandro Marini
This paper aims to overcome the inability of both comparing loss costs and accounting for production resource losses of Overall Equipment Effectiveness (OEE)-related approaches.
Abstract
Purpose
This paper aims to overcome the inability of both comparing loss costs and accounting for production resource losses of Overall Equipment Effectiveness (OEE)-related approaches.
Design/methodology/approach
The authors conducted a literature review about the studies focusing on approaches combining OEE with monetary units and/or resource issues. The authors developed an approach based on Overall Equipment Cost Loss (OECL), introducing a component for the production resource consumption of a machine. A real case study about a smart multicenter three-spindle machine is used to test the applicability of the approach.
Findings
The paper proposes Resource Overall Equipment Cost Loss (ROECL), i.e. a new KPI expressed in monetary units that represents the total cost of losses (including production resource ones) caused by inefficiencies and deviations of the machine or equipment from its optimal operating status occurring over a specific time period. ROECL enables to quantify the variation of the product cost occurring when a machine or equipment changes its health status and to determine the actual product cost for a given production order. In the analysed case study, the most critical production orders showed an actual production cost about 60% higher than the minimal cost possible under the most efficient operating conditions.
Originality/value
The proposed approach may support both production and cost accounting managers during the identification of areas requiring attention and representing opportunities for improvement in terms of availability, performance, quality, and resource losses.
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Abul Bashar, Ahsan Akhtar Hasin, Samrat Ray, Md. Nazmus Sakib, Md. Mahbubur Rahman and Nabila Binta Bashar
Lean Manufacturing Systems (LMS) gained popularity among manufacturers globally. However, their efficacy in developing and least-developed countries remained noticeably…
Abstract
Purpose
Lean Manufacturing Systems (LMS) gained popularity among manufacturers globally. However, their efficacy in developing and least-developed countries remained noticeably understudied. Motivated by this research gap, the researchers of this study designed a quantitative study with a structured survey technique to investigate its context-specific impact on the apparel industry of a developing country. Hence, this study aimed to examine the relationship between LMS and elimination of waste (EOW) and operational performance (OP) and comprehend how the EOW mediates the relationship between an LMS and OP within the apparel industry of a developing economy.
Design/methodology/approach
The researchers collected data from 227 garment companies in Bangladesh. These organization-level data were then analyzed using the structural equation modeling approach with AMOS 20.0 software to examine the direct and indirect effects among EOW, LMS and OP.
Findings
The findings of this study suggest that EOW has a direct and significant effect on OP. This research also revealed that EOW has a partial mediating effect on the relationship between LMS and OP.
Research limitations/implications
This research focused on a single industry administering self-reported data and cross-sectional design, limiting generalizability and causal inference.
Practical implications
LMS and directing efforts towards EOW can significantly improve the operational performance of apparel companies by reducing lead times and costs, improving quality and increasing productivity.
Originality/value
These findings can provide useful insight to managers, practitioners and future researchers to understand the relationship between EOW, LMS and OP to optimize their production processes and improve OP in the apparel industry.
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