Managing variation during preproduction activities

Thesis (M.S.)--Massachusetts Institute of Technology, Dept. of Mechanical Engineering, 1994, and Thesis (M.S.)--Massachusetts Institute of Technology, Sloan School of Management, 1994.Includes bibliographical references (p. 100-102).by Shawn P. Patterson.M.S

Summary of Research Conducted by the Manufacturing Systems Team 1994-2002

The Manufacturing Systems team was one of the research teams within the Lean Aerospace Initiative (LAI) whose goal was to document, analyze and communicate the design attributes and relationships that lead to significant performance improvements in manufacturing systems in the defense aerospace industry. This report will provide an integrated record of this research using the Production Operations Transition to Lean Roadmap as its organizing framework

Preventing data loss in PFMEA; a digital solution

Kaizen, a Japanese term, defines continual improvement or a scope of improvement that exists in each process, has motivated the author for this research. The fourth industrial revolution has high demands for lean productivity, reducing waste activities and eliminating defect generation possibilities. PFMEA, a tool known for analysing potential risks is not much developed in the past few years in its knowledge handling capabilities. One of the significant input required for PFMEA generation is PTDB; perhaps, the PTDB is maintained on spreadsheets or Microsoft Excel in general by many organisations and has been proven ineffective in research and events globally in the past few years. However, no development is witnessed in PTDB knowledge handling processes, both in academia and industry. Thus the current thesis aims to answer the basic research question of the study – “What are the advantages of using software-based PTBD over traditional spreadsheet-based PTDB for PFMEA”? The study empirically evaluated the disruptiveness in spreadsheets and its impact on data quality and decision making, linking the possible challenges for PFMEA. In addition, the study intends to capture industry voice and opinion on a digital solution for PTDB. Semi-structured interviews and online surveys were conducted with industry professionals globally to answer the research question. Data has been analysed through content analysis and it was found that, spreadsheets are inefficient in big data handling due to its list of risks, such as; calculation and formatting errors, data security and data transfer issues. Whereas, the industry respondents welcomed the idea of a better but economical digital solution. To overcome the challenges, the author has designed a conceptual framework capable of big data handling, delivers security and flexibility. The framework has an inbuilt PFMEA template that eliminates the possibility of data loss, saves time and deliver quality PFMEA. The future scope exits with the design and trial run of the framework

Power and Narrative in Project Management: Lessons Learned in Recognising the Importance of Phronesis

A component part of modern project management practice is the ‘lessons learned’ activity that is designed to transfer experience and best practice from one project to another, thus improving the practice of project management. The departure point for this thesis is: If we are learning lessons from our experiences in project management, then why are we not better at managing projects? It is widely cited in most project management literature that 50–70% of all projects fail for one reason or another, a figure that has steadfastly refused to improve over many years. My contention is that the current rational approach to understanding lessons learned in project management, one entrenched in the if–then causality of first-order systems thinking where the nature of movement is a ‘corrective repetition of the past in order to realise an optimal future state’ (Stacey 2011: 301), does not reflect the actual everyday experience of organisational life. I see this as an experience of changing priorities, competing initiatives, unrealistic timescales, evaporation of resources, non-rational decisions based on power relations between actors in the organisations we find ourselves in; and every other manner of challenge that presents itself in modern large commercial organisations. I propose a move away from what I see as the current reductionist view of lessons learned, with its emphasis on objective observation, to one of involved subjective understanding. This is an understanding rooted in the particular experience of the individual acting into the social, an act that necessarily changes both the individual and the social. My contention is that a narrative approach to sense making as first-order abstractions in the activity of lessons learned within project management is what is required if we are to better learn from our experiences. This narrative approach that I have termed ‘thick simplification’ supports learning by enabling the reader of the lessons learned account to situate the ‘lesson learned’ within their own experience through treating the lessons learned as a potential future understanding .This requires a different view of what is going on between people in organisations – one that challenges the current reliance on detached process and recognises the importance of embedded phronesis, the Aristotelian virtue of practical judgement. It is an approach that necessarily ‘focuses attention directly on patterns of human relating, and asks what kind of power relations, ideology and communication they reflect’ (Stacey 2007: 266)

Power and Narrative in Project Management: Lessons Learned in Recognising the Importance of Phronesis

A component part of modern project management practice is the ‘lessons learned’ activity that is designed to transfer experience and best practice from one project to another, thus improving the practice of project management. The departure point for this thesis is: If we are learning lessons from our experiences in project management, then why are we not better at managing projects? It is widely cited in most project management literature that 50–70% of all projects fail for one reason or another, a figure that has steadfastly refused to improve over many years. My contention is that the current rational approach to understanding lessons learned in project management, one entrenched in the if–then causality of first-order systems thinking where the nature of movement is a ‘corrective repetition of the past in order to realise an optimal future state’ (Stacey 2011: 301), does not reflect the actual everyday experience of organisational life. I see this as an experience of changing priorities, competing initiatives, unrealistic timescales, evaporation of resources, non-rational decisions based on power relations between actors in the organisations we find ourselves in; and every other manner of challenge that presents itself in modern large commercial organisations. I propose a move away from what I see as the current reductionist view of lessons learned, with its emphasis on objective observation, to one of involved subjective understanding. This is an understanding rooted in the particular experience of the individual acting into the social, an act that necessarily changes both the individual and the social. My contention is that a narrative approach to sense making as first-order abstractions in the activity of lessons learned within project management is what is required if we are to better learn from our experiences. This narrative approach that I have termed ‘thick simplification’ supports learning by enabling the reader of the lessons learned account to situate the ‘lesson learned’ within their own experience through treating the lessons learned as a potential future understanding .This requires a different view of what is going on between people in organisations – one that challenges the current reliance on detached process and recognises the importance of embedded phronesis, the Aristotelian virtue of practical judgement. It is an approach that necessarily ‘focuses attention directly on patterns of human relating, and asks what kind of power relations, ideology and communication they reflect’ (Stacey 2007: 266)

The U.S. Motor Vehicle Industry: Confronting a New Dynamic in the Global Economy

[Excerpt] This report provides an in-depth analysis of the 2009 crisis in the U.S. auto industry and its prospects for regaining domestic and global competitiveness. It also analyzes business and policy issues arising from the unprecedented restructurings that occurred within the industry. The starting point for this analysis is June-July 2009, with General Motors Company (GM or new GM) and Chrysler Group LLC (or new Chrysler) incorporated as new companies, having selectively acquired many, but not all, assets from their predecessor companies. The year 2009 was marked by recession and a crisis in global credit markets; the bankruptcy of General Motors Corporation and Chrysler LLC; the incorporation of successor companies under the auspices of the U.S. Treasury; hundreds of parts supplier bankruptcies; plant closings and worker buyouts; the cash-for-clunkers program; and increasing production and sales at year’s end. This report also examines the relative successes of the Ford Motor Company and the increasing presence of foreign-owned original equipment manufacturers (OEMs), foreign-owned parts manufacturers, competition from imported vehicles, and a serious buildup of global overcapacity that potentially threatens the recovery of the major U.S. domestic producers. This report, which establishes a context for examining the industry and analyzes a unique but highly specific period in the U.S. automobile industry’s history, will not be updated

Modeling human-machine interaction in production systems for equipment design

Thesis (S.M.)--Massachusetts Institute of Technology, Dept. of Mechanical Engineering, 1999.Includes bibliographical references (p. 125-127).by Micah Thomas Collins.S.M

A Structured Approach to Modelling Lean Batch Production

A problem relating to the manufacture of automotive body panels concerns the appropriate choice of production size or batch quantity of a body panel production run that ensures a minimum inventory profile is maintained while not compromising production efficiency. Due to underlying variation within the body panel production process it is difficult to determine a relationship between the batch quantity and production efficiency.This thesis determines the appropriate production batch size through the creation of an iterative modelling methodology that initially examines the nature of the variation within the panel production process. Further iterations of the methodology apply appropriate analytical modelling methods until a satisfactory solution is achieved. The modelling construction is designed so that it is potentially applicable to a wider range of manufacturing problems. As there is variation inherent within the system, regression analysis, experimental design (traditional and Taguchi) are considered. Since an objective of creating the modelling methodology is the potential of apply the methodology to a wider variety of manufacturing problems, additional modelling methods are assessed. These include the operational research methods of mathematical programming (linear and non-linear and dynamic programming) and queuing systems. To model discrete and continuous behaviour of a manufacturing system, the application of hybrid automata is considered. Thus a suite of methodologies are assessed that assess variation, optimisation and networks of manufacturing systems. Through the iterative stages of the modelling approach, these analytical methods can be applied as appropriate to converge on to the appropriate solution for the problem under investigation. The appropriate methods identified to quantify a relationship between the batch production quantity and production efficiency include regression modelling and traditional experimental design. The conclusion drawn from the application of both methods is that relative to the inherent variation present in the production system, lower batch quantities can be chosen for production runs without affecting the production performance. Consequently, a minimum inventory profile can be maintained satisfying the objective of a lean system

Development of a supply planning methodology in the automotive industry

Supply Planning in the Automotive Industry is a vital ingredient for Supply Chain Integration. The role and function of a Supply Planner, although clearly defined in European developed methods, lacks the practical dimension. This paper describes such a practical approach that was developed for Supply Planning in the South African Automotive Industry. The framework highlights all the aspects – from a business and functional perspective - that need to be considered on a global and local scale. The framework describes the role and responsibilities of the Supply Planner as an active supply chain designer during the product/production development process.Dissertation (MEng (Industrial Engineering))--University of Pretoria, 2006.Industrial and Systems Engineeringunrestricte

A next generation manufacturing control system for a lean production environment

This thesis focuses on addressing the need for a new approach to the design and implementation of manufacturing control systems for the automotive industry and in particular for high volume engine manufacture. Whilst the operational domain in the automotive industry has moved to lean production techniques, the design of presentday manufacturing control systems is still based on systems intended for use in a mass production environment. The design and implementation of current manufacturing control systems is therefore inappropriate when viewed from a business context. The author proposes that it is possible to create a more appropriate manufacturing control systems based on an optimised use of advanced manufacturing technology within the complete business context. Literature is reviewed to provide a detailed understanding of the relationship between modem operating practices and the application of contemporary control systems. The primary tasks of manufacturing control systems, within the context of a structured systems approach to manufacturing technology, production management and industrial economics are identified. A study of modem manufacturing control system technology is carried out, highlighting the fundamental principles that influence application engineering in this area. The thesis develops a conceptual design framework that aids the identification of attributes required of a next generation manufacturing control system (NGCS), in order to enhance the business performance of lean automotive manufacturing. The architecture for a next generation control system is specified and a Proof of concept system implemented. Potential advances over contemporary practice are identified with the aid of a practical implementation at a major automotive manufacturer