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Article
Publication date: 25 July 2019

Yinhua Liu, Rui Sun and Sun Jin

Driven by the development in sensing techniques and information and communications technology, and their applications in the manufacturing system, data-driven quality…

Abstract

Purpose

Driven by the development in sensing techniques and information and communications technology, and their applications in the manufacturing system, data-driven quality control methods play an essential role in the quality improvement of assembly products. This paper aims to review the development of data-driven modeling methods for process monitoring and fault diagnosis in multi-station assembly systems. Furthermore, the authors discuss the applications of the methods proposed and present suggestions for future studies in data mining for quality control in product assembly.

Design/methodology/approach

This paper provides an outline of data-driven process monitoring and fault diagnosis methods for reduction in variation. The development of statistical process monitoring techniques and diagnosis methods, such as pattern matching, estimation-based analysis and artificial intelligence-based diagnostics, is introduced.

Findings

A classification structure for data-driven process control techniques and the limitations of their applications in multi-station assembly processes are discussed. From the perspective of the engineering requirements of real, dynamic, nonlinear and uncertain assembly systems, future trends in sensing system location, data mining and data fusion techniques for variation reduction are suggested.

Originality/value

This paper reveals the development of process monitoring and fault diagnosis techniques, and their applications in variation reduction in multi-station assembly.

Details

Assembly Automation, vol. 39 no. 4
Type: Research Article
ISSN: 0144-5154

Keywords

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Article
Publication date: 27 August 2019

Nhlanhla Sibanda and Usha Ramanathan

This research is elucidating quality control theories to reduce variation in chocolate manufacturing process in the UK food company that will help maintain the processes…

Abstract

Purpose

This research is elucidating quality control theories to reduce variation in chocolate manufacturing process in the UK food company that will help maintain the processes stable and predictable. The purpose of this paper is to reduce defects of the output; to identify the root causes of variation; to establish and implement solutions to this variation problem; and to establish a control system to monitor and report any variation in the process.

Design/methodology/approach

The authors use experimental case study of a chocolate company to achieve the objective. In this paper, the authors predominantly use established theory define–measure–analyse–improve–control, customised to the case of the chocolate factory to reduce variations in production processes.

Findings

The results confirm that customised-traditional theoretical quality models will support manufacturing companies to maintain customer satisfaction while enhancing quality and reliability.

Practical implications

Implementation of customised approach reduced the rate of defect from 8 to 3.7 per cent. The implications of reduced variation are improved product quality; reprocessing elimination; and a more stable process that support sustainability and reliability in producing chocolates to meet customer needs.

Social implications

The authors used an experimental-based case study approach to test with one company. Testing in multiple case companies may help to generalise results.

Originality/value

The research study experimentally tested quality approach with a real case company and hence the findings of this study can be applied to other cases working in similar settings.

Details

International Journal of Quality & Reliability Management, vol. 37 no. 5
Type: Research Article
ISSN: 0265-671X

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Article
Publication date: 1 August 1996

Curtis P. McLaughlin

Highlights that one service industry in the USA ‐ health care ‐ has accepted high inherent rates of variation into its process designs. Notes that, increasingly, health…

Abstract

Highlights that one service industry in the USA ‐ health care ‐ has accepted high inherent rates of variation into its process designs. Notes that, increasingly, health care industry leaders recognize that elimination of unnecessary variation is a necessary, but not a sufficient, condition for producing quality professional services at reasonable costs. Using the innovation model of Boynton et al. (1993), identifies continuous improvement, rather than mass production, as the key step in the rationalization of what has been a craft industry and the ultimate objective of delivering health care in a mass customization mode. Claims, however, that it is not sufficient, because high levels of inherent variation will continue to exist and must be managed, even in the best of all possible worlds. Reviews the health care experience (in the context of that model) to suggest how service operations managers and researchers should conceptualize variation, and then discusses what that conceptualization of variation implies about how operations management should treat variation in its modelling and decision making.

Details

International Journal of Service Industry Management, vol. 7 no. 3
Type: Research Article
ISSN: 0956-4233

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Article
Publication date: 12 June 2007

James D.T. Tannock, Oluwatuminu Balogun and Hisham Hawisa

The purpose of this paper is to describe new methods to manage variation in complex manufacturing process chains and to show synergies between the variation risk…

Abstract

Purpose

The purpose of this paper is to describe new methods to manage variation in complex manufacturing process chains and to show synergies between the variation risk management (VRM) and six‐sigma approaches.

Design/methodology/approach

The research methodology was experimental prototyping conducted in collaboration with industry partners. A prototype IT system was developed and tested to implement the approach. A quality cost‐based system was used to assess variation at each operation stage, for every product characteristic.

Findings

A comprehensive approach to the management of manufacturing variation is introduced, based on a new process risk matrix which can be used to specify an individual variation risk for every manufactured characteristic, throughout a manufacturing process chain. The approach has been implemented in a prototype software system and is aimed at the complex products such as those manufactured by the aerospace industry.

Research limitations/implications

The IT approach described was developed during the research and is not commercially available.

Practical implications

Manufacturing industry should be able to use this approach, in particular the process risk matrix concept, to develop more effective management of product variation and resultant cost, in complex process chains.

Originality/value

The paper describes a novel approach to combine VRM and six‐sigma concepts, and introduces the process risk matrix as a structure to understand process variation.

Details

Journal of Manufacturing Technology Management, vol. 18 no. 5
Type: Research Article
ISSN: 1741-038X

Keywords

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Article
Publication date: 1 March 1991

R. Haworth

The management and control of random process variations is often neglected in Europe. The Japanese emphasise the control and reduction of these variations and some…

Abstract

The management and control of random process variations is often neglected in Europe. The Japanese emphasise the control and reduction of these variations and some multinationals have realised that this is an area of great potential for quality improvements. There are essentially two approaches. The first is to design the effects out of the product and therefore make it robust against both the random and the non‐random process variations. The second approach is to improve the process capability. It is stressed that if industry is to stay competitive then it must tackle product quality at all levels of design and manufacture. Some useful insights into process variation reduction are given.

Details

International Journal of Quality & Reliability Management, vol. 8 no. 3
Type: Research Article
ISSN: 0265-671X

Keywords

Content available
Article
Publication date: 13 June 2016

Diego Tlapa, Jorge Limon, Jorge L García-Alcaraz, Yolanda Baez and Cuauhtémoc Sánchez

The purpose of this paper is to extend the understanding of Six Sigma (SS) and the underlying dimensions of its critical success factors (CSF) via an analysis of the…

Abstract

Purpose

The purpose of this paper is to extend the understanding of Six Sigma (SS) and the underlying dimensions of its critical success factors (CSF) via an analysis of the effects of top management support (TMS), implementation strategy (IS), and collaborative team (CT) on project performance (PP) in Mexican manufacturing companies.

Design/methodology/approach

Based on a SS literature review, a survey was conducted to capture practitioners’ viewpoints about CSFs for SS implementation and their impact on performance in manufacturing companies. A factor analysis and structural equation modeling were conducted in order to identify and analyze causal relationships.

Findings

The results suggest that CSFs grouped in the constructs TMS, IS, and CT have a positive impact on PP as measured by cost reduction, variation reduction, and quality improvement.

Research limitations/implications

Although the empirical data collected supported the proposed model, results might differ among organizations in different countries. In addition, the study did not analyze a unique performance metric; instead, general PP dimensions were used.

Practical implications

Boosting the TMS, IS, and CT enhances positive PP of SS in manufacturing companies.

Originality/value

IS as a construct has not been studied exhaustively; this work contributes to a better understanding of it and its impact on PP. Additionally, studies of SS in Latin America are limited, so this study gives a complementary vision to practitioners and researchers about it.

Details

Industrial Management & Data Systems, vol. 116 no. 5
Type: Research Article
ISSN: 0263-5577

Keywords

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Article
Publication date: 24 May 2011

Mahesh Gupta and Lynn Boyd

The purpose of this paper is to extend the role of the theory of constraints (TOC) to complement, reinforce, and help integrate conventional operations management (OM…

Abstract

Purpose

The purpose of this paper is to extend the role of the theory of constraints (TOC) to complement, reinforce, and help integrate conventional operations management (OM) concepts by using an Excel‐based version of the dice game discussed in The Goal by Goldratt.

Design/methodology/approach

The paper discusses the motivation for and the development and evaluation of an Excel‐based dice game model of a production system for novice managers to experiment with. A set of experiments related to OM concepts (e.g. inventory, capacity, and variability) is designed and counterintuitive results are discussed. The paper concludes by demonstrating how TOC provides an integrative OM framework.

Findings

The novel The Goal by Goldratt serves as a comprehensive case study in OM. The computerized dice game provides a mechanism for understanding relationships among various OM concepts. The proposed set of experiments strengthens the linkages between OM and TOC concepts. Managers can conduct additional experiments and predict/interpret the results without spending time in the logistics of setting up the manual dice game repeatedly.

Research limitations/implications

The proposed dice game simulates a fairly simple serial production system so the generalization of results obtained might not be intuitively convincing for more complex production systems. More advanced OM concepts such as push (MRP) and pull (JIT) systems can easily be investigated using the underling logic of the dice game proposed here.

Practical implications

The model provides an innovative way to integrate TOC concepts with mainstream OM concepts and thereby, renews interest in OM.

Originality/value

Several versions of dice games, both manual and spreadsheet based, have appeared in the literature, however, none attempt to address as wide a variety of operations issues as the game proposed here.

Details

International Journal of Operations & Production Management, vol. 31 no. 6
Type: Research Article
ISSN: 0144-3577

Keywords

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Article
Publication date: 7 March 2016

Basant Chaurasia, Dixit Garg and Ashish Agarwal

Today’s global business environment essential requirement to an industries reduction of wastes, reduction of variations, reduction of lead time and innovative feature…

Abstract

Purpose

Today’s global business environment essential requirement to an industries reduction of wastes, reduction of variations, reduction of lead time and innovative feature quality product with minimum cost. That strives to improve customer satisfaction, break through strategies to solve problems with fastest process speed. Lean Six Sigma (LSS) strategy and framework can help during recession or upcoming recession to improve business excellencies and companies strategies against recession. The paper aims to discuss these issues.

Design/methodology/approach

The paper followed views of authors, industrial experts from oil industries regarding LSS strategy, framework, comparative key factors of Lean and Six Sigma to overcome continuously decline oil prices globally. LSS strategy will proactively work as preventive tool for insipid economical growth of oil-exporting countries.

Findings

To follow the LSS guidelines, oil-exporting countries can improve their business performance during ongoing oil price fall that may be influenced on gross domestic product of countries.

Originality/value

The case study may provide some help to survive ongoing crisis of continuously fallen oil price that is highly problematic for oil-exporting countries.

Details

International Journal of Productivity and Performance Management, vol. 65 no. 3
Type: Research Article
ISSN: 1741-0401

Keywords

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Article
Publication date: 31 July 2008

Nusser Raajpoot, Rubina Javed and Khoon Koh

The purpose of this paper is to introduce the concept of robust design in retail service literature.

Abstract

Purpose

The purpose of this paper is to introduce the concept of robust design in retail service literature.

Design/methodology/approach

Using a Taguchi design comprising of inner L8 (27) and outer 22 arrays, a discrete choice task was designed for 233 students respond to. Signal‐to‐noise (S/N) ratio was used to test design robustness.

Findings

Negative effects of uncontrollable design factors on service choice were minimized through the use of inner and outer Taguchi arrays. The single composite measure of consumer choice called S/N ratio accounted both for mean and variance of choice probabilities.

Research limitations/implications

Use of student sample was a major limitation. Also, the interaction between design factors was not tested as it required the use of more complicated designs.

Practical implications

This method can be used to improve design robustness by minimizing the impact of uncontrollable noise factors. Use of S/N ratio can help to select the design that simultaneously maximized the choice probabilities and minimized performance variation.

Originality/value

The paper makes important methodological and operational contributions to the retail service design literature. First, the concept of controllable and uncontrollable factors in choice‐based designs is introduced. Second, the use of S/N ratio as a single, composite measure of design robustness was incorporated. Operationally, this study highlights the impact of less‐studied concepts of wayfinding and customer incompatibility on satisfaction of retail customers.

Details

International Journal of Commerce and Management, vol. 18 no. 2
Type: Research Article
ISSN: 1056-9219

Keywords

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Article
Publication date: 12 February 2021

Pramod Kumar, Dharmendra Singh and Jaiprakash Bhamu

The purpose of this paper is to develop and validate an extended Define-Measure-Analyze-Improve-Control (DMAIC) based framework through a case study of an Indian fasteners…

Abstract

Purpose

The purpose of this paper is to develop and validate an extended Define-Measure-Analyze-Improve-Control (DMAIC) based framework through a case study of an Indian fasteners manufacturing organization.

Design/methodology/approach

Research methodology is established on the development of the existing DMAIC framework through an extensive literature review of 25 LSS/DMAIC based frameworks and discussions held with practitioners. This paper also depicts a case study of Indian manufacturing organization for validation of the developed framework.

Findings

The study proposed an extended DMAIC based framework for effective implementation of Lean Six Sigma (LSS) methodology. Furthermore, this framework has been implemented successfully in the Indian manufacturing organization and showed encouraging results. The in-house rejections of Nut Cylinder Head (NCH) were brought down to 966 from 2910 PPM and sigma level was improved by 0.40. The case organization has achieved significant improvements in the process capability, customer satisfaction, and cost savings of US$ 0.25 million in one financial year. Intangible benefits like improvements in employee's morale, communication, housekeeping and decision-making capabilities were also observed significantly.

Practical implications

The proposed DMAIC based framework has been implemented successfully in the Indian case organization, and the results will enable the policymakers, specifically practitioners, to strategically leverage the resources for successful implementation of the LSS in healthcare, aerospace, service sectors etc.

Originality/value

This research develops a DMAIC based framework which can be used to implement LSS effectively in different industries. Moreover, the pre (initial/introduction) and post (validation/verification) implementation phase provides the top management, an edge to think strategically into broader improvement areas.

Details

International Journal of Quality & Reliability Management, vol. ahead-of-print no. ahead-of-print
Type: Research Article
ISSN: 0265-671X

Keywords

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