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A proper framework for design of aircraft production system based on lean manufacturing principles focusing to automated processes
Abstract
This paper focuses on a proper framework that uses the requirements and concepts of lean manufacturing for a specific application to projects of aerospace manufacturing processes aiming production automation. The main goal of this guideline is to provide information, for engineers who work on the development processes, about the automation benefits that can be achieved when using this proposed guidance method of analysis presented herein. A case study is presented to validate this method’s effectiveness.
... Naqvi et al. [22] Systematic layout planning Barbosa et al. [23] TPM Downtime ...
... The study showed that the result could increase system profits by reducing overall costs to the manager. Previous researchers have appreciated the implementation of the lean approach in production management [21,23,26,[30][31][32][33][34], because it is an approach that was proven to be able to solve almost all kinds of production problems. It has been observed in reviewed research work that management team members were facing various problems in the control of operational performance in Industry 4.0 using the lean concept. ...
... The literature review on previous research was used to develop the proposed model, as mentioned in the present research article. The previous research work shows that the management system failed to control operational performance in uncertain conditions [1,2,7,8,11,12,23,24,36,42,71]. It was observed that the developed models in previous research works had several limitations and could not provide efficient management systems in uncertain conditions [22,26,27,33,34,40,42,49,53]. ...
Industry 4.0 emphasizes developing an innovative approach to eliminating the problems caused by environmental and shop floor waste, which is accomplished by a suitable process optimization approach. The process optimization approach is used to maximize productivity within limited constraints by observing end-to-end management systems. The present research work developed an innovative agile model using the lean, smart, and green approach to improve operational performance within limited constraints in Industry 4.0. The proposed model was developed by thoroughly reviewing research articles conducted over the past decades on process optimization approaches that include lean manufacturing, smart manufacturing, kaizen, and lean six sigma. The model was validated through two real production case studies in the mining machinery and automobile industries. The present article concluded that overall operational performance was enhanced in both case studies by improvement in different factors, including working environment, worker efficiency, environmental evolution, logistics management, and resources utilization. The authors of the present article strongly believe that the proposed innovative agile model would help people in industry make aesthetic and smart sustainable production systems in Industry 4.0 within limited constraints.
... Virtual Manufacturing concept implemented in aerospace industry as design and development tools like Finite Element Analysis (FEA) to design and optimize parts by reducing the weight of frames by integral construction, 3D-kinematics simulation to program automatic riveting machines to support complex assembly (Grieves, 2005) [9]. Some researchers [10,11] have developed a framework based on lean and virtual manufacturing for automatic production of aircraft by using some set of guideline during design phase implemented to engineers at shop floor for reducing flow time at the work center. The success of digital manufacturing implementation is in the arena using advanced computer aided methods that enable manufacturing engineers to operate more directly in assembly planning and concurrent engineering design to improve the efficiency of workers at shop floor [12]. ...
... With time, the technologies getting advanced, so the kind of information created by Computer-Aided Design, Manufacturing and Engineering (CAD/CAM/CAE) tools threatened to get out of control. As a result, Product Data Management (PDM) systems emerged in the 1980s [10]. Product Lifecycle Management (PLM) concept arises in the 1990s with the goal of moving outside the engineering aspects of an enterprise. ...
... Product definition includes information about how the product is designed, manufactured, operated or used, serviced, and then disposed. All these data can be updated throughout a product's lifecycle [10]. ...
The high cost and long lead times of traditional manufacturing makes it difficult for manufactures to efficiently meet eternally changing market demands. In order to determine the manufacturability of the component and low cost production of aircraft manufacturing, Digital Virtual Manufacturing plays a vital role. By the advancement in technologies like Virtual Manufacturing tools used through Product Lifecycle Management (PLM), are competent to access and reuse the best practices, as well as evaluate 3-D manufacturing scenarios. By implementing advance 3-D CAD systems with the CNC machines enables the success of the determinate assembly approach to significantly reduce the lead time aircraft manufacturing. This paper encompasses the virtual manufacturing concept to enable complex manufacturing set-up analysis, exchanging expertise at collaborative work. Virtual Manufacturing is using the manufacturing knowledge at PLM environment for defining the assembly process of an aircraft parts.
... 1. Flexibilidade (Barbosa, Carvalho, & Filho, 2014, p. 1260 3. Parceria entre montadora com seus fornecedores (Arnheiter, & Greenland, 2008;Womack, et al., 1992 Flexibilidade (Barbosa et al., 2014(Barbosa et al., , p. 1260. ...
... 1. Flexibilidade (Barbosa, Carvalho, & Filho, 2014, p. 1260 3. Parceria entre montadora com seus fornecedores (Arnheiter, & Greenland, 2008;Womack, et al., 1992 Flexibilidade (Barbosa et al., 2014(Barbosa et al., , p. 1260. ...
... Layout para minimizar o uso do espaço são regras já padrão de layout (minimizar área utilizada devido ao seu alto custo e manter a flexibilidade da linha). (Barbosa et al., 2014(Barbosa et al., , p. 1260). ↓ Estoques (Womack, et al., 1992). ...
A estratégia modular tem sido aplicada com bom desempenho na indústria automobilística e nos fabricantes de computadores que tradicionalmente utilizam o Lean Manufacturing. Mas qual é o seu efeito no Lean Manufacturing? Será que a modularidade está restrita somente a estes setores? Este trabalho responde a estas questões por meio de uma revisão da literatura e do uso dos diagramas de afinidade e de árvore em conjunto com a matriz de correlação. Nos resultados verificou-se o uso da modularidade na fabricação de máquinas industriais, residência, prédios, aviões, eletrodomésticos, brinquedos entre outros. Estes resultados mostram que a modularidade pode ser aplicada em vários tipos de produtos manufaturados. Em relação ao Lean Manufacturing a modularidade tem um efeito positivo nesta aplicação ajudando a atender alguns dos objetivos do Lean.
... 1. Flexibilidade (Barbosa, Carvalho, & Filho, 2014, p. 1260. De modo a permitir alterar rapidamente o mix de produção conforme a demanda real e trabalhar com pequenos lotes, o que é possível com a redução do tempo de set up; 2. Função do operário no Lean Manufacturing (Womack, Jones, & Roos, 1992). ...
... Layout para minimizar o uso do espaço são regras já padrão de layout (minimizar área utilizada devido ao seu alto custo e manter a flexibilidade da linha). (Barbosa et al., 2014(Barbosa et al., , p. 1260). ...
... (L24): Fluxo Contínuo (Gong, & Janssen, 2015, p. 371;Barbosa et al., 2014Barbosa et al., , p. 1260). ...
A estratégia modular tem sido aplicada com bom desempenho na indústria automobilística e nos fabricantes de computadores que tradicionalmente utilizam o Lean Manufacturing. Mas qual é o seu efeito no Lean Manufacturing? Será que a modularidade está restrita somente a estes setores? Este trabalho responde a estas questões por meio de uma revisão da literatura e do uso dos diagramas de afinidade e de árvore em conjunto com a matriz de correlação. Nos resultados verificou-se o uso da modularidade na fabricação de máquinas industriais, residência, prédios, aviões, eletrodomésticos, brinquedos entre outros. Estes resultados mostram que a modularidade pode ser aplicada em vários tipos de produtos manufaturados. Em relação ao Lean Manufacturing a modularidade tem um efeito positivo nesta aplicação ajudando a atender alguns dos objetivos do Lean.
... Taking a cue from how the western automotive companies upgraded their manufacturing systems (Crute et al., 2003;Barbosa et al., 2014) through the International Motor Vehicle Program (IMVP) benchmark study founded at Massachusetts Institute of Technology in 1985, the Lean Aerospace Initiative (LAI) was launched in 1993 at Massachusetts Institute of Technology to aid all aerospace companies and stakeholders study the potencies of Lean as a manufacturing system for achieving the demands of value in the sector (Murman et al., 2002). Boeing being a privileged participant of the LAI, it decided to use the services of Lean to solve the manufacturing problems it encountered in the latter ends of the 20th century. ...
... The craft and mass production method is known to have to introduced techniques of design and the concept of assembly line, etc., to the aerospace sector (Crute et al., 2003;Koren, 2010;Barbosa, Carvalho and Filho, 2014). Basically, the production of civil aircrafts center on fabrication and assembly. ...
... These plans specify the processes required to produce an airplane the Boeing way. The plan per (Leitner, 2005;Barbosa et al., 2014) are, namely, valuestream mapping, balancing of the line, standardized work procedures, visual controls at positions, putting all on using points, establishment of supply lines, redesign of products and processes of business, continuous flow and use of moving line. ...
Purpose-The purpose of this paper is to review how lean through the Boeing Production System impacted the production of civil aircraft in Boeing. Design/methodology/approach-The paper engages the usage of literature on lean from researchers, book authors and the Boeing Company. These literatures were studied to ascertain why Boeing pursued the lean journey and the transformations it attained. Findings-The outcomes disclose lean offers Boeing an all-inclusive approach in managing the value-stream of a company. It further presents a sustainable business model that prioritizes customer and industry demands, births innovative ways of satisfying them and keeps Boeing in business. Originality/value-This research is useful to upcoming aircraft manufacturers who seek to optimize their production as well as satisfy their customers.
... Taking a cue from how the western automotive companies upgraded their manufacturing systems (Crute et al., 2003;Barbosa et al., 2014) through the International Motor Vehicle Program (IMVP) benchmark study founded at Massachusetts Institute of Technology in 1985, the Lean Aerospace Initiative (LAI) was launched in 1993 at Massachusetts Institute of Technology to aid all aerospace companies and stakeholders study the potencies of Lean as a manufacturing system for achieving the demands of value in the sector (Murman et al., 2002). Boeing being a privileged participant of the LAI, it decided to use the services of Lean to solve the manufacturing problems it encountered in the latter ends of the 20th century. ...
... The craft and mass production method is known to have to introduced techniques of design and the concept of assembly line, etc., to the aerospace sector (Crute et al., 2003;Koren, 2010;Barbosa, Carvalho and Filho, 2014). Basically, the production of civil aircrafts center on fabrication and assembly. ...
... These plans specify the processes required to produce an airplane the Boeing way. The plan per (Leitner, 2005;Barbosa et al., 2014) are, namely, valuestream mapping, balancing of the line, standardized work procedures, visual controls at positions, putting all on using points, establishment of supply lines, redesign of products and processes of business, continuous flow and use of moving line. ...
Purpose
The purpose of this paper is to review how lean through the Boeing Production System impacted the production of civil aircraft in Boeing.
Design/methodology/approach
The paper engages the usage of literature on lean from researchers, book authors and the Boeing Company. These literatures were studied to ascertain why Boeing pursued the lean journey and the transformations it attained.
Findings
The outcomes disclose lean offers Boeing an all-inclusive approach in managing the value-stream of a company. It further presents a sustainable business model that prioritizes customer and industry demands, births innovative ways of satisfying them and keeps Boeing in business.
Originality/value
This research is useful to upcoming aircraft manufacturers who seek to optimize their production as well as satisfy their customers.
... e main aim of developed methods is to eliminate waste found in different production conditions on the shop floor [9]. In previous research, several strategies were used to identify waste found in production conditions and to investigate the real shop floor condition and constraints of the relevant production management system. ...
... e implementation of an appropriate strategy is a crucial decision for shop floor management. erefore, industry people emphasize developing a robust decision-making system and guidelines to make this decision right [6,9,16,26,53,56,58,60,61]. e present research focuses on developing a data-driven decision-making system for sustainable shop floor management using lean and smart manufacturing concepts. ...
Nowadays, industries are emphasizing the implementation of a smart shop floor management method because of different types of problems faced in controlling the production activities in Industry 4.0. Several shop floor management methods are currently implemented in the present Industry 4.0 scenario, including lean manufacturing, logistics, Internet of things, smart manufacturing, cyber-physical system, and artificial intelligence. The present research work is focused on the development and Taguchi validation methodology of a data-driven decision-making system using L9 orthogonal array for smart shop floor management based on the relationship between production sustainability and constraints. The proposed system has been validated by a comprehensive investigation of a case of mining machinery manufacturing unit. The result of the investigation revealed that productivity has been enhanced by effective controlling of production activities on the shop floor. Taguchi L9 orthogonal array method of design of experiments is implemented to enhance flexibility for shop floor control and meanwhile minimize the production time due to inefficient operating conditions on the shop floor. Taguchi method was implemented for critical conditions affecting production lead time and resource utilization. The authors have detailed discussion on developing present novel hybrid integration of lean and smart manufacturing approaches to enhance operational excellence in production activities and other complicated manufacturing environment on the shop floor within available resources. The present finding demonstrates that the adopted digital technologies under smart manufacturing with lean manufacturing are found to be cost-effective approach under different environmental conditions. The proposed system has significantly improved the efficiency of production management and operational performance by using smart systems and has proved effective in improving the financial position by making a safer shop floor management approach. In this article, a robust problem-solving system is provided. The present work aims to introduce revolutionary methods for Industry 4.0 that would result in productivity enhancement and beneficial impact on industry persons by improving the smart shop floor management. The study also provides valuable perspective and sustainable guidelines to facilitate industry individuals to implement lean and smart manufacturing for productivity enhancement in the production environment of Industry 4.0.
... [3]. Entretanto, a automação não necessariamente se justifica para a produção de itens em pequeno volume e muitas vezes personalizada, como estruturas do interior de aeronaves para uso executivo [7]. No desenvolvimento do produto, limitações para a otimização econômica e ambiental da manufatura de componentes em material compósito do interior de aeronaves podem ser relacionadas à concepção baseada em poucos materiais de uso já consolidado, e selecionados por critérios fortemente influenciados pelo design do produto [8]. ...
... A redução dos tempos possibilita maior flexibilidade e agilidade no fornecimento dos produtos, redução do ciclo financeiro, redução dos estoques e das áreas ocupadas para fabricação e armazenagem [20]. As oportunidades identificadas foram comparadas com as orientações presentes em guias de DFMA [7,17,31]. Na análise dos impactos ambientais, as oportunidades identificadas conforme critérios do Quadro 1 foram comparados com orientações para Ecodesing gerais e específicas para a indústria aeronáutica [11,15,32]. A expectativa de redução do tempo total de fabricação do gabinete pela utilização de vernizes de cura rápida e eliminação da atividade de pré-montagem poderia ser de até 43%. ...
... Articles specifically discussing lean techniques or tools were not included. Since lean manufacturing is an evolution of the Toyota Production System (TPS) [48], which is more general and culturally less specific than the Japanese TPS [49], it was also excluded from the study. Finally, the review team ensured there were no significant omissions or oversights related to the selected terms, databases, time periods, and other relevant factors. ...
Lean implementation focuses on reducing waste and improving efficiency in business operations, a strategy widely embraced in developed countries. However, its adoption among Indonesian SMEs is limited and lacks adequate research. Understanding how lean practices can effectively enhance competitiveness and productivity in this vital sector of the Indonesian economy is crucial. Despite its widespread use in Western countries, there's a noticeable gap in research specifically examining how lean principles are applied within SMEs, especially in developing countries like Indonesia. Furthermore, there's a clear scarcity of studies detailing the current state of lean implementation in Indonesia, particularly within SMEs. This study conducted a systematic literature review (SLR), thoroughly searching peer-reviewed journals and conference papers. We identified 441 articles related to lean practices in Indonesia, with 40 focusing specifically on SMEs. Through this review, we uncovered key themes and trends in lean implementation, offering valuable insights into current practices and highlighting areas for future research. This paper represents one of the first comprehensive SLRs exploring lean practices within Indonesian SMEs. It aims to deepen our understanding of how lean methodologies impact SME operations in Indonesia and provides practical guidance for researchers and practitioners interested in lean implementation. By bridging these research gaps, we hope to contribute to the body of knowledge on lean implementation in Indonesian SMEs, suggesting strategies for effective implementation and paving the way for further study in this important area.
... Non-productive activities (NPA) are the main problem faced in SFMS and can eliminate by the implementation of suitable actions [6,7]. POA are used to identify NPA and eliminate to achieve desired production enhancement within limited constraints [8,9]. ...
... In this sense along the last 10 years, the aerospace industry has fast advanced in terms of technological innovation on its related production processes [8,27]. Due to being one of the industry sectors focused on development of high-value product with particular characteristics to attend the customers with excellence. ...
This paper presents an advanced robotized cell that integrates a robot manipulator and embedded sensor with communication capacity to perform the machining of mechanical parts assisted by Industry 4.0 principles. The aim of this work is to propose an intelligent manufacturing technology that provides gains of productivity, management and digitalization based on Internet of Things concepts. This advanced approach adds value to the production processes by granting monitoring tools to operators and plant managers. It allows the acquisition and analyses of data to predict failures, and perform adjustments on the process, looking for reduction of wastes and adding value to the business. In order to illustrate the applicability of the proposed cell, a drilling process of a carbon fiber part has been executed as a case study showing the concept of the robotized cell. The proposed approach showed the advantages on the integration of different processes through communication technology and the possible impact related to Industry 4.0 on aircraft industry.
... The result showed that the improvement has been achieved in productivity by reducing waiting time, material handling time, bottlenecking time by implementing developed methodology. Barbosa et al. 57 developed a framework based on lean concept for design an aircraft production system for the automation of the processes. The developed framework helps engineers to achieve the highest level of automation in the production of aircraft. ...
In the present competitive landscape industry, individuals have emphasized fulfilling the consumer needs in available resources and limited constraints. However, the industry individuals face several problems in achieving operational efficiency. These problems include ergonomics issues, environmental waste, work processes waste, inobservance on the shop floor, and workers’ apathy. The operations management teams use various approaches to improve operational excellence on the shop floor, including lean manufacturing, smart manufacturing, green manufacturing, and artificial neural network. These approaches are used to enhance productivity by eliminating problems in the operations management on the shop floor. The present research aims to develop a framework for improvement in operational excellence and sustainability in operations management on the shop floor in an industry 4.0 environment using lean, green, and smart manufacturing concepts. In the study, a strategic ergonomics assessment and environmental assessment have been used to assess working and operational performance on the shop floor. The adaptability of the developed framework has been investigated by implementing it in mining machinery manufacturing industry. The framework has been developed with insights gained from previous research, industry individuals, and brainstorming analysis on problems faced in operations management on the shop floor in industry 4.0 working environment. The novelty of the present study lies in the fact that no model has been developed for achieving operational excellence on the shop floor in industry 4.0 using the smart, lean green manufacturing concept. The developed framework significantly improved productivity by 85%, improved machinery utilization by 21%, reduced production time by 65%, reduced manufacturing defects by 96%, and production cost by 75%. The present research work strongly believe that the developed model would benefit industry individuals in enhancing sustainability in operational excellence on the shop floor in industry 4.0 environment by establishing a more competent and cleaner working environment with available resources.
... Marodin, Germán, Luz & Netland (2018), sugieren que las empresas pueden sacar más provecho de sus implementaciones Lean si persiguen una implementación sistemática tanto de Lean Production Development como de Lean Manufacturing, en lugar de seguir el enfoque aislado más común. Finalmente, se puede argumentar que no solo se utiliza en un solo sector, Barbosa, Carvalho, & Filho (2014) desarrollan una aplicación específica en proyectos de procesos de fabricación aeroespacial que apuntan a la automatización de la producción. ...
Actualmente el sector automotriz de la región de ciudad Sahagún, Hidalgo, se encuentra en la necesidad del desarrollo de prácticas de mejora continua, se ha detectado que solo utilizan algunas metodologías de forma básica y aislada como lean manufacturing y seis sigmas, además de que para ejecutarlas lo realizan con equipos multidisciplinarios aislados, que ocasionalmente presentan acciones repetidas. Por lo anterior, en esta investigación se propone una metodología que integra la manufactura esbelta con los Coretools, dando como resultado un sistema de productividad esquematizado, enfocado a los requisitos de los clientes de la industria automotriz y con una perspectiva de mejora continua. Es un modelo integrado por 5 fases de despliegue y 5 niveles de madurez, que tiene como objetivo mantener un desarrollo y crecimiento constante, los cuales se representan de la siguiente forma: N1 Entiende, N2, Utiliza, N3 Determinación de lineamientos, N4 Afectación del desempeño y N5. Utilización cotidiana.
... Previous works have emphasized the necessity to develop an agile model for helping industry individuals to implement an e cient process optimization approach. Barbosa et al. [31] described that there is no standardized and easy-to-use strategy available for the implementation of the process optimization approach. Yadav et al. [32] highlighted the necessity of simpli ed implementation for the lean concept as a process optimization approach. ...
In industry 4.0, industry individuals are emphasizing enhancing the adaptability of the production management system by a suitable approach. To accomplish it, the management individuals use various process optimization approaches includes lean manufacturing, smart manufacturing, computational intelligence, and hybrid approaches. Process optimization approaches are used to enhance production within limited constraints. The present research aims to develop an agile model using a hybrid approach for productivity enhancement in industry 4.0, this hybrid approach is the integration of lean, smart, and computational intelligence. The developed model has been validated through a case study of real production conditions in industry 4.0. The results obtained in the case study shown that the developed model can enhance production within limited constraints in industry 4.0. The authors believe that the developed model would be able to obtain productivity enhancement and providing guidelines to industry personals for improvement in the sustainability of the production management system in industry 4.0.
... When people think of sustainability, emissions and waste usually come in mind. However, during aircraft production, there is usually a great amount of waste produced (Barbosa, 2014). Everything from paintbrushes to excess wiring and even slight defects in parts are all often waste. ...
... Lean thinking is characterised by identifying the effective means of eliminating the waste. Lean converts more satisfying turning waste into value (Barbosa et al., 2014;Prasad et al., 2019). Some of the characters of lean manufacturing as identified by Rymaszewska (2014) are focused customer value, understanding the priorities, cross functional collaboration, improved methodologies, valued culture. ...
The economic development of a country is mostly based on manufacturing industries, wherein
the role of the SMEs in manufacturing industries is considered to be more vital. The SMEs, which
mostly depend on large manufacturing industries, are not able to sustain, hence could not achieve any
long-term benefit. To address this issue, a novel effort is made to achieve long-term benefits by
implementing the Lean concepts in Indian SMEs by deploying a research instrument to measure
performance. This paper has been designed to analyse the performance of SMEs in India by a newly
developed Model, namely System for Small Medium Implementing Lean Enterprises (S-SMILE). The
model comprises of twelve critical success factors (CSFs) with 71 variables, which are analysed and
validated through the perception of managerial executives. The results showed that the twelve CSFs of
the S-SMILE model have a structural relationship and support the implementation towards attaining the
performance.
... Lean manufacturing philosophy promotes a one-at-a time manufacturing strategy to reduce inefficiency in production activities [51]. Line balancing is a lean practice which helps to (13) increase a company's efficiency [52] and adapts it to a pull system. ...
In the UAV (often called drones) industry a zero defects culture is required. However, process improvement through the DMAIC lean methodology has not been widely studied in this industry. This paper examines how to solve the increasing quality problems of a small drones’ assembly company. A circular DMAIC methodology was used as an adaptation of the DMAIC methodology. Principal results obtained demonstrate a reduction of the lead time and an increment in the leanness degree level from 23% to 60%. Multifunctional worker rate increased from 75% to 83% and motion waste was reduced almost in a 50%. Line balancing and Simulation were applied.
... Service and assembly operations seek to prevent FOD-related damage, or defects, by means of effective training and awareness throughout an organization [2]. Poka-yoke techniques aim to prevent any form 1 Contact author: dceddy@engin.umass.edu of defect, of which FOD damage is a subset, that may occur in such vulnerable operations [3]. ...
Defect prevention is particularly critical in operations such as aircraft assembly or service. Failure Modes and Effects Analysis (FMEA) procedures have been deployed manually for many years. However, the manual procedures fail to utilize capability to build intelligence into inspection processes that can facilitate elimination of human error. In this work, we introduce an artificial intelligence (AI)-based concept that can iteratively learn to assure zero defects from a given inspection process. This work introduces a schema that can serve as a knowledge management framework in a relational database for instantiation with inspection process information and data from a detection system. A companion algorithm is presented for the case of a wiring harness bracket installation in a fuselage. The schema and algorithm analyze and assess potential defects posed by Foreign Object Debris (FOD) in parallel to the assembly inspection. A closed loop of logic was introduced to enable anomaly detection by this algorithm to assure zero defects.
... The concept of JIT focuses on lean manufacturing within a production system by using the concepts of waste reduction. Lean manufacturing also naturally reduces flow times while increasing efficiency for customer response [82]. Additionally, by holding low inventory levels and pulling production by customers, JIT improves supply chain competitive performance in terms of inventory cost, terms of production and customisation [83]. ...
The purpose of this study was to align integrative tactics and coordination programme to develop a supply chain integration process. The taxonomy approach was employed in this study. An empirical sample comprising 655 responses to the International Manufacturing Strategy Survey 6 (IMSS-6) were used to test the research question. This study identified an integrative process that entailed four steps: initial integration, basic integration, junior integration, and senior integration. In addition, the research results show which integrative tactic should be improved, and how they should be improved, in each step, as well as which coordination programme should be implemented in each step to expedite integration. Finally, the research results show changes in competitive capabilities between the steps. In terms of practical implications, our research results can be used as a guideline for practitioners to develop a stepwise process of integration and to gradually improve and expand integration until complete integration is achieved.
... Authors of References [5,6] have focused on the speed and separation method, defined as one of the available ISO standards for collaborative robots, to increase operator safety in the shared workspace. Having used this standard, the safety of the operator in the manufacturing cell increased by determining the minimum protective distance between humans and robots. ...
Human-robot collaboration (HRC) is a complex procedure in manufacturing due to the problems posed by compatibility and operational safety among humans and robots, and by task definitions among them in a collaborative order. In this paper, the research results of the human-robot collaboration study for the case of an automotive brake disc assembly is presented. The analytic hierarchy process (AHP) is proposed as a decision-making method for the human-robot collaboration system, and detailed hierarchical task analysis (HTA) is applied to allocate operational tasks to humans and robots, thus reducing the chance of duty interference. Additionally, a virtual environment software (Tecnomatix Process Simulate, version 11.1,80, Siemens, Munich, BY, Germany, 2012) is used to model the assembly workstation, providing an opportunity to evaluate the feasibility of the process through different scenarios. Finally, an experimental test is conducted to evaluate the performance of the assembly procedure. This research proves that, although human-robot collaboration increases the total process time slightly, this collaboration improves human ergonomics considerably and reduces the operator injury risk.
... The differential of this work if compared with others researchers [42][43][44][45][46][47][48], is the practical point of view to the predictability of construction planning, making the schedule more adherent to what is actually achieved and improving the cooperation between stakeholders. The framework was evaluated in a real-world case study, helping them to choose the adequate management strategies, guide their actions according to the prioritized principle and indicate in which step of the PDCA these synergies would happen to optimize scheduling, reduce waste, improve quality, have a precise scope, avoid errors, motivate teams, and promote an interdisciplinary management with shared information and clear communication in the oil and gas sector. ...
Industrial construction management increasingly needs to integrate processes, technologies, and people to support strategic objectives and seeks to eliminate waste to achieve more efficient results. From this, the synergistic use of building information modeling (BIM) and lean construction (LC) principles can bring continuous improvements to the construction industry. This paper proposes a novel methodology for interdisciplinary management of construction projects by integrating BIM into LC. First, the study presents a literature review of BIM and lean methods and tools. Afterward, the research proposes the Digital Obeya Room framework for visual management of industrial pipelines manufacturing. A real-world application evaluates this new proposal on production planning and control of an industrial construction. From this experiment, the study presents results from a focus group that correlates the applied BIM functionalities and lean principles with the PDCA stages of industrial construction. This paper contributes to planning predictability, integration among stakeholders and usage of lean and BIM for continuous improvement of engineering management.
... Thus, it has sought better solutions during the development phase concerning manufacturing processes. The challenge is to find a better-quality final product, minimization of cycle times, manpower labour, and production wastes to aid the company's competitiveness in the global market [2]. ...
This paper reviews the applications of Industry 4.0 concepts within the aerospace manufacturing processes. A contextual overview of Robotics, Additive Manufacturing, Augmented Reality, Internet of Things, Simulation and Aircraft Industry is provided. Some applications of Robotics integrated with other Industry 4.0 principles are showed to present the trends of Industry 4.0 principles in different areas of aircraft manufacturing. This paper presents some innovations in aerospace industry related to Industry 4.0 and how its benefits and advantages can be reached dayby-day. Finally, it has been concluded that Industry 4.0 brings gains productivity, quality, costs reduction and increase the competitiveness of any business.
... A parallel research path aims to identify how manufacturing industries can improve their lean production strategies through industrial robot automation (Barbosa, Carvalho, & Filho, 2014;Bowler & Kurfess, 2010;Hedelind & Jackson, 2011). The reasons to automate the manufacturing processes include increased quality and efficiency demands, as well as the presence of hazardous working conditions and the high cost of specialized manual workers. ...
... To provide customization-oriented menu, the product-service modularity method is proposed with ontology-based configuration method. G. F. Barbosa (2014) [4] In this paper a frame work has been prepared by using the lean concepts and compared with the specific application of projects case study in automated production. It gives an information about the automation benefits for engineers. ...
In present world, every customer needs their products to get on time with good quality. Presently every industry is striving to satisfy their customer requirements. An aviation concern trying to accomplish continuous improvement in all its projects. In this project the maintenance service for the customer is analyzed. The maintenance part service is split up into four levels. Out of it, three levels are done in service shops and the fourth level falls under customer's privilege to change the parts in their aircraft engines at their location. An enhancement for electronics initial provisioning (eIP) is done for fourth level. Customers request service shops to get their requirements through Recommended Spare Parts List (RSPL) by eIP. To complete this RSPL for one customer, it takes 61.5 hours as a cycle time which is very high. By mapping current state VSM and takt time, future state improvement can be done in order to reduce cycle time using Lean tools such as Poke-Yoke, Jidoka, 5S, Muda etc.
... A parallel research path aims to identify how manufacturing industries can improve their lean production strategies through industrial robot automation (Barbosa, Carvalho, & Filho, 2014;Bowler & Kurfess, 2010;Hedelind & Jackson, 2011). The reasons to automate the manufacturing processes include increased quality and efficiency demands, as well as the presence of hazardous working conditions and the high cost of specialized manual workers. ...
Lean manufacturing is a production method that was established in the wake of the Japanese Toyota Production System and rapidly established in the worldwide manufacturing industry. Lean characteristics combine just-in-time practices, work-in-progress and waste reduction, improvement strategies, defect-free production, and standardization. The primary goal of lean thinking is to improve profits and create value by minimizing waste. This study introduces a novel mathematical model to design lean processes in hybrid assembly lines. The aim was to provide an effective, efficient assembly line design tool that meets the lean principles and ergonomic requirements of safe assembly work. Given the production requirements, product characteristics and assembly tasks, the model defines the assembly process for hybrid assembly lines with both manual workers and automated assembly machines. Each assembly line solution ensures an acceptable risk level of repetitive movements, as required by current law.
... Well designed and optimized floor layout may contribute in to mitigation of unnecessary transportation and material handling towards reduction of cost (Al-Aomar, 2012; Barbosa and Carvalho, 2014). ...
- ‘Reduction of waste’ has been key theme of ‘lean’ concept implementation in manufacturing, process and up to some extent in service sectors of industries; however, ‘six-sigma’ concept implementation focuses upon ‘quality improvement techniques’ in production and delivery of products/services. ‘Lean six-sigma (LSS)’ concept combines tools and techniques of ‘lean’ and ‘six-sigma’ towards achieving enhanced benefits to gain competitive advantage. Implementation of LSS concept has been emphasized in this paper by addressing identification of appropriate enablers and ranking of these enablers. Literature review and subsequent discussions with experts enabled to: identify; sort and combine; and finalize twelve enablers important to implement ‘lean six-sigma’ concept. Analytical hierarchy process (AHP) has been used to rank identified LSS enablers by utilizing experts’ opinions. ‘Management involvement and funds allocation’ has been rated as top ranked enabler to implement LSS concept. Decision making authorities may be benefited in dealing with planning and implementation of ‘lean six-sigma’ concept in manufacturing and service sectors.
To meet evolving customer expectations, companies need to take into consideration most challenging requirements. To help designers meet these increased needs, various methodologies, known as “Design for X (DfX)”, have been created.
Nowadays, companies rely on a conventional view of Lean application during the use phase to integrate new requirements: let the system produce, detect wastes, then apply Lean tools to remedy them. However, this solution confront several
limitations and constraints such as the initial design of the existing system, time and cost of implementing new Lean tools and resistance to change, etc. This implies a change of mindset by proactively integrate Lean requirements from the design
phase. This paper aims to support designers in improving the overall performance of production systems by designing Leanless (Minimal Lean application required) sustainable, adaptable systems with minimal waste and human-centered
considerations. For this purpose, we have analyzed Lean principles and tools in an Industry 5.0 context in the aim to extract a set of Lean requirements and parameters in line with Industry 5.0 principles. In addition, we have conducted a literature
review of 34 DfX methodologies and classified them into six categories: Production, maintenance, quality, sustainability, human-centricity and Resilience. For each category, we have identified the Lean requirements and parameters that meet its
objectives. To assess Lean requirements and select the appropriate Lean tools to be integrated from the design phase, we recommend the use of Multi-Criteria Decision Making (MCDM) methods. In addition, this study proposes to take advantage
of inventive design to resolve potential contradictions between Lean requirement parameters and technical parameters. This study can serve as a guide for designers, assisting them in considering various requirements that can
enhance the performance of the system being designed.
Purpose
Many future research proposals of Lean Manufacturing (LM) are presented in the literature. The purpose of this paper is to determine these future research proposals of LM which are country-related and classify them.
Design/methodology/approach
A systematic literature review (SLR) of peer-reviewed journal articles in LM was conducted. A total of 145 articles published in 34 journals during 2010–2020 were collected from four major management science publishers namely, Emerald Online, Elsevier/Science Direct, Springer Link and Taylor and Francis. The country-related future research proposals of LM identified in the literature were classified according to, firstly, the continent of the country of reference, and secondly, some form of natural affinity of these proposals creating meaningful themes. The quality tool “affinity diagram” was applied to classify the country-related future research proposals of LM.
Findings
The country-related future research proposals of LM, which are increasing in the literature over time, refer mostly to studies to be conducted in several continents/countries and to multinational studies. Conducting studies specifically in Asia, Europe, South and North America, Africa and Australia–New Zealand is also suggested. The plethora of the country-related future research proposals of LM were classified, based on the affinity of their content, into 18 meaningful themes. These themes were also classified based on their affinity into two broad categories, namely “themes concerning the LM approach itself” and “themes concerning factors outside the LM approach”.
Research limitations/implications
The restricted number of the databases searched and the subjectivity of classifying the large number of the country-related future research proposals into themes are the main limitations of the present SLR. Based on these limitations, future literature review studies can be carried out.
Practical implications
Useful proposals are provided to researchers of several countries for conducting original and country-specific research studies which can enrich the knowledge of the implementation of LM under the specific circumstances of a country for the benefit of practitioners.
Originality/value
This study goes beyond previous literature review studies on LM by focusing exclusively on the LM future research agenda which is country related. The analytical presentation of the country-related future research proposals as well as the formulation of clusters of these proposals make the present SLR study substantially different from those carried out worldwide so far.
Aviation is one of the pivotal transportation modes that has a transformative impact on both social and economic production factors – mobility. Clearly, the aviation industry with its elements creates interaction between sustainability of both nations and organizations – economic, social and environmental ones. Moreover, the aviation industry supports the improvement of production mobility. In essence, the aviation industry may give more effective and efficient sustainable support to the business environment and sustainable development if it is lean in both operations and management.
In the present industry revolution, operations management teams emphasize implementing an efficient process optimization approach with a suitable strategy for achieving operational excellence on the shop floor. Process optimization is used to enhance productivity by eliminating idle activities and non-value-added activities within limited constraints. Various process optimization approaches are used in operations management on the shop floor, including lean manufacturing, smart manufacturing, kaizen, six sigma, total quality management, and computational intelligence. The present study investigates strategies used to implement the process optimization approach provided in the previous research to eliminate problems encountered in shop floor management. Furthermore, the authors suggest an idea to industry individuals, which is to understand the operational conditions faced in shop floor management. The novelty of the present study lies in the fact that a methodology for implementing a process optimization approach with an efficient strategy has been reported for the first time that eliminates problems faced in shop floor management, including industry 4.0. The authors of the present research strongly believe that this research will help researchers and operations management teams select an appropriate strategy and process optimization approach to improve operational performance on the shop floor within limited constraints.
In industry 4.0, shop floor management teams are increasingly focused on developing an unprecedented strategy to avoid financial losses and address the challenges and problems encountered in operations management. In the present scenario, the management teams use various process optimization approaches for operational control, including lean manufacturing, smart manufacturing, the internet of things, and artificial intelligence. The process optimization approach is used to maximize productivity within limited constraints on the shop floor. The present research aims to develop a smart production management system and suggest an efficient process optimization approach to enhancing industrial sustainability by identifying problems and challenges encountered in the complex shop-floor conditions in industry 4.0. The developed production management system has been prepared by classifying the challenges and problems found in the previous research work and organizing brainstorming sessions. The developed management system has been validated by a comprehensive investigation of a case study of an earthmoving machinery manufacturing unit. The analysis showed that the developed system could enhance operation excellence and industrial sustainability in industry 4.0 by optimizing the utilization of resources on the shop floor within limited constraints. The authors of the present article strongly believe that the developed production management system will improve operational excellence and would be beneficial for industry personnel and researchers in controlling operations management in shop floor management of heavy machinery manufacturing, including industry 4.0.
Purpose – The purpose of this study is to integrate Green technology, Lean and Six Sigma methodology under
the umbrella of Green Lean Six Sigma (GLSS). Further, the study also proposes an eight facet GLSS framework
for small and medium enterprises (SMEs) to enhance organizational sustainability.
Design/methodology/approach – In this study, GLSS integration has been proposed based on intangible
features like barriers, challenges, toolsets, etc. Moreover, the GLSS framework has been realized based on Six
Sigma well-known define, measure, analyze, improve and control (DMAIC) approach.
Findings – It has been found that lack of customer involvement, financial constraints and ignorance towards
Kaizen are the most pre-eminent barriers for GLSS execution. Further, it has been found that most frequently
used GLSS tools are the 5S, environmental value stream mapping (EVSM) and life cycle assessment (LCA). The
proposed GLSS framework encompasses systematic application of different GLSS tools that lead improved
organization sustainability.
Practical implications – The present study will facilitate industrial managers to incorporate the GLSS
approach in their business process through systematic understanding of key elements related to this
sustainable approach. This study further prompts practitioner to incorporate GLSS in industry through
systematic adoption of the proposed framework for improved environmental performance.
Social implications – This work provides detailed knowledge for the researchers and academicians by
dispensing awareness into integral measures and framework. GLSS toolsets dispensed in this work augments
academicians and researchers to make decision which tools to be used at distinct phases of GLSS project
execution.
Originality/value – The present study is the first of its kind that provides integral measures and GLSS
framework for SMEs.
The global competition in the manufacturing industry is becoming more and more aggressive each day. The technologies of Industry 4.0, based on the Internet of Things (IoT), have been pursued in Research and Development, manufacturing, and management processes. In this way, the research consolidated in this paper aims to extend the use of nature-inspired robots in aircraft manufacturing, exploiting the state-of-art technologies and their benefits for productive purposes. This research presents an integrated robotic solution for the inspection of fastened structural joints by a hexapod crawler robot, equipped with a vision sensor, embedded systems, managed by a deep learning algorithm and coordinated in the cloud that moves on the surface of an aircraft providing real-time monitoring via mobile devices. A case study regarding the inspection of airframe fasteners was carried out to demonstrate the application of the proposed solution, the developed method, and its tasks. The automation of the inspection process strives to increase efficiency, cost reduction, streamline ergonomics issues, and support aircraft fabricators. This novel proposal looks for an innovative application in the aeronautical sector based on state-of-art technology faced by intelligent manufacturing.
With the vision of Industry 4.0 and cobots, working conditions in industrial settings are starting to change. We review related literature from the fields of human–robot interaction, work and organizational psychology, and sociology of work, as well as an exemplary project case study, and identify research gaps regarding the implications of cobots for work environments. We argue that we are in a transition phase from automation to actual collaboration with robots in manufacturing, and that this will open up a new problem space for investigations, in which a practice lens will be crucial. Based on this, we propose a research agenda for social practice and workplace studies to explore the sociotechnical environment of Industry 4.0 involving cobots at the individual, team, and organizational levels.
Manufacturing sector has traditionally employed the concepts of lean manufacturing for production optimization and waste elimination. However, the looming danger of climate change demands responsible production and consumption; oftentimes the environmental aspects have been ignored for economic gains. The fourth industrial revolution brought about a paradigm shift in the manufacturing landscape, yet there is dearth of approaches that combine the concepts of lean manufacturing, environmentally conscious manufacturing and Industry 4.0 for improving the production and ecological performance of manufacturing sector. This study has fulfilled this research gap by developing a comprehensive implementation framework that combines lean manufacturing, green manufacturing and Industry 4.0 in a harmonious manner. Using a longitudinal case study approach, the developed framework has been applied to an auto-parts manufacturing firm to achieve reduced lead time, value added time, non-value-added time and greenhouse gases (GHG) emissions. The results revealed that the approaches of first-in-first out (FIFO), total productive maintenance (TPM), smart production control, cyberphysical systems, 6R and smart energy monitoring are extremely beneficial in achieving optimized and cleaner production, where the lead time, non-value added time and value added time has been reduced by 25.60%, 56.20% and 24.68% respectively, whereas the carbon dioxide, methane and nitrous oxide emissions were reduced by 55%. The theoretical contribution of this research work lies in the development of a novel integration framework that combines the concepts of lean manufacturing and green manufacturing with Industry 4.0 technologies, whereas practitioners can benefit from the synergistic combination to achieve automation-based fast and environmentally conscious manufacturing.
The purpose of this paper is to discuss the relevance of Lean Thinking principles implementation around the world, both in industry and services, based on the growing number of published case studies and surveys. A comprehensive review has been conducted on case studies and surveys published between 1990 and 2018 describing Lean Production/Thinking implementations on different countries, classified by year of publication, country and type of company (discrete-industry/process-industry/services) and intervention scope (product/sector). The main findings of this study show that Lean Thinking is a real global (worldwide) and transversal approach to improve organizations’ performance (all types of industries and services). However, several organizations are not yet fully aware of the Lean principles as they do not apply the approach to an entire value stream (i.e. to products or families of products) but only to parts of value streams (i.e. to sectors or areas of the company). The review includes the identification of benefits related to environmental issues that contribute to the sustainability of the organizations.
Purpose
Literature contributions to Lean manufacturing (LM) are fragmented and show some significant limitations. The purpose of this paper is to identify the existing research gaps in LM as well as to group them into respective themes.
Design/methodology/approach
A systematic literature review (SLR) of peer reviewed journal articles in LM was carried out by the authors, based on four major publishers, namely, Emerald Online, Science Direct, Springer Link and Taylor & Francis. In total, 120 articles published in 30 journals during 2005–2016 were collected which revealed LM research gaps. A simple affinity diagram was applied in order to group the research gaps into logical themes.
Findings
A large number of research gaps are identified in the LM literature and meaningful themes of these gaps are also revealed.
Research limitations/implications
The SLR carried out by the authors is based on only four academic journal publishers and some of other publishers might have been missed out in this search. Excluding articles focusing on an individual Lean principle or tool/technique is also a limitation of the present SLR.
Practical implications
Researchers and practitioners can use the LM research gaps presented in this study for further development of LM methodology.
Originality/value
Presenting LM research gaps analytically and grouping them into meaningful themes, significantly differentiates the present SLR study from those published so far.
Purpose
The purpose of this paper is to identify the originality value of the lean manufacturing (LM) studies carried out worldwide so far.
Design/methodology/approach
Four major publishers, namely, Emerald Online, Science Direct, Springer Link and Taylor and Francis provided the databases for a systematic literature review (SLR) of peer-reviewed journal articles in LM. In total, 211 articles published in 52 journals during 2005-2016 were collected. The affinity diagram was applied to group the originality value statements identified into logical themes.
Findings
The plethora of originality value statements identified in the literature are analytically presented. Furthermore, meaningful themes of the originality value of the LM studies are formulated.
Research limitations/implications
Some publishers might have been missed out in this SLR, given that it is based on only four academic publishers.
Practical implications
Identifying the originality value of the existing LM studies and presenting respective meaningful themes can help researchers and practitioners design their future research and implementation plans, respectively.
Originality value
The originality value of the LM studies is a subject which has not been reviewed in the literature previously.
Purpose: This paper adds to the quality management body of knowledge by solidifying the
connection between operational and strategic aspects of Lean transformation. Previous research
has examined these issues in isolation, demonstrating mixed results in financial and operational
efficiencies. We show that when operational and strategic change are jointly considered the
likelihood of success for Lean transformation increases.
Design/methodology/approach: We provide a literature review of 109 peer-reviewed papers on
Lean manufacturing and qualitative analysis of 23 Baldrige award winners (2000-2014) that
implemented Lean to assess the importance of strategic actions in achieving a sustainable
competitive advantage through Lean transformation.
Findings: We find that Lean transformation yields mixed results unless strategic actions are
taken by senior management. These strategic actions include but are not limited to knowledge
management, human resources, and business growth and can result in performance heterogeneity
by improving the output/input ratio of the firm. This performance can then manifest as either
doing the same level of business with fewer resources (a profit play) or doing more business with
the same resources (a growth play). As specific examples, we found thatwe analyzed Baldrige
Aaward winners overwhelmingly utilizedfor evidence of Lean strategic action to drive
performance gains. We suggest further model validation through directed interview and/or
survey research.
Originality/value: This paper clarifies the need for jointly implementing Lean tools with
strategic actions. Our findings provide more deliberate strategic actions for organizations
wishing to increase the likelihood of success of Lean transformation and ultimately improve
quality.
Keywords: Lean Manufacturing, Lean Management, Operations Strategy, Baldrige Award,
Strategic Action.
Purpose
The literature in the field of Lean Six Sigma (LSS) is escalating with frameworks, but, till date, no effort has been made in existing literature to critically reviewing LSS frameworks. The aim of this paper is to investigate the literature about Lean, Six Sigma and LSS frameworks and critically reviewing the existing literature over numerous parameters.
Design/methodology/approach
This study focuses on a literature review of Lean, Six Sigma and LSS frameworks. The time span of this analysis is 30 years. The analysis is restricted to searching online databases such as Elsevier Science direct, Taylor and Francis, Emerald, Springer link, Wiley Inter-Science and Inder-Science. A total number of 58 frameworks have been used as sample size for this study. The study focuses on reviewing these 58 frameworks based on measures such as the novelty of frameworks, source of frameworks, framework verification, approach of verification and identification of vital elements/tools/constructs of frameworks and lastly comparative analysis of all these 58 frameworks
Findings
The analysis has identified major discrepancy such as laxity of researcher toward utilizing existing frameworks, lack of participation of practitioners and consultants in the development of LSS frameworks, and the elements/constructs used in structuring the frameworks are highly incoherent. Higher proportions of frameworks are verified through various modes of verification such as survey, case study, simulation, which encourages other researchers for applicability of the frameworks. Case study is found most popular research design method for verification of frameworks. Various frameworks are highly abstract or superficial. Some of the frameworks do not show how each construct/element are related to implementation in the organization. Out of 58 frameworks, the only single framework is highly comprehensive. A coherent framework for LSS is still lacking.
Research limitations/implications
This analysis is limited to peer review articles from Elsevier Science direct, Taylor and Francis, Emerald, Springer link, Wiley Inter-Science and Inder-Science databases and contains the search keywords in title only.
Originality/value
This study is first of its kind attempt, making an effort to the knowledge of the authors to critically review Lean, Six Sigma and LSS frameworks. This analysis will assist to recognize the LSS filed trends and framework applicability.
Nowadays, lean implementation seems to be very effective when combined with technologies like radio frequency identification (RFID) but a gap has been observed regarding the availability of certain lean implementation approaches that practice this confluence. Keeping this requirement in view, an extensive systematic literature study has been conducted to first confirm this gap and then to propose an implementation approach by selecting the right approach, methodologies, tools and steps from previous literature. In order to achieve this task, 39 most relevant previous lean implementation approaches have been selected through rigorous search and selection (based on studying their originality, methodology, objectives and limitations) which first confirmed the gap and then enlighten that 56% of previous implementation approaches have utilised ‘implementation framework’ as the most common approach and the common methodologies utilised were case study and literature review. Moreover, about 25.6% of previous approaches have utilised Value Stream Mapping (VSM) for lean implementation and Technology-Organisation-Environment (TOE) framework was considered as the most appropriate methodology for RFID deployment. So, these statistics were further utilised to invent an implementation framework comprising 21 steps and four implementation phases in which confluence of VSM and TOE has been effectively utilised to achieve successful deployment of technology combined lean.
Over the last 30 years, Lean production (LP) is a kind of production mode which could improve the production efficiency of enterprises proved by theory and practice, and caused strong repercussions in the industry and academia. However, there are very few successful cases by importing the lean production from enterprise practice around the world. In China, many enterprises implement the lean production often failed to succeed. Learning and effective promotion of lean production enterprises are put forward by means of the analyzing of many problems that exist in the process of implementing lean production in this paper.
This study introduces a novel cross-generation automation transportation system (ATS) model to implement production manufacturing systems in the thin-film-transistor liquid-crystal-display (TFT-LCD) industry. The proposed cross-generation ATS model describes the construction of each generation system to implement production requirements and follow a fixed cycle. The extent to which automation associated with technological upgrading can led to the full implementation of automated production has become increasingly important in production manufacturing strategy. Implementation of ATS has evolved from an early traditional thinking model to a human-oriented production process, i.e., a fully automated system that integrates planning with thinking. Therefore, this study focuses on cross-generational data collected from company operations to examine the feasibility of implementing cross-generation ATS in the production manufacturing system patterns of the conventionally used thinking model.
In order to improve the accuracy of productivity calculation and prediction, this paper aims to establish a mathematical model, which takes multi-factor revision into account, to evaluate the personnel operational capacity (POC) of aircraft assembly lines. Firstly, the assembly operation is divided into assembly operating elements (AOEs), which is based on the features of aircraft assembling and is for the provision of statistical units. Secondly, effective man-hour (EMH) is adopted as a yardstick to measure the POC. Then, considering the technical characteristics and environmental constraints of the real assembly line, detailed quantitative descriptions about the chosen key factors, namely assembling accuracy, learning effect, and assembling intensity, are provided, and these quantitative descriptions are used for the revision of the EMH in order to guarantee a higher precision. After that, several critical parameters such as the cycle time, tact time, and output of an assembly line can be solved out, from which the POC can be analyzed and reflected. Finally, this method has been successfully applied to a practical case, and the result justifies its advantage as well as feasibility.
This paper describes the application of a new variant of process benchmarking called value stream mapping to the development of a supplier network around a prominent distributor of electronic, electrical and mechanical components. This involved mapping the activities of the firm, identifying opportunities for improvement and then undertaking with the firm an improvement programme. The resulting supplier association programme involved around 50 key suppliers across eight product category areas. The paper explores the different methods employed together with the support structure that was created. It concludes with evidence of the early results of the programmes as well as a number of key learning points for other organisations wishing to follow a similar path.
RESUMO O artigo direciona a atenção a um aspecto ainda pouco estudado na gestão de empreendimentos: uma abordagem mais ampla de seus processos e agentes envolvidos. Desta forma, destaca a relevância da gestão na fase de uso e operação predial para a retroalimentação do processo de projeto e à satisfação das necessidades dos usuários de empreendimentos, bem como para seu adequado desempenho-estrutural, segurança no uso, conforto ambiental, funcionalidade e impactos econômico e ambiental. O segmento hoteleiro foi adotado em face de uma profunda relação de dependência existente entre seus edifícios e a atividade da gestão da manutenção predial, em prol do desempenho que viabiliza a operacionalidade do empreendimento. São apresentadas ponderações preconizando a eficiência e eficácia na gestão destes empreendimentos, partindo de resultados de estudos de caso, que embasam os primeiros contornos de uma ferramenta envolvendo a integração entre a gestão da tecnologia e o planejamento da qualidade, na fase de operação, para gerar retroalimentação ao processo de projeto. Para embasar a proposta, a metodologia prevê revisão teórica sobre os temas 'desempenho', 'gestão e ciclo de vida de empreendimentos', 'gestão da tecnologia' e 'planejamento da qualidade'; os quais são verificados junto a estudos de caso, através da ferramenta de 'Avaliação Pós-Ocupação' (APO).
ABSTRACT The article focuses on a point of view seldom researched in the project management field: a wider approach of its processes and players. In this way, it highlights the relevance of manage the use, operation and maintenance phase of the project to ensure design process feedback and the users' satisfaction, as well as for its appropriated performance-structural, safety in use, environmental comfort, functionality, economic and environmental impacts. The hospitality sector was taken due to deep interrelations between its buildings and the building maintenance management, in favor of the performance that makes possible the project operationality. Reflections are presented praising the efficiency and effectiveness in these project management, taking as basis the results of case studies that establish the briefing of a tool involving the integration between management of technology and quality planning, along its operation phase, to engender feedback.
The proper use of physical space in a factory is an important operational factor since it establishes its primary organization as well as the material and information flow patterns, with long run impacts. In order to systematize an adequate plant layout, methods for macro-space planning such as SLP (Systematic Layout Planning) have been proposed to support the development of layout alternatives. However, due to the generation of sub-optimal solutions with different pros and cons, the process of determining the best layout alternative becomes critical to assure the company's efficiency and flexibility, when facing different market scenarios. In this paper we propose the use of multicriteria decision support tools in conjunction with SLP. The multicriteria analysis proposed is illustrated in a case study from the automotive industry. The company analyzed is expanding its physical area to house new machines and optimize material flows. Nine different macro-layout alternatives were generated and the best overall alternative was evaluated in relation to seven criteria using AHP (Analytic Hierarchy Process).
For the last few years almost every manufacturing industry has been trying to get ‘lean’. A headlong rush to offer value to the customers by becoming lean and responsive has created an urgency for researchers and practitioners to apply new tools and techniques to address various wastes. The process of mapping the material and information flows of all components and sub-assemblies in a value stream that includes manufacturing, suppliers and distribution to the customer is known as value stream mapping (VSM). VSM has proved effective in identifying and eliminating wastes in a facility with similar or identical product routings, such as in assembly facilities. In this paper, an attempt has been made to use VSM as a technique to achieve productivity improvement at supplier end for an auto industry. Both current and future (‘as is’ and ‘to be’) states of supplier shopfloor scenarios are discussed using value stream concepts. This is analysed along with takt time calculations and the application of other gap areas. Finally, gain in production output per person, reduction of work in process and finished goods inventory affecting productivity are also reported.
The growing need for better monitoring and control of road construction projects, together with rapid technological progress, have led to a number of interesting developments, which are reviewed below. The present paper describes the development of a real-time monitoring model capable of measuring productivity and progress automatically. The model, which uses global positioning system for on-site automated data collection, was tested and validated on site. The results of the field experiments have indicated that the expected accuracy level of the model can be assessed as ±4-5% for unstructured activities and even higher for more structured ones, such as asphalt spreading. The paper concludes that it is possible to automatically measure the performance of earthmoving operations. Based on the results, it also highlights the needs for further research.
Learning to see" is the message of the powerful Value Stream Mapping (VSM) technique, which was developed within the lean production paradigm to help practitioners redesign production systems, eliminate waste and create continuous flow manufacturing in a high-mix, low-volume manufacturing environment. It was originally developed mainly for disconnected flow lines of the automotive industry. In this contribution, both the adaption of this method to the characteristics of semiconductor manufacturing and its application in a Wafertest environment at Infineon Technologies, an important frontend site for microcontroller manufacturing, are shown. The article provides guidelines on how to implement continuous flow manufacturing into typical semiconductor production areas. The advantages of this production principle, as well as the special expenditures during the implementation, are demonstrated.
Purpose
The value stream mapping (VSM) is a tool created by the lean production movement for redesigning the productive systems. Since, it was theoretically developed, some cases have been published where the mentioned tool has been used; however, there is a need to see how it is put into practice, that is to analyze the level in which theory is able to adapt to real practice, the strengths, weaknesses and the key aspects to be taken into account by the applicant teams to obtain the highest performance of the VSM. This paper aims to discuss all of these aspects.
Design/methodology/approach
The methodology used is a case study of a company in which the process of application of the VSM has been thoroughly analyzed. A team created to improve the productive system of a manufacture for plastic casings for mobile phones has carried out this application.
Findings
The research shows that the VSM is a valuable tool for redesigning the productive systems according to the lean system. Nevertheless, there are some key points for the establishing teams that have to take into account, as follows: the time and training resources spent, the use of suitable information systems and a suitable management of the application phases.
Research limitations/implications
The conclusions of this research can be reinforced by the monitoring of the application process in more company cases.
Practical implications
The conclusions of this research are useful for future practitioners, so that they may bear in mind the different aspects of planning projects for redesigning productive systems by using VSM. On the other hand, these conclusions can also be useful for the academic field in order to enhance the theory of VSM.
Originality/value
The paper is a contribution based on practical references according to a thoroughly monitoring of a successful case in establishing VSM.
This paper describes the application of a new variant of process benchmarking called value stream mapping to the development of a supplier network around a prominent distributor of electronic, electrical and mechanical components. This involved mapping the activities of the firm, identifying opportunities for improvement and then undertaking with the firm an improvement programme. The resulting supplier association programme involved around 50 key suppliers across eight product category areas. The paper explores the different methods employed together with the support structure that was created. It concludes with evidence of the early results of the programmes as well as a number of key learning points for other organisations wishing to follow a similar path.
Continued development of modern machines and production equipment, supported by advanced control systems and based on recent achievements in computer and software technology, is necessary to fulfil client requirements. A significant number of manufacturing systems are able to work automatically with a limited contribution from employees. However, even in advanced manufacturing systems, one of the most important factors is still the human being. Usually overall system performance depends on human decisions, and the significance of such decisions is higher than it was in the past because of more complex and costly production systems. In such a situation, the efficient utilisation of manufacturing equipment via proper man-machine interaction is necessary. The paper deals with problems in man machine interactions and with an attempt to model human behaviour. The interaction media are explained and a short survey of research in this area is provided. The aim of the paper is to classify knowledge regarding man-machine interactions.
Our research addresses the confusion and inconsistency associated with “lean production.” We attempt to clarify the semantic confusion surrounding lean production by conducting an extensive literature review using a historical evolutionary perspective in tracing its main components. We identify a key set of measurement items by charting the linkages between measurement instruments that have been used to measure its various components from the past literature, and using a rigorous, two-stage empirical method and data from a large set of manufacturing firms, we narrow the list of items selected to represent lean production to 48 items, empirically identifying 10 underlying components. In doing so, we map the operational space corresponding to conceptual space surrounding lean production. Configuration theory provides the theoretical underpinnings and helps to explain the synergistic relationships among its underlying components.
We develop a model of a failure-prone, bufferless, paced, automatic transfer line in which material flows through a number of workstations in series, receiving continuous processing along each workstation. When a workstation fails, it stops operating, and so do all the other workstations upstream of it. The quality of the material trapped in the stopped workstations deteriorates with time. If this material remains immobilized beyond a certain critical time, its quality becomes unacceptable and it must be scrapped. We develop analytical expressions for important system performance measures for two cases. In the first case, the in-process material has no memory of the quality deterioration that it experienced during previous stoppages, whereas in the second case it has. In both cases, we assume that the workstation uptimes and downtimes follow memoryless distributions. We use the analytical expressions to numerically study the effect of system parameters on system performance. To evaluate the memoryless assumption, we compare the performance of the original model to that of a modified model in which the workstation downtimes do not follow memoryless distributions. The performance of the modified model is obtained via simulation.
Application of robots in spray-painting tasks results in low-cost production, persistent quality and protects humans from a hostile working environment. Automated planning of applicator’s trajectory requires a model of paint deposition onto the treated surface and formulation of an appropriate criterion for the painting quality. In previous research several painting models and quality measures were derived. The research efforts were concentrated on the determination of the trajectory that provided the best quality of painting. In contrast with previous approaches, painting quality here is not considered as a criterion function, which is to be maximized, but as a constraint — we limit its lower level. This gives an opportunity for proper minimization of some additional cost function. Particular objective is ergonomic-based optimization of the painting task that results in reduced motor load, energy consumption, and control jerks, preserving the required quality. Practical fulfilment of such objectives requires a painting model applicable for an arbitrary spray-gun’s position, orientation and velocity. Since existing models only partially satisfy these requirements, our research also includes derivation of the appropriate painting model. Thus, this paper treats two topics: modeling and simulation of the spray-painting process, and dynamic optimization of an anthropomorphic painting robot. An ergonomic shape of the spray-gun’s trajectory is proposed. A set of diagrams for the optimal choice of characteristic trajectory parameters, in the sense of minimum energy consumption and preserved painting quality, is given. Benefits of the applied approach on reduced paint wastage and increased efficiency of the job, are pointed out.
The Toyota Production System is a paradox. On the one hand, every activity, connection, and production flow in a Toyota factory is rigidly scripted. Yet at the same time, Toyota's operations are enormously flexible and responsive to customer demand. How can that be? After an extensive four-year study of the system in more than 40 plants, the authors came to understand that at Toyota it's the very rigidity of the operations that makes the flexibility possible. That's because the company's operations can be seen as a continuous series of controlled experiments. Whenever Toyota defines a specification, it is establishing a hypothesis that is then tested through action. This approach-the scientific method-is not imposed on workers, it's ingrained in them. And it stimulates them to engage in the kind of experimentation that is widely recognized as the cornerstone of a learning organization. The Toyota Production System grew out of the workings of the company over 50 years, and it has never actually been written down. Making the implicit explicit, the authors lay out four principles that show how Toyota sets up all its operations as experiments and teaches the scientific method to its workers. The first rule governs the way workers do their work. The second the way they interact with one another. The third governs how production lines are constructed. An the last, how people learn to improve. Every activity, connection, and production path designed according to these rules must have built-in tests that signal problems immediately. And it is the continual response to those problems that makes this seemingly rigid system so flexible and adaptive to changing circumstances.
The purpose of the study is to assess efficiency in public tertiary education systems across EU countries plus Japan and the US with semi-parametric methods and stochastic frontier analysis.� The study identifies a core group of efficient countries. A good quality secondary system, output-based funding rules, institutions' independent evaluation and staff policy autonomy are positively related to efficiency.� Moreover, the study provides evidence that public spending on tertiary education is more effective in what concerns labour productivity growth and employability when it is coupled with efficiency.
Growing concern for the environment has spurred interest in environmentally conscious design and manufacturing. The concept of Design for the Life Cycle encompasses all aspects of a product’s life cycle from initial conceptual design, through normal product use, to the eventual disposal of the product. A product’s architecture, determined during the configuration design stage, plays a large role in determining the product’s life cycle characteristics. In this paper, modularity of product architectures with respect to life cycle concerns, not just product functionality and structure, is defined and applied in the analysis of architecture characteristics. A principal hypothesis underlying this work is that high degree of life cycle modularity can be beneficial across all viewpoints of interest because all interested people will view the product similarly and consistently. An architecture decomposition algorithm from the literature is adopted for partitioning architectures into modules from each life cycle viewpoint. Two measures of modularity are proposed: one that measures module correspondence between several viewpoints, and another that measures coupling between modules. The algorithm and measures are applied to the analysis and redesign of an automotive center console. Results of applying the algorithm and measures accurately reflected our intuitive understanding of the original center console design and predicted the results of our redesign. Furthermore, these measures incorporate only configuration information of the product; hence, can be used before detailed design stages.
Lean Aerospace Initiative Plenary Workshop presentation
Growing concern for the environment has spurred interest in product Design for the Life Cycle (DFLC) which encompasses all aspects of a product's life cycle from initial conceptual design, through normal product use, to the eventual disposal of the product. A product's architecture, determined during the configuration design stage, plays a large role in determining its life cycle characteristics. In this paper, modularity of product architectures with respect to life cycle concerns, not just functionality and structure, is defined and applied in the analysis of architecture characteristics. An architecture decomposition algorithm from the literature is adopted for partitioning architectures into modules from each life cycle viewpoint. Two measures of modularity are proposed: one that measures module correspondence between several viewpoints, and another that measures coupling between modules. The algorithm and measures are applied to the analysis and redesign of an automotive center console. Results of applying the algorithm and measures accurately reflected our intuitive understanding of the original center console design and predicted the results of our redesign. Furthermore, these measures incorporate only configuration information of the product, hence, can be used before detailed design stages.
For the past few years almost every manufacturing industry has been trying to get 'lean'. A headlong rush to become lean also resulted in many misapplications of existing lean manufacturing tools often due to inadequate understanding of the purpose of tools. While tool descriptions abound, there is no way systematically to link a manufacturing organization to its problems and to the possible tools to eliminate these problems. The main purpose of this paper is to propose a classification scheme to serve as a link between manufacturing waste problems and lean manufacturing tools. A manufacturing organization can then match its manufacturing wastes with the appropriate lean manufacturing tools. The classification of existing knowledge is often the first step in moving from a practice to a science. This classification scheme systematically organizes lean manufacturing tools and metrics according to their level of abstraction, appropriate location of application of the tool in the organization, whether it addresses management waste or activity waste, the type of resource waste it addresses, and whether it identifies waste, measures waste, eliminates waste, or a combination of the three. We have organized 101 lean manufacturing tools and metrics using this classification scheme. We have also described some common manufacturing problems using this classification scheme and shown the problem-tool connection through examples. The classification scheme is not intended as a decision-making tool, i.e. it does not decide if something is a waste. However, the proposed scheme does an excellent job of classifying all well-known lean manufacturing tools and metrics and suggests lean manufacturing tools and metrics that will help to address manufacturing problems. This classification scheme will assist companies trying to become lean and can serve as a foundation for research into the science of lean.
The robotization of on-site surface finishing work, particularly sandblasting, is considered. A possible system design is presented with a cost estimate. Costs and benefits of applying the proposed robot system to on-site sandblasting are outlined and estimated. Net present value of the contractor’s investment in the robot equipment is analyzed. Conclusions regarding the purchase price of the robot based on its economic feasibility are drawn.
Purpose
The purpose of this paper is to adopt the total productive maintenance (TPM) in the food industry and especially in bakery products. The paper aims to develop a methodology for increasing production rate, improving the quality of the products and providing a healthier and safer work environment.
Design/methodology/approach
The methodology is based on analysing the reliability data of an automatic production line. It is divided into four steps, whose aims are to bring forth improved maintenance policies of the mechanical equipment. Also, the continuous and thorough inspection of the production process is achieved through measurements of the overall equipment effectiveness (OEE).
Findings
The goal of development methodology is to bring competitive advantages, such as: increasing the productivity; improving the quality of the products; and reducing the cost production of the line.
Practical implications
The development methodology in the food industry increases the production rate, improving the quality of the products and providing a healthier and safer work environment. It can be useful to guide food product machinery manufacturers and bread and bakery products manufacturers to improve the design and operation of the production lines that they manufacture and operate.
Originality/value
This paper presents the implementation of TPM in a pizza production line and, using certain assumptions, the generalization of the results in bakery production lines.
Purpose
To compare the performance of a new hybrid manufacturing system (HMS) with a conventional cellular manufacturing system (CMS). The hybrid system is a combination of the cellular manufacturing and job shop.
Design/methodology/approach
A hypothetical manufacturing facility with eight machines and 20 parts is used as a case. Simulation models are developed for two manufacturing systems. A multi‐factor comparison is carried out to test the performance of the systems under different scenarios.
Findings
It was found that group scheduling rules (GSR) and the manufacturing system design factors have significant impact on the performance of the system. In particular, the hybrid system shows its best performance when the MSSPT GSR is applied, whereas the cellular system is superior when DDSI is implemented. The results also demonstrate that, by adding non‐family parts to the production schedule of the HMS, significant benefits in the performance measures can be attained.
Research limitations/implications
The conclusion cannot be generalized, as the result is dependent upon the input data and the size of the problem.
Practical implications
The application may be limited to certain industry sectors. Further studies may be needed to identify the appropriate industry.
Originality/value
While the majority of the literature focuses on either a job shop or a pure CMS, this paper has a distinctive approach that allows the combined use of both systems. This could be a useful transitional approach from one system to the other.
The literature on robot-related accidents clearly shows that the greatest risk of accidents occurs during programming and/or maintenance, times when the individual is within the operating envelope of the robot. The circumstance of the accidents and incidents reported has frequently involved an unexpected robot movement which was caused by equipment failure or human error. The need for human factors research on human-robot interface safety and productivity has been widely reported in the literature. Unfortunately, the number of actual studies of human performance in man-robot systems is comparatively small. A search of the literature revealed only 11 such studies. The goal of this article is to briefly describe and synthesize the experimental results generated in the human factors studies, make recommendations to improve the safety of the persons working in the vicinity of industrial robots, and to propose future research avenues in this area. @ 1995 John Wiley & Sons, Inc.
The key challenge of this work is to research the safety design and development of a close range active human-robot collaboration system in which no governing safety standards and regulations are currently present. Active robot assistance in a human-centered cellular manufacturing system is very promising proposal, however safety is the uppermost consideration before this idea can be materialized. In this development, five main safety designs in both hardware and control levels have been proposed and discussed in this work. In the prototype system development, human area and robot area are setup as safe working areas but border crossing is allowed and monitored for safety. At the close region of collaboration, three safety robot working zones are defined by light curtains to control the behavior of the robot based on the collaboration requirements. The assisting mobile robot manipulators system is designed with additional safety control strategies in term of robot gripper speed and travel area to minimize the collaboration risks. Vision system by IP cameras is developed to monitor the human operator safety conditions by measuring the body posture and position. The overall control system is developed to coordinate the collaboration flow between the human operator and mobile robot manipulators system to ensure the safety of the assembly operation. Risk assessments are conducted to make evaluations before and after implementation of safety design into the prototype system. Various safety improvements are observed and discussed. It has proven that the safety designs can reduce the potential collaboration risks in the system.
Companies can no longer capture market share and gain higher profits by producing large volumes of a standard product for a mass market. Success requires adopting methods in the customer acquisition and order fulfilment processes to manage anticipated change with precision while providing a fast and flexible respond to unanticipated change. This paper describes how technology such as genetic algorithms and autonomous agents can be used to enable a mass customization strategy to respond to this challenge.
This paper presents a framework to integrate requirements management and design knowledge reuse. The research approach begins with a literature review in design reuse and requirements management to identify appropriate methods within each domain. A framework is proposed based on the identified requirements. The framework is then demonstrated using a case study example: vacuum pump design. Requirements are presented as a component of the integrated design knowledge framework. The proposed framework enables the application of requirements management as a dynamic process, including capture, analysis and recording of requirements. It takes account of the evolving requirements and the dynamic nature of the interaction between requirements and product structure through the various stages of product development.
It is widely argued that competition is no longer between organizations, but among supply chains. Effective supply chain management (SCM) has become a potentially valuable way of securing competitive advantage and improving organizational performance. This research conceptualizes, develops, and validates six dimensions of SCM practices (strategic supplier partnership, customer relationship, information sharing, information quality, internal lean practices, and postponement). Data for the study were collected from 196 organizations and the measurement scales were tested and validated using structural equation modeling. It is hoped that this study will provide a parsimonious measurement instrument to assess the performance of the overall supply chain.
Partial translation of: Toyota Seisan Hooshiki Datsukibo no Keiʻei e Mezashile (romanized) With Japanese text. Thesis (M.A.)--Monterey Institute of International Studies, 1987.
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