Showing papers in "International Journal of Manufacturing Technology and Management in 2000"

Information sharing in a supply chain

Abstract: Advances in information system technology have had a huge impact on the evolution of supply chain management. As a result of such technological advances, supply chain partners can now work in tight coordination to optimise the chain-wide performance, and the realised return may be shared among the partners. A basic enabler for tight coordination is information sharing, which has been greatly facilitated by the advances in information technology. This paper describes the types of information shared inventory, sales, demand forecast, order status, and production schedule. We discuss how and why this information is shared using industry examples and relating them to academic research. We also discuss three alternative system models of information sharing - the information transfer model, the third party model and the information hub model.

Reconfigurable manufacturing systems and their enabling technologies

Abstract: A reconfigurable manufacturing system (RMS) is designed for rapid adjustment of production capacity and functionality in response to new market conditions and new process technology. It has several distinct characteristics including modularity, integrability, customisation, convertibility and diagnosability. There are a number of key interrelated technologies that should be developed and implemented to achieve these characteristics. This paper examines and identifies these technologies. After a brief description of the RMSs and their goals, aspects of reconfiguration (reconfigurable system, software, controller, machine, and process) are explained; this provides one with a better understanding of the enabling technologies of RMSs. Some of the issues related to the technology requirements of RMSs at the system and machine design levels, and ramp -up time reduction are then explained. The paper concludes with descriptions of some of the future research directions for RMSs.

Complex systems theory: implications and promises for manufacturing organisations

Abstract: This paper discusses the body of knowledge known as complex systems theory and its relevance to manufacturing organisations. It begins by addressing the development of systems thinking, in order to explore the different views on how systems should be studied. This initial commentary provides an introduction to the concepts of the complex systems theory approach, along with its various metaphors, tools and techniques. This is followed by a discussion on how manufacturing organisations conform to complex systems theory, and in particular complex adaptive systems. An account of the complex systems characteristics of manufacturing organisations, and the relationship between manufacturing complexity is also given. Finally, the paper concludes by discussing the potential application and advantage for manufacturing organisations from using a complex systems theory approach to model, understand and in some cases optimise manufacturing operations and strategy.

Developing manufacturing agility in SMEs

Abstract: The problem of manufacturing in the late twentieth century can be seen as the latest version of two long-standing puzzles to do with responding to demanding internal and external environments. The continuing search for solutions to these puzzles leads to investment in innovation - via R&D, technology transfer, etc. But evidence suggests that the key requirement is not solving the puzzle for one set of circumstances but in continually solving problems as the puzzles mutate. This places emphasis on organisational capability - it is not what you know or what you can buy but how well you learn and adapt which is the key. We term this "manufacturing agility" - and this paper explores the definition in terms of the "dynamic capability" view of strategic management. This paper draws on case study research being carried out as part of a major UK program of work in manufacturing agility. The paper presents a reference model which seeks to explain and guide the development of agility within manufacturing enterprises.

Using the Competing Values Framework to identify the ideal culture profile for TQM: a UK perspective

Abstract: There is growing concern about why some organisations fail in their attempts to implement TQM and so few gain the benefits of such implementation. The literature often points to the constraining effects of an organisation's culture as a major barrier. Few studies, however, link organisational culture and TQM implementation. In short, understanding the relationship between an organisation's culture and TQM philosophy can provide a greater insight into the TQM implementation process. A well known framework for an organisational model, the Competing Values Framework (CVF), was used to identify the ideal cultural profile for TQM implementation. A questionnaire using the CVF, was sent to "Quality Experts" in the UK to help identify the ideal cultural characteristics that they believed would support the TQM philosophy and facilitate its implementation. The findings indicated that the ideal cultural characteristics in the context of TQM can be classified as a group and developmental culture. Its characteristics tend to be flexible and customer oriented which emphasises participation, innovation, concern for human resource development and an attempt to decentralise decision making. This paper shows that the CVF can be a useful tool in helping organisations study the change needed to reach a desired quality culture.

A Path-based Approach To Information Technology in Manufacturing

Abstract: Two archetypal approaches to performance improvement in operations are to undertake periodic "strategic leaps" or to take frequent small actions in a quest for "continuous improvement". Much research on the implementation of advanced manufacturing technologies (AMTs) indicates that even though their introduction appears to be a strategic leap, principles of continuous improvement can be important in determining success. Three such principles are: modularity, accessibility, and inclusiveness. These principles are applied to non-shop floor information technology, an important category of AMT. The monolithic information technologies that have historically been dominant are characterised both by low levels of modularity, accessibility and inclusiveness, and by an installation-based approach to implementation. Recent innovations, however, permit a substantively different, path-based approach. The migration from installation- to path-based approaches is illustrated with the example of enterprise resource planning (ERP) systems. The modularity and accessibility of ERP systems appear to be improving, while inclusiveness lags.

Manufacturing in the 21st Century

Abstract: Manufacturing in the early decades of the 21st Century will reflect continuation of trends and developments in the last quarter of the 20th Century. The accumulated effects of those trends will alter many aspects of manufacturing. For example, the increasing role of information technology will affect the manufacturing system from vendors and suppliers through production and on to delivery to customers and consumers, and waste disposal. Social forces, such as the environmental movement through pressures for recycling, reclamation and remanufacturing, will affect the choice of materials, design for dismantlement, and manufacturing for maintenance and repair. New tools and factors will come into play using micromachines in the early decades of the 21st Century. There may even be practical nanomachines. The vast new developments created by molecular genetics will develop new markets for manufacturing. Virtual reality design, test and evaluation will improve the quality of all products.

Engineering design change management

Abstract: Outlines the economic consequences of changes that are made during the design process and manufacture. Computer and paper based systems are considered, and the advantages of a computer based system are discussed. Experience in the use of a computer based system in a company is reviewed with respect to the sources of design changes, the control of design changes and the benefits gained. The use of bespoke and proprietary software is briefly discussed. Notes that engineering design change management plays an essential role in successful manufacturing organisations. Also notes that the bespoke system described has led to a considerable improvement in the company’s change control process.

Developing an exploratory model to determine the link between organisational culture, leadership style and contingency factors on the corporate strategy of manufacturing SMEs

Abstract: It is broadly accepted that manufacturing Small and Medium Size Enterprises (SMEs) play a vital role in the economic health of the country. A clearer understanding of the factors that influence the performance of SMEs can help: a) policy makers develop more relevant policies; b) support agencies design and deliver a more appropriate support package, c) education and training establishments design more appropriate and relevant education and training programs, and d) owner/mangers by clarifying, articulating and codifying the key variables. In fact, lack of deep understanding is signalled by some as a major reason for the failure of a number of initiatives designed to make SMEs more competitive. In this paper, the authors present a model of variables that can affect the performance of SMEs. This model was developed through in-depth semi-structured interviews with owner/managers of 20 manufacturing SMEs. Moreover, the authors test the validity of this inductive model using existing literature.

Changing to a lean organisation: the case of a chemicals company

Abstract: This paper will describe the development of an analytical tool - the Manufacturing Business Strategic Framework - which highlights how many of the recent manufacturing techniques are interrelated due to their aim of achieving 'better management or utilisation of the organisation resources'. The proposed framework is then applied to a large UK Chemical Company which has embraced many changes and innovations throughout the last six years in order to succeed. From a position of survival in 1990 the company first drove culture changes in peoples behaviour from the top, before restructuring the organisation which led to outstanding results in 1995. The paper will outline the process of change and, evaluate it both in terms of the effect and the future "health" of the organisation.

Improving the new product introduction process in manufacturing companies

Abstract: Product differentiation and market penetration in a competitive global market will continue to be dependent upon developing quality products. This paper describes the product differentiation and market penetration in a competitive global market will continue to be dependent upon developing quality products. It describes the process of introducing new products to the market-place and outlines one example of best practice for the development, production and support of new products, in a customer-focused manufacturing business. It discusses the implications for organization structure, teamwork and the application of information technology as a means of continuously improving the new product introduction process to secure a competitive advantage.

Time to reassess the size criterion for SME classification? An empirical investigation

Abstract: Firms employing between one and 250 people are usually classified as small and medium sized organisations. An important question that by and large has remained unanswered is whether these firms behave the same and whether their behaviour is governed by their size. In this paper, the authors empirically examine the relationship between the size of small and medium sized manufacturing organisations and their culture, leadership and strategic planning. The analysis suggests that size is not a significant influence on leadership, organisational culture or the strategic planning processes. Therefore, it is possible to conclude that the criterion for the definition of SMEs is appropriate and that SMEs with up to 250 employees can be treated as a homogenous grouping. This finding has profound implications for policy makers and small business advisers and dispels the suggestions that there are significant differences between the various SME sizes using the number of employees. In particular, it means that policy makers can formulate policies directed at SMEs in the knowledge that all firms employing fewer than 250 employees have broadly similar emphases on strategic planning, culture and leadership dimensions. Although the number of employees is the most common way of classifying organisations, this paper questions whether this is an appropriate criterion.

The characteristics of high performing supply chains

Abstract: This paper contrasts the characteristics of high and low performing supply chains in Japan, the US and Europe. From an initial set of 20 supply chains (all of which produced brake products for the automotive industry) six ''high'' and six ''low'' performing chains were identified, based on their levels of performance on quality (defect rates) and on-time delivery. Comparison of the characteristics of the two groups reveals that, on average, the high performing supply chains have lower inventories, more frequent deliveries, a higher number of second tier suppliers (but serve the same number of car makers) and have higher production volumes. They also possess more sophisticated and active structures for information exchange and learning. Supply chains located in Japan are considerably over-represented in the high performing category, but interview data revealed the danger of equating the long-term relationships found in Japan with ''cosiness'' between car makers and suppliers. The characteristics of both high and low performing supply chains appear to be shaped by a variety of contingencies, and exploration of these contingencies is a fruitful avenue for future research.

Flexibility and robustness in manufacturing

Abstract: All manufacturing systems will, at some time, have to cope with changes and disturbances such as changes in products, changes in demand, machine failures or worker absences. To deal with change, we would like them to be flexible or robust. However, while most people have a vague idea what is meant by flexibility or robustness and think they understand what these concepts mean, it is surprisingly difficult to come up with good operational definitions which enable flexibility or robustness to be measured. If such operational measures could be developed they would help make decisions about the relative merits of systems and compare different designs or different system operating rules. In this paper, we look at a variety of approaches to operational definitions of flexibility and robustness. However, we also show that the resulting measures are open to criticism and it is indeed not at all clear that measuring flexibility is meaningful, thus raising some challenging questions about the usefulness and appropriateness of flexibility and robustness as decision criteria. Nevertheless, thinking about the issues raised by the attempt to come up with measures of flexibility and robustness is very valuable as a means of seeking to improve manufacturing performance.

Competencies management in knowledge-based firms

Abstract: As people are called to transform data, information and past experiences into effective knowledge, the management of individual competencies will become more and more important in knowledge-based firms. This paper presents both theoretical and practical aspects concerning the management of competencies, based on a seven year field research conducted in a large RD 2) it is impossible to separate the act of competencies' identification from the act of evaluation; 3) relevant competencies emerge from explanation discourses delivered by observers in the attempt to justify their judgement about the performance of an individual within given situations; (4) it is possible, by means of fuzzy logic, to design evaluation support systems (ESS) of competencies by analysing explanation discourses. These assumptions are particularly suitable for organisations operating in a turbulent context, where competencies frequently change.

Using Hoshin Kanri for strategy deployment

Abstract: Hoshin Kanri is a technique for policy deployment that represents a core aspect of Japanese companies management systems and is the means by which the overall control system and total quality management (TQM) are deployed. Industrial applications of Hoshin Kanri have tended to focus on Japanese companies, with a handful of practitioners evident in the USA, and no significant evidence of application within the European business community. This research is a significant application of Hoshin Kanri adapted for use within the European industrial sector, to create a five-year quality strategy that identifies improvement milestones for each of the key business processes at Rover Group. Deployment included a rigorous review process for the quality strategy milestones to establish progress and up-date the quality strategy.

New dimensions of competence development in industrial enterprises

Abstract: In view of the dynamics of both market and technology development, the notion of competency may play an important role as a bridge between market and technology. However, a more differentiated view is needed. Based on a definition of competencies as a system of human beings, technology, organisation and culture, we shall identify two important drivers of competence development - technological change and organisational learning. Three kinds of competencies are introduced and illustrated by means of case examples. This will form the basis for discussing issues related to competence development, such as technological and functional forecasting, forecasting versus visioneering, organisational learning as an enabler for competence development. Theoretical and practical implications conclude the paper.

World class manufacturing in small and medium enterprises

Abstract: Small and medium enterprises (SMEs) play a significant role in improving the national economy. In most cases, SMEs produce their own products, but at the same time they produce items for large scale industries. These create certain interdependencies among SMEs and between them and large scale industries to improve the competitiveness of SMEs. Over recent years, large scale industries have undergone many changes in their production environment by implementing World Class Manufacturing (WCM) techniques such as JIT, DE, TQM, BPR, Lean and Agile manufacturing, and technologies like FMS, CIM and OPT with the objectives of improving productivity and quality. However, the implementation of WCM techniques has not received due attention from SMEs. Realising the importance of SMEs in the national economy, an attempt has been made in this paper to discuss the application of WCM strategies/techniques in SMEs. In this paper, a conceptual model has been developed to demonstrate the importance of best practices of manufacturing (WCM) in SMEs. Furthermore, a case experience from British SMEs is discussed. In addition, a strategic framework has been offered for improving the competitiveness of SMEs with the help of WCM strategies/methods.

Building manufacturing capabilities

Abstract: The majority of manufacturing strategy literature focuses on the process of formulation rather than implementation. This paper focuses on the process of change and in particular on how businesses can build the capabilities required to drive competitive strategy. To this end, the research has taken an existing manufacturing strategy process [1] and expanded it to help businesses create commitment and to take the actions required to build new manufacturing capabilities. This process is based on the concept of "directed strategy" and applies the technique of force field analysis [2]. The research applied the new manufacturing strategy process in six different businesses and observed their progress over the following twelve months.

Product innovation in UK manufacturing companies

Abstract: In many sectors of the manufacturing industry, product innovation is an important way for companies to achieve competitive advantage. Regular introductions of new products can be essential, especially in fast-moving markets. But how often do companies introduce new products? A database of UK manufacturing plants was analysed to determine the innovation rates and typical product development times in specific industry sectors. The results show a wide spread in the development times and innovation rates even within closely defined sectors - implying that some companies are particularly efficient at product innovation whereas others need to improve. In addition, the research identifies a number of key areas of innovation, which require further investigation, both within the UK and on an international basis.

Flexibility, trade-offs and learning in manufacturing system design

Abstract: Three independent case-based research projects are examined, using similar methodologies, so as to understand the relationships between the nature of each manufacturing system's redesign, their strategic context, the assessment of each system's flexibility, their managers' perceptions of the trade-offs involved in the design and the degree of organisational learning. A model is proposed which suggests an interplay between three related sets of activities. These are a "structuring" activity, a "suppositional" activity and an "assimilation" activity. Parallels are drawn between these studies and other work on learning and technological competence.

Quality and business process synergy: key strategies promoting longevity.

Abstract: Evidence suggests that total quality management's (TQM) implementation process affects the likelihood of its ultimate success. The danger of treating quality and TQM as an additional rather than a core activity is widely recognised. This paper argues that failure of organisations to reap considerable benefits that can be derived from introduction of TQM results from the failure to create an explicit link between the quality improvement efforts and the existing business processes. The paper presents conceptual and empirical evidence in support of the proposition that the longevity and success of the TQM process is dependent on the integration of its underlying concepts with the normal business processes. Furthermore, and more importantly, the paper examines the strategies adopted by leading exponents of TQM to achieve this objective.

Promoting technological capabilities of small and medium-sized enterprises through industry-university cooperation: case study of Taiwan machine tool industry

Abstract: Small and medium-sized enterprises (SMEs) play an important role in Taiwan economy. However, the size of these enterprises limits their research resources and research personnel. According to the 1998 Republic of China's indicators of science and technology, a total of 66.7% of the PhD level researchers in Taiwan are found in academia. Out of the many methods that can be used to release the capabilities accumulated within the academic field in order to help and lead Taiwan's industries to perform RD and (2) an IUCPj for wire-cut electrical discharge machine industry is successful by promoting the competitiveness of the whole industry by naturally forming strategic alliances and by diversifying their core technologies.

A genetic algorithm approach to manage ion implantation processes in wafer fabrication

Abstract: The management of ion implantation processes is one of several challenging problems in scheduling wafer fabrication facilities. A complicating factor is the fact that there are sequence dependent set-ups (e.g. species changes). Because of the set-ups, it is sometimes desirable to leave an implanter idle (if another lot requiring this species will arrive soon) rather than to change the set-up. We study the use of a genetic algorithm (GA) to assign the jobs to machines where the First In-First Out (FIFO) dispatching rule is used to schedule the individual machines. This approach is compared to the use of a commonly used dispatching policy-set-up avoidance. The parameters of the genetic algorithm (population size, crossover probability, and mutation probability) are analysed using response surface techniques to find combinations that allow the algorithm to determine a relatively good solution in a short CPU time.

A Route Map for substantially improving supply chain dynamics

Abstract: Traditional supply chains can amplify demand and thereby produce their own internally generated boom-and-bust scenarios. Consequently, there are many real-world examples of businesses experiencing wide swings in both capacity requirements and stock levels. Furthermore such businesses usually find that they may be grossly overstocked with some products simultaneously with having a substantial backlog for other items. This paper reviews the problem areas generating such unwanted supply chain behaviour as experienced in many market sectors. It provides a proven Route Map of actions which will greatly smooth operations to the benefit of all "players" in the supply chain. The Route Map aims to "design-out" undesirable behaviour rather than to try and correct chaotic operation of the supply chain, retrospectively. As a practical example, many of the proposed actions were included in a package of improvement measures applied to a mechanical precision products global supply chain. Results recorded include a 45% reduction in global inventory and the damping of product demand patterns by up to 58%. However, "doing the right thing" is only a necessary, and not a sufficient condition for actually achieving change. Unless there is an associated attitudinal change thereby accepting progress towards the seamless supply chain the reengineering effort is likely to be wasted.

The performance of multiple-load AGV systems under different guide path configurations and vehicle control strategies

Abstract: The majority of research on multiple-load Automated Guided Vehicle (AGV) systems has been focused on vehicle control problems. None of it investigates how well multiple-load AGVs will perform under different guide path configurations and different vehicle control strategies (i.e. dispatching rules and load selection and delivery rules). This paper investigates the performance of multiple-load AGV systems in two configurations - unidirectional single loop (SL) and segmented bi-directional single loop (SBSL). Simulation experiments are conducted to study the performance of multiple-load AGVs in these guide path configurations when different combinations of dispatching rules and load selection and delivery rules are applied. Based on this study, one is able to select good control strategies for multiple-load AGV systems with SL guide paths or SBSL guide paths.

Resource-based view: paradigm or checklist?

Abstract: This paper explores the concept of the Resource-Based View (RBV) of strategy development. It presents a historical perspective on the reasons for its growth and then examines its main elements in order to identify its contribution to the strategic process. In particular, it investigates the claim that the RBV constitutes the dominant paradigm for the future development of strategic thinking. Five significant difficulties with the RBV are identified and their implications are discussed in the context of such a claim.

Manufacturing strategies of small technology-based firms in the UK oil industry

Abstract: Changes in the industrial network of the UK offshore oil and gas industry have been brought about by the introduction of new contracting and purchasing arrangements. Companies at all levels have been affected, including the small, technology-based, oil-related companies (STBORs) who have traditionally provided much of the innovation required by the industry. This study, funded by the EPSRC, investigated technology management issues in the light of these changes, particularly as they affect STBORs and innovation. Issues raised by the research include the evolving manufacturing strategies of these small, technology-based firms. This paper seeks to illustrate these problems and the strategies devised by certain STBORs to overcome them.

Evaluating ROBOTIC safety using quality function deployment

Abstract: Improper design of the robotic safety system could create sources of hazards to humans. Regardless of the robotic safety guidelines defined by the National Institute of Standards and Technology (NIST), a synchronous consideration between the safety issue and system requirements is needed. In this study, quality function deployment (QFD) is used to evaluate safety for the design of a robotic workcell to ensure that the safety as well as system requirements are designed to meet the user's needs. QFD converts the consumers' demands into "quality characteristics" and develops a design quality for the finished product by systematically deploying the relationship between the demands and characteristics. A series of QFD matrices is developed in this study, and the advantages and disadvantages between different designs are also illustrated.

A bottleneck-based due-date assignment methodology

Abstract: On-time delivery is one of the most important performance criteria in today's manufacturing systems. To enhance delivery performance, the appropriate assignment of an order's due-date is necessary. In recent years, many due-date setting methods based on regression analysis models have been proposed. Although some of them emphasise the use of shop floor information in due-date setting, the bottleneck scheduling information has not yet been taken into consideration by those methods. It is the objective of this paper to propose a new due-date assignment method based on bottleneck scheduling information. To assign an order's due-date, this proposed method first optimises the job sequence at the bottleneck using a Tabu search algorithm and then predicts the order's flow time after its completion of its bottleneck operation. Experimental results show that the proposed method can greatly enhance the delivery performance.