Challenges in the industrialization process of low-volume production systems

A critical part of new product development projects is the industrialization process of new products which affects both time and the cost. The industrialization of new products or variants in low-volume production systems has some specific challenges which are caused by characteristics of low-volume products and production systems. Therefore, an exploratory case study is made within two Swedish manufacturing companies to understand these challenges and compare the industrialization process in high and low volume production systems. The results of the multiple case studies indicate four challenges including knowledge transfer from the projects into production, development of the work instructions, the need for a higher level of training of the operators and production system design and the obligatory tailoring of the new products to the existing production systems

Designing distribution centres for agile supply chains

Increasing globalisation and market volatility represent major challenges for many supply chains, and particularly for the distribution centres within them. This paper examines how distribution centres are being designed to be agile even though they are, by their nature, long-term fixed assets. The research is based on semi-structured interviews with warehouse design companies to identify the range of agility types that were regarded as necessary during the design phase, and how these were addressed. The research also explores the cost, time and service level implications, whilst handling variances in demand or supply. The interviewee responses are expressed in terms of qualitative measures on Likert scales. The results indicate that there is generally a slightly or moderately higher cost to design for agility. Based on the literature and the case study responses, a methodology is developed of how to address agility within warehouse design, and areas of further research are identified

A framework of justification criteria for advanced manufacturing technology implementation in small and medium enterprises

Today in order to stay in businesses and prosper, Small and Medium Enterprises (SMEs) are seeking higher electiveness and competitiveness across the entire cycle of marketing, product design, manufacture, test and sales. SMEs play an increasingly important role in all aspects of competitiveness: both products and production techniques, but also management methods, the organization of the firm and human resources training. One of the ways by which SMEs can achieve a competitive advantage in manufacturing is through the implementation of Advanced Manufacturing Technology (AMT). An increasing number of them have chosen and are choosing various levels of AMT as the solution. Realizing the importance of SMEs, an attempt has been made in this paper to review the application of AMT in SMEs. Also, a framework has been offered for the implementation of AMT in SMEs. Finally, a summary of findings and conclusions are presented

Discrete Event Simulation Modelling for Dynamic Decision Making in Biopharmaceutical Manufacturing

With the increase in demand for biopharmaceutical products, industries have realised the need to scale up their manufacturing from laboratory-based processes to financially viable production processes. In this context, biopharmaceutical manufacturers are increasingly using simulation-based approaches to gain transparency of their current production system and to assist with designing improved systems. This paper discusses the application of Discrete Event Simulation (DES) and its ability to model the various scenarios for dynamic decision making in biopharmaceutical manufacturing sector. This paper further illustrates a methodology used to develop a simulation model for a biopharmaceutical company, which is considering several capital investments to improve its manufacturing processes. A simulation model for a subset of manufacturing activities was developed that facilitated ‘what-if’ scenario planning for a proposed process alternative. The simulation model of the proposed manufacturing process has shown significant improvement over the current process in terms of throughout time reduction, better resource utilisation, operating cost reduction, reduced bottlenecks etc. This visibility of the existing and proposed production system assisted the company in identifying the potential capital and efficiency gains from the investments therefore demonstrating that DES can be an effective tool for making more informed decisions. Furthermore, the paper also discusses the utilisation of DES models to develop a number of bespoke productivity improvement tools for the company

New Tasks in Old Jobs: Drivers of Change and Implications for Job Quality

This overview report summarises the findings of 20 case studies looking at recent changes in the task content of five manufacturing occupations (car assemblers, meat processing workers, hand-packers, chemical products plant and machine operators and inspection engineers) as a result of factors such as digital transformations, globalisation and offshoring, increasing demand for high quality standards and sustainability. It also discusses some implications in terms of job quality and working life. The study reveals that the importance of physical tasks in manufacturing is generally declining due to automation; that more intensive use of digitally controlled equipment, together with increasing importance of quality standards, involve instead a growing amount of intellectual tasks for manual industrial workers; and that the amount of routine task content is still high in the four manual occupations studied. Overall, the report highlights how qualitative contextual information can complement existing quantitative data, offering a richer understanding of changes in the content and nature of jobs

Empirical Evidence of RFID Impacts on Supply Chain Performance

Purpose - The purpose of this paper is to investigate the actual benefits of radio frequency identification (RFID) on supply chain performance through the empirical evidence. Design/methodology/approach - The research reviews and classifies the existing quantitative empirical evidence of RFID on supply chain performance. The evidence is classified by process (operational or managerial) and for each process by effect (automational, informational, and transformational). Findings - The empirical evidence shows that the major effects from the implementation of RFID are automational effects on operational processes followed by informational effects on managerial processes. The RFID implementation has not reached transformational level on either operational or managerial processes. RFID has an automational effect on operational processes through inventory control and efficiency improvements. An informational effect for managerial processes is observed for improved decision quality, production control and the effectiveness of retail sales and promotions coordination. In addition, a three-stage model is proposed to explain the effects of RFID on the supply chain. Research limitations/implications - Limitations of this research include the use of secondary sources and the lack of consistency in performance measure definitions. Future research could focus on detailed case studies that investigate cross-functional applications across the organization and the supply chain. Practical implications - For managers, the empirical evidence presented can help them identify implementation areas where RFID can have the greatest impact. The data can be used to build the business case for RFID and therefore better estimate ROI and the payback period. Originality/value - This research fills a void in the literature by providing practitioners and researchers with a better understanding of the quantitative benefits of RFID in the supply chain

A Study On Influencing Factors And Performance Of Logistics Outsourcing Practices Among Electrical And Electronics Firms In Malaysia

Penyumberluaran aktiviti logistik telah menjadi strategi popular bagi kebanyakan organisasi dalam memburu kecemerlangan operasi di era persaingan sengit pasaran global. Logistics outsourcing has been growing as a popular strategy for many organizations in pursuit of operational excellence despite the fierce competitive market globally

Micro-manufacturing : research, technology outcomes and development issues

Besides continuing effort in developing MEMS-based manufacturing techniques, latest effort in Micro-manufacturing is also in Non-MEMS-based manufacturing. Research and technological development (RTD) in this field is encouraged by the increased demand on micro-components as well as promised development in the scaling down of the traditional macro-manufacturing processes for micro-length-scale manufacturing. This paper highlights some EU funded research activities in micro/nano-manufacturing, and gives examples of the latest development in micro-manufacturing methods/techniques, process chains, hybrid-processes, manufacturing equipment and supporting technologies/device, etc., which is followed by a summary of the achievements of the EU MASMICRO project. Finally, concluding remarks are given, which raise several issues concerning further development in micro-manufacturing

Operations management in high value manufacturing

This paper explores the issue of high value manufacturing from an operations management perspective and discusses the critical role that the operations management community must play in moving manufacturing organisations to 'higher value ground'. An exploratory study was carried out in two phases. In Phase 1 existing literature was examined following a systematic review process. This was followed by a stakeholder analysis that included manufacturing companies, government agencies and consultancies and case studies of three organisations that had recently repositioned their businesses. Phase 2 comprised of a focus group based industry consultation exercise. The aim of the second phase was to validate and refine the findings from the initial phase and to generate the key ideas that would inform a future research agenda. This paper provides the foundation for further research by identifying those operational issues that are affecting industry as it seeks to move to higher value ground