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The purpose of this paper is to understand how the full potential of the global phenomenon “Six Sigma” can be realised in low volume, high complex manufacturing.

The research reported on in this paper is based on a case study company – ComplexCo plc. A questionnaire to gauge user perceptions about the tools and techniques was used, combined with interviews with five master black belts (MBB) which were conducted as part of the study. The usefulness and the frequency of use of common Six Sigma tools and techniques as deployed in low volume complex manufacturing was gauged and also the identification of the key challenges faced during Six Sigma deployment in ComplexCo are explored.

The analysis clearly shows that the difficulty in acquiring data is restricting the use of analytically biased tools during the analyse phase of DMAIC (Define Measure Analyse Improve Control). It was also evident, through all stages of DMAIC, that the “softer” tools are deployed more often and the usefulness rank higher than for the “harder” tools. Finally an alternative to the traditional DPMO metric was developed called “% Right First Time”.

The paper is based on a single case study company and so the results from the study are not currently widely generalisable.

There is a lack of literature available which explores the deployment of Six Sigma in low volume, high complex manufacturing environments. This paper contributes to the body of knowledge through the establishment of adaptations, which both ComplexCo and other organisations can use to successfully deploy Six Sigma programmes in low volume and high complex manufacturing.

Several authors have proposed different approaches to help practitioners deal with the complexity of prioritising improvement projects and initiatives. However, these approaches have been developed as “generic” methods which do not consider the specific needs, objectives and capabilities of different industries and organisations. The purpose of this paper is to present an integrated methodology that prioritises improvement projects or initiatives based on two key performance objectives, cost and quality, specifically important for low volume‐high integrity product manufacturers.

The paper reviews some of the most commonly used prioritisation methods and the theory and logic behind the proposed prioritisation methodology. Then, the prioritisation methodology is empirically tested, through a case study, in a world class manufacturing organisation.

The results obtained from the case study indicate that the integrated methodology proposed in this paper is an effective alternative for low volume‐high integrity products manufacturers to identify, select and justify improvement priorities.

Selection and prioritisation of projects and initiatives are key elements for the successful implementation of improvements. The integrated methodology presented in this paper intends to aid organisations in dealing with the complexity that is normally handled over the selection and prioritisation of feasible improvement projects.

This paper presents a novel methodology that integrates two commonly used approaches in industry, Process Activity Mapping (PAM) and Failure Mode and Effect Analysis (FMEA), to prioritise improvements. This methodology can help, in particular, organisations embarked in the manufacture of low volume‐high integrity products to take better decisions and align the focus of improvement efforts with their overall performance and strategic objectives.

The purpose of this paper is to investigate the productivity performance at the firm level from the perspective of manufacturing capability development at the process level. Moreover, it reveals how alignment of manufacturing capabilities with market requirements has influenced a firm’s productivity over a period that includes the 2008 global recession.

A conceptual framework was derived from established theories and employed as part of a case study design encompassing a multiple methods research approach. The case of a UK SME was selected to reflect some of the issues associated with the wider productivity stagnation experienced by the UK economy in recent years.

The firm’s manufacturing strategy had become incrementally misaligned with market requirements due to external changes in its business environment. The complex relationships between capabilities such as quality, speed and cost were characterised. Realigning the firm’s manufacturing strategy to regain productivity performance required a range of prioritised actions including capital investment and changes in management practices concerning bottom-up process improvement and regular, top-down strategy review.

The findings of the case study cannot be generalised and the outcomes are specific to just one firm. However, the approach lends itself to replication, particularly within SMEs.

Prior studies have focussed on capability development at higher levels of abstraction. The study operationalized established theoretical perspectives at the firm level to derive context-based outcomes that can be used to improve manufacturing strategy alignment and productivity. Furthermore, the study contributes empirical evidence from the SME sector to the ongoing debate regarding the UK’s productivity puzzle.

Fabrication of customized products in low volume through conventional manufacturing incurs a high cost, longer processing time and huge material waste. Hence, the concept of additive manufacturing (AM) comes into existence and fused deposition modelling (FDM), is at the forefront of researches related to polymer-based additive manufacturing. The purpose of this paper is to summarize the research works carried on the applications of FDM.

In the present paper, an extensive review has been performed related to major application areas (such as a sensor, shielding, scaffolding, drug delivery devices, microfluidic devices, rapid tooling, four-dimensional printing, automotive and aerospace, prosthetics and orthosis, fashion and architecture) where FDM has been tested. Finally, a roadmap for future research work in the FDM application has been discussed. As an example for future research scope, a case study on the usage of FDM printed ABS-carbon black composite for solvent sensing is demonstrated.

The printability of composite filament through FDM enhanced its application range. Sensors developed using FDM incurs a low cost and produces a result comparable to those conventional techniques. EMI shielding manufactured by FDM is light and non-oxidative. Biodegradable and biocompatible scaffolds of complex shapes are possible to manufacture by FDM. Further, FDM enables the fabrication of on-demand and customized prosthetics and orthosis. Tooling time and cost involved in the manufacturing of low volume customized products are reduced by FDM based rapid tooling technique. Results of the solvent sensing case study indicate that three-dimensional printed conductive polymer composites can sense different solvents. The sensors with a lower thickness (0.6 mm) exhibit better sensitivity.

This paper outlines the capabilities of FDM and provides information to the user about the different applications possible with FDM.

The purpose of this paper is to demonstrate the application of vendor rationalization strategy for streamlining the supplies and manufacturing cycle time reduction in an Indian engineer-to-order (ETO) company. ETO firms are known for a large number of vendors, co-ordination hassles, rework problems and its impact on cycle time and operational excellence.

The research demonstrates the case-based application of Kraljic’s matrix for supply and leverages items, on-the-job observations, field visits, discussions and analysis of supplies reports.

The study guides on the rationalization of supplies and the necessary strategic alignments that can significantly reduce supply risk, costs, manufacturing and delivery cycle time along with co-ordination hassles. The study depicts the challenges of ETO environment with respect to supplies, and demonstrates the effectiveness of vendor rationalization application for the case company and weaknesses of commonly practiced vendor management approaches.

To be competitive, companies should rationalize supply items and vendors based on the nature of items and their subsequent usage by applying Kraljic’s matrix-based classification. The immediate implication of vendor rationalization is misunderstood as reducing supply base, but it does much more and includes review of supplies, nature of items and strategic alignments, leading to win-win situation for company and suppliers.

For the rationalization of supplies, while procuring and dealing with vendors, executives should envisage engineering nature of components, considering cross-functional requirements and integration of components in context to ETO products/projects environments. There is a dearth of studies focusing on vendor rationalization aspects in ETO setups in fast-developing country context.

An automated sheet‐metal manufacturing systems for low‐volume production utilises an industrial robot to move blanks from a store to a press brake.

The purpose of this paper is to explore concepts and manufacturing issues for the emerging piezo on silicon technology being used in ultra‐sound devices. Development of 3D silicon‐on‐silicon structures is now under way. Additional functionality can be achieved using piezoelectric‐on‐silicon structures and work in this area has started. A commercialisation road map is required, specifying development of the design and fabrication techniques from research to high volume and lower volume high‐value manufacture of niche products.

This conceptual paper outlines processes needed, along with their possible sources with illustrations of present capabilities. Included are surface finishing techniques such as grinding, bonding technology for dissimilar materials, and through‐wafer‐via fabrication. Control of acoustic propagation, thermal expansion and electric field fringing effects will be considered.

Areas that require research and development are identified with possible starting points using techniques already used in other applications. Strong emphasis on empirical research highlights possible issues with examples including surface finishing and wafer dicing to show current methods.

Archetypal pixellated piezoelectric‐on‐silicon structures highlight critical points. In the authors' work, such pixellated structures occur in 1‐3 connectivity piezoelectric ceramic‐polymer composites with unit cell length scales from several millimetres, manufactured with mechanical dicing, to less than 50 μm, manufactured with micro‐moulding.

A forward looking approach of “thinking freely” is taken, this opens up potential manufacturing routes and ideas precluded from an iterative approach.

The conclusion suggests the criteria for a “design for” approach linked to either bottom up or top down assembly techniques for the integration of conventional and unusual piezoelectric materials with silicon in 3D structures.

Laser cutting of sheet metal in both the flat and pressed form is a well‐established technique which has been used for many years. The limitations of this process are a relatively slow speed of operation and the high capital and running costs of operating lasers. The quality of edge finish and dangers of working with lasers are additional disadvantages of the technology. Contour Cutting Technology Limited have now developed a multi‐axis plasma cutting system which produces a high‐quality finish at speeds three or four times the speed of lasers, and at around 40 per cent of the capital cost of a comparable laser system. Material from 0.8mm up to about 6mm can be successfully cut with a good quality edge finish.

The creation of well‐designed products is widely acknowledged as an important contributor to company success. In principle, an effective design process, as part of the wider new product development (NPD) process, should result in well‐designed products. This paper aims to present a tool to enable a design team to evaluate their design process in a workshop setting, with a view to targeting improvements.

This tool is based on literature and has been iteratively developed using a mixed research approach, including detailed exploratory cases and application in action research mode.

The resulting tool comprises two main components. A “process audit” based on process maturity principles, which targets the design‐related activities in NPD. The process audit enables a company team to identify improvement opportunities in the design process. A product audit enables perceptions towards product characteristics to be assessed. The audit tool does not seek to be a benchmarking tool, but aims to capture “good design” principles in a form which is accessible and useful to practitioners.

In use, the tool enabled managers to balance their concern with meeting budget and timescale demands against the importance of producing well‐designed products. By first focusing on the tangible output of the design process – the product – practitioners are better able to understand the way in which design decisions influence product usability, desirability and producibility. Evidence from cases confirms the value and originality of this tool.

Previous tools addressing product development have focused on strategic and managerial concerns. This novel assessment tool focuses explicitly on design issues, within the wider context of NPD.

Fused filament fabrication (FFF) is a type of additive manufacturing (AM) based on materials extrusion. It is the most widely practiced AM route, especially used for polymer-based rapid prototyping and customized product fabrication in relation to aerospace, automotive, architecture, consumer goods and medical applications. During FFF, part quality (surface finish, dimensional accuracy and static mechanical strength) is greatly influenced by several process parameters. The paper aims to study FFF parametric influence on aforesaid part quality aspects. In addition, dynamic analysis of the FFF part is carried out.

Interpretive structural modelling is attempted to articulate interrelationships that exist amongst FFF parameters. Next, a few specimens are fabricated using acrylonitrile butadiene styrene plastic at varied build orientation and build style. Effects of build orientation and build style on part’s ultimate tensile strength, flexure strength along with width build time are studied. Prototype beams (of different thickness) are fabricated by varying build style. Instrumental impact hammer Modal analysis is performed on the cantilever beams (cantilever support) to obtain the natural frequencies (first mode). Parametric influence on natural frequencies is also studied.

Static mechanical properties (tensile and flexure strength) are greatly influenced by build style and build orientation. Natural frequency (NF) of prototype beams is highly influenced by the build style and beam thickness.

FFF built parts when subjected to application, may have to face a variety of external dynamic loads. If frequency of induced vibration (due to external force) matches with NF of the component part, resonance is incurred. To avoid occurrence of resonance, operational frequency (frequency of externally applied forces) must be lower/ higher than the NF. Because NF depends on mass and stiffness, and boundary conditions, FFF parts produced through varying build style may definitely correspond to varied NF. This aspect is explained in this work.