Anthropocentric perspective of production before and within Industry 4.0

Abstract This paper presents a systematic literature review (SLR) of the anthropocentric perspective of production before and after (or, better, within) Industry 4.0. We identify central research clusters regarding traditional Anthropocentric Production Systems (APS) and Anthropocentric Cyber Physical Production Systems. By comparing the two perspectives, we are able to analyse new emerging paradigms in anthropocentric production caused by Industry 4.0. We further make prediction of the future role of the human operator, his needed knowledge and capabilities and how assistance systems support the Operator 4.0. Our paper gives a brief outlook of current and needed future research. It builds grounds for further scholarly discussion on the role of humans in the factory of the future

An implementation model of a quality management information scheme for cellular manufacturing environments

As today's global competition grows in manufacturing industries companies are forced to work smart in all areas of operations, starting with suppliers and ending with customers. This competition in general requires firms to improve market responsiveness, product quality, use computerised information systems for production planning and control, have more rapid changeovers, reductions in setup times, work-in-progress reduction and hence throughput time reduction. In order to accomplish these formidable tasks, there are a number of management philosophies available for manufacturing companies. These include just-in-time, flexible manufacturing systems, computer integrated manufacturing, total quality management, concurrent engineering. Implementation of these philosophies, however, requires mass mobilisation encompassing many areas of operations such as production, sales and marketing, suppliers, finance, customer servicing, product design and method engineering, maintenance, personnel and training, etc. This thesis details a study which evaluates the total quality management philosophy in cellular manufacturing environment. Following this evaluation, a quality management information scheme, which is structured and integrated, has been produced using the Manufacturing Systems Analysis and Design Method. In order to manage smoothly this mobilisation and incorporate the scheme to other integrated functional areas, a new approach namely the Activity Based Implementation (ABI) has also been produced. Justification of the model from various points of view has shown that the model is expected to address a considerable gap in the area concerned. The model was designed to be used as an integrated part of a system or as a stand-alone scheme by quality practitioners, the management board of organisations implementing TQM and quality management researchers

A Multi-Skilled Approach to Property Maintenance Considering Temporal, Spatial and Resource Constraints

With the continued increase in age of the United States housing and building stock, as well as the continued need to maintain properties across the U.S., the need for timely, cost-optimal maintenance is ever more critical. This paper proposes the application of a mathematical model to aid in the scheduling and assignment of construction and maintenance tasks, considering the multi-skilled workforce. The benefit of this approach is to take advantage of the economies of scale that can be developed using cross-functional skilled workers with varying levels of competence and efficiency. This approach schedules and assigns tasks using data from maintenance task software datasets, using the least-cost, competent worker available for the job while also considering the trade-off between skilled labor cost and travel costs, both in terms of travel wage and vehicle wear and tear. The model is enhanced to include pairing between a mentor and an apprentice, where combined efficiency and pairing costs are considered at the same time as travel costs. Due to the practical nature of this research, a case organization was used and data from that firm was analyzed so that operational insights into the necessity of such a model could be considered. The mathematical backbone of the optimization approach to multi-skilled resource allocation considers the temporal and spatial demands of a geographically dispersed property management program. Actual, as opposed to sample, data allows us to evaluate the real financial implications on the case firm, if such an approach to scheduling is used. The generalization of this data provides excellent fit for a model that can be used to assign the best capable worker to the most cost-efficient task, considering deadlines, priorities and availability. Results of this scheduling approach provide significant cost and resource reductions over the historical firm performance, though practical considerations should temper that expectation. The above approach offers exceptional scalability and adaptability with the continued advancement of algorithm approaches to network-distribution and peer-to-peer work platforms

Enabling flexibility through strategic management of complex engineering systems

”Flexibility is a highly desired attribute of many systems operating in changing or uncertain conditions. It is a common theme in complex systems to identify where flexibility is generated within a system and how to model the processes needed to maintain and sustain flexibility. The key research question that is addressed is: how do we create a new definition of workforce flexibility within a human-technology-artificial intelligence environment? Workforce flexibility is the management of organizational labor capacities and capabilities in operational environments using a broad and diffuse set of tools and approaches to mitigate system imbalances caused by uncertainties or changes. We establish a baseline reference for managers to use in choosing flexibility methods for specific applications and we determine the scope and effectiveness of these traditional flexibility methods. The unique contributions of this research are: a) a new definition of workforce flexibility for a human-technology work environment versus traditional definitions; b) using a system of systems (SoS) approach to create and sustain that flexibility; and c) applying a coordinating strategy for optimal workforce flexibility within the human- technology framework. This dissertation research fills the gap of how we can model flexibility using SoS engineering to show where flexibility emerges and what strategies a manager can use to manage flexibility within this technology construct”--Abstract, page iii

Cost-conscious manufacturing – Models and methods for analyzing present and future performance from a cost perspective

Manufacturing is an industry in which the effects of globalization are obvious. Manufacturing costs are a key factor in this respect and affect, for example, decisions about offshoring, i.e., moving production abroad. If Sweden and other Western countries are to maintain large manufacturing sectors, they must be competitive, making cost one of the most critical parameters. The work presented here seeks to develop tools for cost-conscious manufacturing. These tools should provide insight into how well a manufacturing system is performing and support the analysis and prioritization of manufacturing development activities. To achieve this objective, two research questions were formulated. The first research question (RQ1) concerns how a general cost model should be designed to take into consideration the most important process-near parameters influencing manufacturing system performance. A cost model developed in accordance with this research question includes critical parameters affecting performance, such as cycle time, setup time, and performance loss parameters. The model is centered on the processing steps involved in processing a part. The losses occurring in the processing steps are important in the model, so the links between structured, detailed monitoring of the loss causes and their impacts on costs are emphasized. Modified versions of the model to analyze volume flexibility and downtime variability are also presented. The second research question (RQ2) concerns how such a cost model can be used in practice, i.e., the requirements and conditions for industrial use. Implementation in an automotive company indicated that the model was applicable in this context and that interesting insights into manufacturing costs could be gained from using the model. A study of the industrial conditions for applying the cost model identified software products for collecting manufacturing loss data that support the level of detail needed for model input, but found that manufacturing companies do not necessarily collect such detailed data. A demonstration program developed based on the databases available in a collaborating company indicated how the cost model could be used practically in a company. The somewhat deficient detail in the collected loss data, found in the above study, led to an inquiry in another company into the pros and cons of collecting highly detailed performance loss data. The results identified more advantages than disadvantages with collecting more detailed data: the operators responsible for data collection did not perceive any particular difficulties with the increased detail and the production manager believed that the increased detail led to better knowledge of performance losses

Application of lean scheduling and production control in non-repetitive manufacturing systems using intelligent agent decision support

This thesis was submitted for the degree of Doctor of Philosophy and awarded by Brunel University.Lean Manufacturing (LM) is widely accepted as a world-class manufacturing paradigm, its currency and superiority are manifested in numerous recent success stories. Most lean tools including Just-in-Time (JIT) were designed for repetitive serial production systems. This resulted in a substantial stream of research which dismissed a priori the suitability of LM for non-repetitive non-serial job-shops. The extension of LM into non-repetitive production systems is opposed on the basis of the sheer complexity of applying JIT pull production control in non-repetitive systems fabricating a high variety of products. However, the application of LM in job-shops is not unexplored. Studies proposing the extension of leanness into non-repetitive production systems have promoted the modification of pull control mechanisms or reconfiguration of job-shops into cellular manufacturing systems. This thesis sought to address the shortcomings of the aforementioned approaches. The contribution of this thesis to knowledge in the field of production and operations management is threefold: Firstly, a Multi-Agent System (MAS) is designed to directly apply pull production control to a good approximation of a real-life job-shop. The scale and complexity of the developed MAS prove that the application of pull production control in non-repetitive manufacturing systems is challenging, perplex and laborious. Secondly, the thesis examines three pull production control mechanisms namely, Kanban, Base Stock and Constant Work-in-Process (CONWIP) which it enhances so as to prevent system deadlocks, an issue largely unaddressed in the relevant literature. Having successfully tested the transferability of pull production control to non-repetitive manufacturing, the third contribution of this thesis is that it uses experimental and empirical data to examine the impact of pull production control on job-shop performance. The thesis identifies issues resulting from the application of pull control in job-shops which have implications for industry practice and concludes by outlining further research that can be undertaken in this direction

The effect of lean manufacturing on operations performance and business performance in manufacturing companies in Indonesia

The purpose of this mixed methods sequential explanatory study was to understand the effect of lean manufacturing on operations performance and business performance in the context of manufacturing companies in Indonesia. In the first phase, a quantitative research was conducted to investigate the relationship among the variables. 174 large manufacturing companies were involved in the quantitative phase. Structural equation modeling (SEM) approach was applied to test all the hypotheses. The findings of the quantitative data analysis indicate that all the lean manufacturing practices are highly correlated and interdependent. The results provide evidence that lean manufacturing should be implemented holistically, because the practices are mutually supportive and complement each other. Lean manufacturing is also positively related with operations performance and business performance. More importantly, operations performance complementary mediates the relationship between lean manufacturing and business performance. A qualitative research based on a case study method was conducted in Toyota Indonesia to explain, elaborate, and triangulate the quantitative findings. The outcomes of the qualitative research are consistent and supporting the quantitative results. This study provides a deeper insight regarding the relationship between lean manufacturing, operations performance, and business performance. Therefore, this study could expand the boundary of the existing literature, and contributes to the body of knowledge related to the effect of lean manufacturing theoretically, practically, and methodologically

Critical factors of lean implementation in manufacturing environments

Tese de mestrado integrado. Engenharia Industrial e Gestão. Faculdade de Engenharia. Universidade do Porto. 200