Enhanced integrated modelling approach to reconfiguring manufacturing enterprises

Dynamism and uncertainty are real challenges for present day manufacturing enterprises (MEs). Reasons include: an increasing demand for customisation, reduced time to market, shortened product life cycles and globalisation. MEs can reduce competitive pressure by becoming reconfigurable and change-capable. However, modern manufacturing philosophies, including agile and lean, must complement the application of reconfigurable manufacturing paradigms. Choosing and applying the best philosophies and techniques is very difficult as most MEs deploy complex and unique configurations of processes and resource systems, and seek economies of scope and scale in respect of changing and distinctive product flows. It follows that systematic methods of achieving model driven reconfiguration and interoperation of component based manufacturing systems are required to design, engineer and change future MEs. This thesis, titled Enhanced Integrated Modelling Approach to Reconfiguring Manufacturing Enterprises , introduces the development and prototyping a model-driven environment for the design, engineering, optimisation and control of the reconfiguration of MEs with an embedded capability to handle various types of change. The thesis describes a novel systematic approach, namely enhanced integrated modelling approach (EIMA), in which coherent sets of integrated models are created that facilitates the engineering of MEs especially their production planning and control (PPC) systems. The developed environment supports the engineering of common types of strategic, tactical and operational processes found in many MEs. The EIMA is centred on the ISO standardised CIMOSA process modelling approach. Early study led to the development of simulation models during which various CIMOSA shortcomings were observed, especially in its support for aspects of ME dynamism. A need was raised to structure and create semantically enriched models hence forming an enhanced integrated modelling environment. The thesis also presents three industrial case examples: (1) Ford Motor Company; (2) Bradgate Furniture Manufacturing Company; and (3) ACM Bearings Company. In order to understand the system prior to realisation of any PPC strategy, multiple process segments of any target organisation need to be modelled. Coherent multi-perspective case study models are presented that have facilitated process reengineering and associated resource system configuration. Such models have a capability to enable PPC decision making processes in support of the reconfiguration of MEs. During these case studies, capabilities of a number of software tools were exploited such as Arena®, Simul8®, Plant Simulation®, MS Visio®, and MS Excel®. Case study results demonstrated effectiveness of the concepts related to the EIMA. The research has resulted in new contributions to knowledge in terms of new understandings, concepts and methods in following ways: (1) a structured model driven integrated approach to the design, optimisation and control of future reconfiguration of MEs. The EIMA is an enriched and generic process modelling approach with capability to represent both static and dynamic aspects of an ME; and (2) example application cases showing benefits in terms of reduction in lead time, cost and resource load and in terms of improved responsiveness of processes and resource systems with a special focus on PPC; (3) identification and industrial application of a new key performance indicator (KPI) known as P3C the measuring and monitoring of which can aid in enhancing reconfigurability and responsiveness of MEs; and (4) an enriched modelling concept framework (E-MUNE) to capture requirements of static and dynamic aspects of MEs where the conceptual framework has the capability to be extended and modified according to the requirements. The thesis outlines key areas outlining a need for future research into integrated modelling approaches, interoperation and updating mechanisms of partial models in support of the reconfiguration of MEs

Why design matters? Making the case for the smaller companies in the automotive industry

This research focuses on industrial design and strategic management and more specifically on the way the development of design capabilities can influence the strategic product market position of the Portuguese small and medium supply companies for the automotive industry. Industrial design is not usually highlighted as a cornerstone skill of most small-scale automotive supply companies. Instead, it is usually established as a process in resource-capability combinations due to the highly dynamic environments that characterize this industry. Practice suggests a double bias either in the definition of design, sometimes emphasized as style and associated with carmakers, or in design’s role in developing the position of small and medium enterprises in supply networks. This line of reasoning supports the lead research question: why design matters for smaller companies in the automotive industry? The theoretical constructs and context field supported through the literature and the automotive industry profile (international and Portuguese) review reveal a research procedure supported on an interdisciplinary work process. The exploratory nature of this study calls for a qualitative type of research to be conducted as the use of case studies is the most appropriate research strategy. Three firms from the Portuguese automotive cluster were selected for the case study representing an appropriate automotive industry supplier sample for cross-case analysis. The analysis of the gathered data required three phases: analysis and report of individual cases; analysis and report of cross cases; and the conclusions and implications of the cross cases for both theory and practice. As a result, it is revealed the importance of the development of design capabilities for a determined business strategy. The development of design capabilities is key for the development of high added value products for the supply of complex parts or modules. Hence, a list of suggested positive and negative industrial design practices are proposed

Leveraging Open-standard Interorganizational Information Systems for Process Adaptability and Alignment: An Empirical Analysis

PurposeThe purpose of this paper is to understand the value creation mechanisms of open-standard inter-organizational information system (OSIOS), which is a key technology to achieve Industry 4.0. Specifically, this study investigates how the internal assimilation and external diffusion of OSIOS help manufactures facilitate process adaptability and alignment in supply chain network.Design/methodology/approachA survey instrument was designed and administrated to collect data for this research. Using three-stage least squares estimation, the authors empirically tested a number of hypothesized relationships based on a sample of 308 manufacturing firms in China.FindingsThe results of the study show that OSIOS can perform as value creation mechanisms to enable process adaptability and alignment. In addition, the impact of OSIOS internal assimilation is inversely U-shaped where the positive effect on process adaptability will become negative after an extremum point is reached.Originality/valueThis study contributes to the existing literature by providing insights on how OSIOS can improve supply chain integration and thus promote the achievement of industry 4.0. By revealing a U-shaped relationship between OSIOS assimilation and process adaptability, this study fills previous research gap by advancing the understanding on the value creation mechanisms of information systems deployment

Characteristics of redistributed manufacturing systems: a comparative study of emerging industry supply networks

This paper explores the characteristics of redistributed manufacturing systems within the context of emerging industry supply networks (EI SNs), with a particular focus on their structure, operations and reconfiguration dynamics. A number of factors have resulted in the redistribution of manufacturing. Within Emerging Industries, advances in process and information technologies, have changed the physical and information characteristics of components and products, and the viable production economies of scale. Further, the emergence of new specialised companies fulfilling key research, production or service roles have changed industry structure and operations, and the conventional model of value creation. Six industrial systems are examined using an Industrial System mapping methodology providing a basis for cross-case analysis, selected on the basis of representing alternative and novel evolution paths that may provide insights into the characteristics of EI SNs within a redistributed manufacturing context. Cross-case analysis suggests several generic aspects to EI SNs, including the blurring of traditional industry boundaries and the critical requirement to manage uncertainty. Alternative forms of EI SNs are observed supporting particular EI evolution paths. Further, more adaptive SNs support increased product variety, with lower inventory models enabled by enhanced production and distribution flexibility, often located closer to demand.The authors would like to acknowledge UK Research Council EPSRC, the industrial collaborators who provided access to their organisations, and their supply network, industrial and institutional partners.This is the author accepted manuscript. The final version is available from Taylor & Francis via http://dx.doi.org/10.1080/00207543.2016.121476

Product to process lifecycle management in assembly automation systems

Presently, the automotive industry is facing enormous pressure due to global competition and ever changing legislative, economic and customer demands. Product and process development in the automotive manufacturing industry is a challenging task for many reasons. Current product life cycle management (PLM) systems tend to be product-focussed. Though, information about processes and resources are there but mostly linked to the product. Process is an important aspect, especially in assembly automation systems that link products to their manufacturing resources. This paper presents a process-centric approach to improve PLM systems in large-scale manufacturing companies, especially in the powertrain sector of the automotive industry. The idea is to integrate the information related to key engineering chains i.e. products, processes and resources based upon PLM philosophy and shift the trend of product-focussed lifecycle management to process-focussed lifecycle management, the outcome of which is the Product, Process and Resource Lifecycle Management not PLM only

How to embed environmental sustainability: The role of dynamic capabilities and managerial approaches in a life cycle management perspective

AbstractLife cycle management (LCM) is a managerial framework to embed a holistic environmental sustainability logic inside organizations. Despite its long tradition, the implementation of LCM is little explored. In this study we observe how sensing, seizing, and reconfiguring capabilities together with managerial approaches to environmental sustainability help organizations embed LCM in their practices. We performed a multinomial logistic regression using a sample of 187 medium and large enterprises. Our findings show that sensing and seizing capabilities and an integrative approach to sustainability help embed LCM in presence of complex environments. Among dynamic capabilities, reconfiguring does not appear to help organizations embed LCM. This study contributes to the literature on LCM and dynamic capabilities

Modular product development for mass customization

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