Process Improvement at Source International

The objective of this Major Qualifying Project was to help Source International to optimize their manufacturing process for the Modular product line while reducing costs, non-value added time, and employee motion within their work area. The methods used to accomplish this included axiomatic design matrix, Lean Methodologies comprised of value stream map, spaghetti diagram, DMAIC, 5S methodology, 7 Wastes, and Arena® Simulation. The team’s recommendations included implementing these Lean Methodologies tools in order to improve the Modular product line. In conclusion, the application of Lean Analytic tools would yield substantial savings in time and money, and increasing efficiency of the manufacturing process that Source International uses

Simulation Of Value Stream Mapping And Discrete Optimization Of Energy Consumption In Modular Construction

With the increased practice of modularization and prefabrication, the construction industry gained the benefits of quality management, improved completion time, reduced site disruption and vehicular traffic, and improved overall safety and security. Whereas industrialized construction methods, such as modular and manufactured buildings, have evolved over decades, core techniques used in prefabrication plants vary only slightly from those employed in traditional site-built construction. With a focus on energy and cost efficient modular construction, this research presents the development of a simulation, measurement and optimization system for energy consumption in the manufacturing process of modular construction. The system is based on Lean Six Sigma principles and loosely coupled system operation to identify the non-value adding tasks and possible causes of low energy efficiency. The proposed system will also include visualization functions for demonstration of energy consumption in modular construction. The benefits of implementing this system include a reduction in the energy consumption in production cost, decrease of energy cost in the production of lean-modular construction, and increase profit. In addition, the visualization functions will provide detailed information about energy efficiency and operation flexibility in modular construction. A case study is presented to validate the reliability of the system

Improving Construction Processes by Integrating Lean, Green, and Six-Sigma

The overall goal of this research was to develop and implement methods to improve the performance and the efficiency of construction processes prior to and during the construction phase in Design-Bid-Build (DBB) projects. In order to accomplish these goals, the three methods Lean, Green, and Six-Sigma were implemented in two different scenarios and validated by different case studies. First, a framework was developed that integrated the three methods Lean, Green, and Six-Sigma with an overall layout of the Define, Measure, Analyze, Improve, and Control (DMAIC) improvement model. The framework was then validated via a construction process of installation of pile caps for an educational institute during the construction phase in Pittsburgh. The framework highlighted two issues with the pile caps construction process. First, disparate quantities of materials (purchased and installed) were determined. Second, the pile caps construction process took a total time of 54 business days while it could have been completed in 30 business days. Using life cycle assessment, environmental impacts of the pile cap construction process were analyzed and results showed that major environmental impacts including global warming potential, release of carcinogenics, negative respiratory effects, ozone depletion, and ecotoxcity could result from the materials used for the process. Next, the root causes behind waste generation were determined via developing and administrating a questionnaire to a local construction company. Second, the previously developed framework was further validated and applied to a residential development project in Saudi Arabia. The construction sector has been growing rapidly in Saudi Arabia; however, the quality of Saudi Arabian construction is decreasing, resulting in excess waste generation and associated environmental impacts. This case study examined a project with 53 residential units overall but only 10 units acceptable at final inspection. The largest quality issue was determined to be exterior paint blistering. Using the developed framework, defective units were investigated through a field examination, narrowing down the causes of the blistering applying the Pareto method as follows: Inadequate method, untrained workers, weather, and others. Next, the Process improvement tool was applied to reduce the blistering causes and to improve the current process. A new method designed and applied to a separate residential unit for validation. The modified method showed a great improvement and in the end the unit was able to pass inspection. Finally, building on the previous case studies, the framework was later refined with the goal of applying it earlier in a project, prior to construction, to further reduce potential waste generation and associated environmental impacts. Using Lean Green, and Six-Sigma (LG6) and adopting the same improvement model, DMAIC, the owner can evaluate all steps separately in the process, addressing all resources consumed and analyzing environmental impacts which might be generated; this highlights potential waste and so can help the owner avoid waste occurrence by indicating where the process needs to be amended to create less environmental impact and more efficiency. For this research, the model was used to help evaluate the construction process for the installation of 160 woodpiles. The model identified that four steps out of eight were considered as non-adding value steps or waste. Three steps out of four non-adding value steps were involved with moving down, moving around, and setting up the equipment. The remaining wasteful step was cutting to length all installed woodpiles. The model showed that if these steps were replaced, eliminated or planned well, environmental impacts would be reduced by 9% and expenses by 1%

A green-lean-six sigma model for environmental performance in manufacturing organizations : a study of a developed and developing nation : a thesis presented in partial fulfilment of the requirement for the degree of Doctor of Philosophy in Engineering Management, School of Food and Advanced Technology, Massey University, Auckland, New Zealand

Table 2.2 (=Kumar et al 2016) was removed for copyright reasonsManufacturing organizations continue to face environmental challenges including greenhouse gas (GHG) emissions, large-scale energy consumption, and solid and liquid waste generation contributing to climate change. While emerging environmental concerns are serious challenges for discrete and process industries in both developed and developing countries, the impact of these issues is more significant for the process industry due to their high energy requirements, GHG emissions, and lack of application of operational strategies. Green-lean-six sigma (GLSS) is recognized as a promising operational and environmental improvement strategy for minimizing waste and conserving resources in manufacturing organizations. However, scant attention has been paid to examining this strategy in addressing the environmental concerns, and in particular, investigating its application between developed and developing nations. The aim of this study is to examine the drivers, enablers, environmental outcomes, and critical success factors (CSFs) of a GLSS strategy in a developed country (New Zealand) and developing country (Pakistan) context in the manufacturing industry. This study draws on the natural resource-based view, institutional theory-based view, and intellectual capital-based view to understand the execution of this strategy and develops a GLSS model for improving the environmental performance in manufacturing organizations. A qualitative research methodology is adopted with semi-structured interviews using the case study approach. In the first phase, a preliminary study is undertaken with lean six sigma and environmental consultants from New Zealand (NZ) and Pakistan (PK). In the second phase, the main study is conducted with senior corporate managers of two large-sized flexible packaging manufacturing companies in both NZ and PK who have implemented the green, lean, and six sigma strategies. This study highlights various internal operational and organizational drivers and external regulatory, market-driven, and society-oriented forces that prompt manufacturing companies to adopt a GLSS strategy. Numerous GLSS enablers for achieving environmental outcomes including waste and emission reduction, resource conservation and recycling, and environmental safety and compliance are revealed. Further, CSFs for the implementation of a GLSS approach comprising the strategic, operational, human resource, and external stakeholder-related elements are presented. By utilizing the results of the preliminary and the main study, a holistic GLSS model is developed for achieving environmental performance in manufacturing organizations, with significant theoretical and practical implications

Lean goods receipt

Changes in the global Maintenance, Repair and Overhaul (MRO) market have caused an increased demand for V2500 MRO services. The Christchurch Engine Centre (CHCEC) must increase its capacity from 100 engines in 2017 to 140 engines in 2019 (+40%) to meet this demand. The current internal part handling logistics system is operating at its maximum capacity and cannot be scaled up due to floor­ space constraints. Optimisation is required to keep up with the upcoming additional engine volume. The purpose of this report is to present recommendations on the design and implementation of an internal logistics system at the CHCEC. The proposed system shall optimise the goods receipt area and material flow at the CHCEC by eliminating 90% non-reusable packaging materials past receipt, improving material handling, and minimising the floor space consumed by cartons by 25%, through implementing re-usable containers. The logistics system shall include all processes and material flows between parts receiving (RX) and Kitting

An integration of Lean Six Sigma and Health and Safety Management System in Saudi Broadcasting Corporation

This thesis was submitted for the award of Doctor of Philosophy and was awarded by Brunel University LondonLean Six Sigma is a method used to improve the quality and efficiency of processes by reducing variation and eliminating wastes (non-value added activities) in an organisation. The concept of combining the principles and tools of Lean Enterprise and Six Sigma has been discussed in the literature. The majority of Lean Six Sigma applications in private industry have focused primarily on manufacturing applications. The literature has not provided a framework for implementing Lean Six Sigma programmes in non-manufacturing or transactional processes like those in the Entertainment Media industry. The Saudi Broadcasting Corporation (SBC), like many other industries in Saudi Arabia, has high occupational safety risks, such as electric, fire and fall hazards which often occur in the media workplace. These risks are considered very costly and affect productivity and employee morale in general. The main objective of this research is to provide a synergistic approach to integrating occupational health and safety programmes and Lean Six Sigma tools using the DMAIC (Define-Measure-Analyse-Improve-Control) problem-solving method to strengthen and assure the success of safety programmes in the Saudi Broadcasting Corporation (SBC). This research identifies the roadmap (i.e. activities, principles, tools, and important component factors) for applying Lean Six Sigma tools in the media industry. A case study addressing the safety issues that affect employees’ performance within the Saudi Broadcasting Corporation (SBC) TV studio is used to validate work outlined in this research. Furthermore, the Bayesian Belief Networks (BBN) method is used to understand the probability occurrence of safety hazards. The application of the Taguchi Experimental Design method and other Lean Six Sigma tools, such as Cause and Effect diagrams, Pareto principles, 5S, Value Stream map, and Poka-Yoke have been incorporated in to this research. The application of Lean Six Sigma DMAIC problem-solving tools resulted in significant improvement in safety within SBC. The average electrical hazard incident decreased from 2.08 to 0.33, the average fire hazard incident decreased from 1.25 to 0.08, and the average fall hazard incident decreased from 3.42 to 0.17. The research has important implications for the company and its employees, with positive outcomes and feedback reported by top management, the senior technicians, and experts. The research improved the safety by reducing electrical, fire and fall risks. The Safety training sessions are one of the most significant factors that improve their safety awareness. It is observed that Lean Six Sigma problem-solving tools and methods are effective in the Saudi Broadcasting Corporation (SBC)

Retrofitting and refurbishment processes of heritage buildings: application to three case studies

Tese de mestrado integrado em Engenharia da Energia e do Ambiente, apresentada à Universidade de Lisboa, através da Faculdade de Ciências, 2014Na Europa, os edifícios são responsáveis por 40% do consumo energético total e por 36% das emissões de gases de efeito de estufa. Este trabalho focou-se nos edifícios de património. Estes edifícios são aqueles que representam o legado de uma sociedade, herdado de gerações passadas, mantido no presente e entregue para o benefício das gerações futuras. Este trabalho fez parte do projecto europeu Reducing Footprints of Monumental Structures, Landscapes and Buildings (ReFoMo) que explorou o potencial e as necessidades de projectos de adaptação e renovação que visavam melhorar o desempenho energético de edifícios de património. Para isso, realizou-se uma extensa revisão bibliográfica a fim de encontrar as soluções já implementadas neste tipo de edifícios. Posteriormente, realizou-se uma análise comparativa dos três casos de estudo – três edifícios em países parceiros do projecto. Ao confluir o que foi aprendido da revisão bibliográfica e dos casos de estudo, foram detectadas as falhas e os exemplos a seguir. Portanto, sugere-se como um plano a seguir: i) a criação de uma equipa multidisciplinar; ii) a realização de uma auditoria energética prévia, iii) a análise cuidadosa das soluções existentes para cada caso específico e; iv) a elaboração de um plano de manutenção de controlo dos benefícios após implementação das medidas que melhoram o desempenho energético dos edifícios. O desempenho energético dos edifícios do património será melhorado sempre que esta metodologia for aplicada.Buildings in Europe represent 40% of total energy consumption and 36% of Greenhouse Gas Emissions. This research focuses in heritage buildings. These represent the legacy of a society that is inherited from past generations, maintained in the present and given for the benefit of future generations. This research was part of the European project Reducing Footprints of Monumental Structures, Landscapes and Buildings (ReFoMo) that explored the potential and demand for retrofitting and refurbishment projects which will improve the energy efficiency of heritage buildings. For this, an extensive literature review was performed in order to find the solutions already implemented in this type of buildings. Then, a comparative analysis of three case studies was executed – three buildings in countries partners of the project. By merging what was learned both from literature review and from the case studies, it was recognised what failed and the good examples. Therefore, it is suggested as the basis of a framework: i) creation of a multidisciplinary team; ii) performance of an energy audit, iii) careful analysis of the existing solutions for each specific case and; iv) elaboration of a maintenance plan after implementing measures aiming at control the benefits of the implementation in long terms conditions. This framework will improve the energy performance of heritage buildings when applied

Production Engineering and Management

It is our pleasure to introduce the seventh edition of the International Conference on Production Engineering and Management (PEM), an event that is the result of the joint effort of the University of Trieste and the Ostwestfalen- Lippe University of Applied Sciences. The conference has been established as an annual meeting under the Double Degree Master Program “Production Engineering and Management” by the two partner universities. This year the conference is hosted at the university campus in Pordenone. The main goal of the conference is to offer students, researchers and professionals in Germany, Italy and abroad, an opportunity to meet and exchange information, discuss experience, specific practices and technical solutions for planning, design and management of manufacturing and service systems and processes. As always, the conference is a platform aimed at presenting research projects, introducing young academics to the tradition of symposiums and promoting the exchange of ideas between the industry and the academy. This year’s special focus is on industry sustainability, which is currently a major topic of discussion among experts and professionals. Sustainability can be considered as a requirement for any modern production processes and systems, and also has to be embedded in the context of Industry 4.0. In fact, the features and problems of industry 4.0 have been widely discussed in the last editions of the PEM conference, in which efficiency and waste reduction emerged as key factors. The study and development of the connections between future industry and sustainability is therefore critical, as highlighted in the recent “German Sustainable Development Strategy and the 2030 Agenda”. Accordingly, the seventh edition of the PEM conference aims to offer a contribution to the debate. The conference program includes 25 speeches organized in six sessions. Three are specifically dedicated to “Direct Digital Manufacturing in the context of Industry 4.0” and “Technology and Business for Circular Economy and Sustainable Production”. The other sessions are covering areas of great interest and importance to the participants of the conference, which are related to the main focus: “Innovative Management Techniques and Methodologies”, “Industrial Engineering and Lean Management” and “Wood Processing Technologies and Furniture Production”. The proceedings of the conference include the articles submitted and accepted after a careful double-blind refereeing process

AN APPROACH TO INVENTORY MANAGEMENT IN MASS CUSTOMIZED PRINTING PRODUCTION ENVIRONMENT

In the competitive industrial setting of present times, it is hard for the manufacturing sector of developed economies to compete with those of developing countries because of the considerably high costs associated with Labor, Material and Transportation in addition to strict Environmental Sanctions, fierce competition from Sinking industries and the ever-shifting global economic patterns. For a manufacturing industry to survive in such conditions, it must be willing to change, should be technologically superior, access multiple markets, be responsive and adapt quickly. New manufacturing concepts and Business strategies are proposed and introduced frequently. One such business/manufacturing strategy that has proved to be successful is Mass Customization. The advantage of MC companies over traditional manufacturing comes with its fair share of challenges. This thesis identifies some important challenges faced by the printing industry, which has adapted MC, and solves one of these challenging problems