Investigating the development and delivery of integrated product-service systems

Driven by the highly cyclical nature of their increasingly commoditised product offerings, many capital goods manufacturers are seeing the benefits of delivering services integrated with their core product offerings. Whilst existing research is almost unanimous in advocating the value of a servitization strategy, understanding how these product-service systems (PSSs) can be developed and delivered remains a significant challenge. The closely related PSS field, which has its heritage in the environmental and social science disciplines, is more mature in this area and a number of models have been proposed. The research reported within this thesis contributes to knowledge by investigating whether the approaches to PSS development, reported within the PSS literature, reflects the PSS development practice of servitized manufacturers. More specifically, soft systems methodology was used to explore the delivery of PSSs within the UK railway industry in order to gain an understanding of the implications for developing new PSSs. With this understanding, the existing approaches to PSS development were evaluated with respect to one servitized manufacturer through an in-depth single case study. The findings highlighted a number of significant differences between the practice of the servitized manufacturer and the literature. A survey was used to investigate whether the differences were generalisable to a larger sample of servitized manufacturers. The findings point towards the simplification of the reported phases within PSS development and the inclusion of a number of previously unreported processes and activities. Based on these results a new model of PSS development is proposed to better reflect the practice of servitized manufacturers. The model, consisting of four phases and seventeen processes, was operationalised in the form of a workbook and tested through application. Applying the workbook resulted in the successful creation of a number of new PSS concepts

Application of the Fourth Industrial Revolution for High Volume Production in the Rail Car Industry

Some recent technological advances in line with the fourth industrial revolution (4IR) are rapidly transforming the industrial sector. This work explores the prospect of robotic and additive manufacturing solutions for mass production in the rail industry. It proposes a dual arm, 12-axis welding robot with advance sensors, camera, and algorithm as well as intelligent control system. The computer-aided design (CAD) of the robotic system was done in the Solidworks 2017 environment and simulated using the adaptive neuro-fuzzy interference system (ANFIS) in order to determine the kinematic motion of the robotic arm and the angles of joint. The simulation results showed the smooth motion of the robot and its suitability to carry out the welding operations for mass production of components during rail car manufacturing. In addition, the ability to fabricate several physical models directly from digital data through additive manufacturing (AM) is a key factor to ensuring rapid product development cycle. Given that AM is embedded in a digitally connected environment, flow of information as well as data processing and transmission in real time will be useful for massive turnout during mass production

Shop floor data in Industry 4.0: study and design of a Manufacturing Execution System

Industry 4.0 brings with it numerous challenges. However, it is being seen by companies as essential in their ability to adapt to the market and to the demands of consumers. Thus, intending to achieve more flexible and more decentralized production, the acquisition of technologies emerging from this fourth industrial revolution is crucial. This is where information systems will make a difference, as they will enable the cohesion of processes within the company, such as a more streamlined flow of information. This article has as main objective to study and design an Information System with characteristics of a Manufacturing Execution System (MES), following an approach capable to respond to a whole set of key processes on the shop floor, such as addressing the problem of so-called information islands stored in fragmented information sources. This study was conducted in a company belonging to the chemical industry located in the center of Portugal

Sensor data-based decision making

Increasing globalization and growing industrial system complexity has amplified the interest in the use of information provided by sensors as a means of improving overall manufacturing system performance and maintainability. However, utilization of sensors can only be effective if the real-time data can be integrated into the necessary business processes, such as production planning, scheduling and execution systems. This integration requires the development of intelligent decision making models that can effectively process the sensor data into information and suggest appropriate actions. To be able to improve the performance of a system, the health of the system also needs to be maintained. In many cases a single sensor type cannot provide sufficient information for complex decision making including diagnostics and prognostics of a system. Therefore, a combination of sensors should be used in an integrated manner in order to achieve desired performance levels. Sensor generated data need to be processed into information through the use of appropriate decision making models in order to improve overall performance. In this dissertation, which is presented as a collection of five journal papers, several reactive and proactive decision making models that utilize data from single and multi-sensor environments are developed. The first paper presents a testbed architecture for Auto-ID systems. An adaptive inventory management model which utilizes real-time RFID data is developed in the second paper. In the third paper, a complete hardware and inventory management solution, which involves the integration of RFID sensors into an extremely low temperature industrial freezer, is presented. The last two papers in the dissertation deal with diagnostic and prognostic decision making models in order to assure the healthy operation of a manufacturing system and its components. In the fourth paper a Mahalanobis-Taguchi System (MTS) based prognostics tool is developed and it is used to estimate the remaining useful life of rolling element bearings using data acquired from vibration sensors. In the final paper, an MTS based prognostics tool is developed for a centrifugal water pump, which fuses information from multiple types of sensors in order to take diagnostic and prognostics decisions for the pump and its components --Abstract, page iv

Balancing Demand and Supply in Complex Manufacturing Operations: Tactical-Level Planning Processes

By balancing medium-term demand and supply, tactical planning enables manufacturing firms to realize strategic, long-term business objectives. However, such balancing in engineer-to-order (ETO) and configured-to-order (CTO) operations, due to the constant pressure of substantial complexity (e.g., volatility, uncertainty, and ambiguity), induces frequent swings between over- and undercapacity and thus considerable financial losses. Manufacturers respond to such complexity by using planning processes that address the business’s needs and risks at various medium-term horizons, ranging from 3 months to 3 years. Because the importance of decision-making increases exponentially as the horizon shrinks, understanding the interaction between complexity and demand-supply balancing requires extending findings reported in the literature on operations and supply chain planning and control. Therefore, this thesis addresses complexity’s impact on planning medium-term demand-supply balancing on three horizons: the strategic– tactical interface, the tactical level, and the tactical–operational interface.To explore complexity’s impact on demand–supply balancing in planning processes, the thesis draws on five studies, the first two of which addressed customer order fulfillment in ETO operations. Whereas Study I, an in-depth single-case study, examined relevant tactical-level decisions, planning activities, and their interface with the complexity affecting demand–supply balancing at the strategic–tactical interface, Study II, an in-depth multiple-case study, revealed the cross-functional mechanisms of integration affecting those decisions and activities and their impact on complexity. Next, Study III, also an in-depth multiple-case study, investigated areas of uncertainty, information-processing needs (IPNs), and information-processing mechanisms (IPMs) within sales and operations planning in ETO operations. By contrast, Studies IV and V addressed material delivery schedules (MDSs) in CTO operations; whereas Study IV, another in-depth multiple-case study, identified complexity interactions causing MDS instability at the tactical–operational interface, Study V, a case study, quantitatively explained how several factors affect MDS instability.Compiling six papers based on those five studies, the thesis contributes to theory and practice by extending knowledge about relationships between complexity and demand–supply balancing within a medium-term horizon. Its theoretical contributions, in building upon and supporting the limited knowledge on tactical planning in complex manufacturing operations, consist of a detailed tactical-level planning framework, identifying IPNs generated by uncertainty, pinpointing causal and moderating factors of MDS instability, and balancing complexity-reducing and complexity-absorbing strategies, cross-functional integrative mechanisms, IPMs, and dimensions of planning process quality. Meanwhile, its practical contributions consist of concise yet holistic descriptions of relationships between complexity in context and in demand– supply balancing. Manufacturers can readily capitalize on those descriptions to develop and implement context-appropriate tactical-level planning processes that enable efficient, informed, and effective decision-making

Servitization of the manufacturing firm:exploring the operations practices and technologies that deliver advanced services

Purpose: This paper aims to explore practices and technologies successfully servitised manufacturers employ in the delivery of advanced services. Design/methodology/approach: A case study methodology is applied across four manufacturing organisations successful in servitization. Through interviews with personnel across host manufacturers, their partners, and key customers, extensive data are collected about service delivery systems. Analyses identify convergence in their practices and technologies. Findings: Six distinct technologies and practices are revealed: facilities and their location, micro-vertical integration and supplier relationships, information and communication technologies (ICTs), performance measurement and value demonstration, people deployment and their skills, and business processes and customer relationships. These are then combined in an integrative framework that illustrates how operations are configured to successfully deliver advanced services. Research limitations/implications: The analyses are reductive and rationalising. Future studies could identify other technologies and practices. Case study as a method is inherently limited in the extent to which findings can be generalised. Practical implications: Awareness and interest in servitization is growing, yet adoption of a servitization strategy requires particular organisational capabilities on the part of the manufacturer. This study identifies technologies and practices that underpin these capabilities. Originality/value: This paper contributes to the understanding of the servitization process and, in particular, the implications to broader operations of the firm

Using gamification to transform the adoption of servitization

Increasingly, manufacturing organizations compete by developing product-service systems rather than offering products alone. To transform themselves into providers of advanced services, however, product-centric manufacturing firms need to overcome a range of barriers. While previous studies have highlighted the teaching/learning potential of 'gamification' (the use of ideas and techniques found in game-playing), the opportunities to harness this approach to help tackle such barriers have yet to be fully realized. Our study extends the debate by integrating established frameworks relating to emotional mechanics of gamification with the adoption of advanced services, arguing that such mechanics can facilitate and strengthen companies' transformation into advanced-service providers. Based on a systematic analysis of nearly 90 selected publications, we develop six conceptual propositions to explore how gamification can aid the transformation process. Our findings will help both practitioners and researchers apply emotional mechanics of gamification when seeking to address different hurdles hindering the development and provision of advanced services

Opportunities for the digital transformation of the banana sector supply chain based on software with artificial intelligence

Artificial intelligence offers great opportunities for the supply chain, being this a competitive advantage for today’s changing market. This article aims to identify the impacts and opportunities that artificial intelligence software can offer to facilitate the operation and improve the performance of the supply chain in the banana sector in Colombia. The work methodology consists of six steps in which a total of 72 investigations were obtained. The sources of information were four databases. As a main conclusion, the supply chain of the banana sector has everything necessary for intelligent software based solutions to be implemented in order to achieve adaptation, flexibility and sensitivity to the context and domain of execution

Successful Collaboration in Global Production Networks - fair, secured, connected

In today\u27s world, manufacturing companies face many challenges due to the uncertainty and complexity of environmental influences as well as increasing competitive pressures. The pandemic has clearly illustrated how volatile and fragile our supply chains have become. One way to overcome these chal-lenges together is to collaborate with other companies in the value network. Collaborations, i.e. successful cooperation with strategic partners and customers to achieve common goals, will continue to gain in importance. Instead of individual companies, entire value chains and networks will therefore compete with each other in the future. This will require a shift toward fast and seamless data exchange between the players in the value network. Advancing digitization and thus a generally increasingly networked world are increasingly supporting such collaborations, as the sharing and collaborative use of data is becom-ing much simpler. At the same time, the right handling of data will be decisive for competition. Digitization is moving from being a driver of change to an enabler of change. Innovative business models and the exploita-tion of the potential hidden in data will make it possible to realize reliable, flexible and, at the same time, resource-conserving value creation. The number of existing cloud-based collaboration platforms is growing steadily. Small and medium-sized enterprises in particular have to serve many different customer platforms at the same time, while they them-selves are still struggling with internal digitization challenges. Standardization initiatives for secure data rooms in the industry, such as GAIA-X, therefore hold great potential. In addition to these fundamental infrastructural issues, there are further challenges with regard to collaboration projects. Particular importance is attached to the competent handling of data protection and data security. There are often reservations that the disclosure of data and information will result in the loss of hard-earned expertise and com-petitive advantages that have been built up over time. At the same time, however, users from an engineering environment are only able to assess the risks of digital collaboration to a limited extent. In order to secure one\u27s own competitive position in the long term, digital competencies must therefore be built up and barriers to collaboration overcome. Success stories and clear recommendations for action can provide an important impetus for the implementation of successful collaboration projects, showing how collaborations can be approached in practice and what added value they generate. That is why we would like to provide manufacturing compa-nies with such guidance in the form of this action guide. The collaboration projects explained below and the best practices derived from them are intended to help companies find their own strategies on the path to more collaboration. We hope you enjoy reading this guide and are always available for questions and discussions