A simulation-enhanced lean design process

A traditional lean transformation process does not validate the future state before implementation, relying instead on a series of iterations to modify the system until performance is satisfactory. An enhanced lean process that includes future state validation before implementation is presented. Simulation modeling and experimentation is proposed as the primary validation tool. Simulation modeling and experimentation extends value stream mapping to include time, the behavior of individual entities, structural variability, random variability, and component interaction effects. Experiments to analyze the model and draw conclusions about whether the lean transformation effectively addresses the current state gap can be conducted. Industrial applications of the enhanced lean process show it effectivenessPeer Reviewe

Waste Reduction, Construction and Demolition Debris: Guide for Building, Construction and Environmental Professionals, Revised November 2008

This document is intended to lay the foundation for resource reduction strategies in new construction, renovation and demolition. If you have an innovative idea or information that you believe should be included in future updates of this manual please email Shelly Codner at [email protected] or Jan Loyson at [email protected]. Throughout this manual, we use the term “waste reduction” to define waste management initiatives that will result in less waste going to the landfill. In accordance with the waste management hierarchy these practices include reducing (waste prevention), reusing (deconstruction and salvage), recycling and renewing (making old things new again) - in that order. This manual will explain what these practices are and how to incorporate them into your projects

Design and financial aspects of the end-of-life management of telecommunications products

As a result of legislation the electronics industry faces product takeback and recycling. It is therefore important to understand the environmental burden caused by discarded consumer electronics and also how to better manage raw materials. The thesis begins with a review of current environmental issues from the viewpoint of the electronics industry. This shows that there are many complex interactions to be considered within any environmental framework particularly those between legislation, technology and business. Consideration of the drivers indicates that work should focus on the design understanding required to allow product life extension as well as current strategies addressing the reprocessing of used products. The body of the thesis therefore has two themes, both of which use telecommunications products, telephones, as their exemplar. The first theme, the design issues related to the end-of-life management is explored via a benchmarking study of eight telephones from European (UK and Germany) and Far Eastern suppliers (China and Malaysia). This study allowed the generation of design rules for such products. The work also examined the impact of design changes to improve end-of-life practices on manufacturing costs in Europe and the Pacific Rim to indicate the constraints of labour and investment costs. The second theme links the business and technological issues faced in the endof- life (EOL) management of electronic products. The EOL options considered are: resale, remanufacturing, recycling, disposal and to a limited extent, upgrading. Building on the technological understanding generated in the first theme accurate economic models are derived, based on commercial data, for exemplar telephone products that reflect the activities within each option. The potential revenue from each option indicates preferred design strategies and the models can therefore help resolve some of the uncertainties faced by decision makers. The thesis closes by identifying that the design rules and financial models are particularly appropriate for mature products such as the telephones used as exemplars, further research is therefore necessary to extend the existing work to high added value products

A lean environmental benchmarking (LEB) method for the management of cutting tools

Manufacturing companies are striving hard to remain competitive hence, they rely on a number of resources to meet customers’ expectations, among which cutting tools are included. This paper addresses the problems faced in the management of cutting tools activities. Production managers have highlighted the lack of procedures containing metrics and targets that would show them whether their company is able to perform an efficient management, and if it is capable of supporting the deployment process. In this context, this paper presents a novel Lean Environmental Benchmarking (LEB) method for performing a diagnosis of practices and performances to support the implementation of a cutting tool management strategy and/or the effective management of these assets. Strategic, technical and logistical aspects are addressed, particularly, with regard to management focused on lean manufacturing and environmental aspects. Field studies were performed in nine Brazilian companies in the metal-mechanical sector to validate the LEB method proposed. The LEB method helped the participant organisations clarify the various activities that involved the management of their cutting tools, while the field studies indicated that all nine organisations had a great concern regarding the preservations of the environment, and also an effective utilisation of resources spent for machining components.N/

Improving Supply Chain and logistics and reducing costs by design and improvement of packaging with the help of Lean and DFL : Project-based case study

Logistics is critical part of supply chain, due to enabling efficient and reliable value-creating operations, with the potential to increase sales and profits. Main goals of the case study are to improve product transport packaging, packaging process, packaging and transportation costs and all related material flows throughout the supply chain in the case company. This is done by analyzing current state and employing rarely used Design for Logistics (DFL) theory framework, combined with Lean, to form a ground up approach for optimizing the supply chain. Empirical study is carried out as case study research utilizing inductive case study framework, action research cycles and mixed methods. Both deductive and inductive reasoning are used. Theories have been employed and tested in practice, but new case related theory has also been made from ground-up based on data, experimentation, observation, and analyses. 3D-modeling is utilized extensively. Case results include various findings regarding current state of logistics processes, costs and their relationship between packaging and packaging processes in the case company. Results also include creating a modular, interchangeable transport packaging for upcoming new product families, creating new material flow processes throughout supply chain, overhauling packaging process and creating a semi-automated packaging cell. Other resulting outcomes include e.g., significantly lower production costs, process variance and time, and transportation costs, together with increased economies of scale as well as flexibility and availability regarding transportation options. Results also point theory-wise the potential and significance of packaging for the whole supply chain entity as a creator of increased value and efficiencies, especially by facilitating and enabling creation of new capabilities regarding various internal and external processes and related production technologies. Results of the study are both valid and reliable due to the methodology used, where de facto continuous validity and reliability evaluation was built-in because of periodical group reviews and other events partaken by cross-functional team of professionals. Results have been realized by utilizing various, both alternative and supplementary research methods. Findings and results have been further verified by prototyping, various in-practice testing, 3D-modeling as well as by ongoing implementation and commissioning to the case company’s operations. Further research could include how to systemically introduce and implement DFL into use as integral part of product and production development alongside other DFX tools

A design method for improving assembly and environmental sustainability in packaging solutions: a case study in household appliances

By using a functional requirement analysis, through Design for Manufacture and Assembly and Design for Environment principles, this paper aims at showing a new design method to improve the overall assembly features and environmental sustainability of a packaging solution. This method provides to rank functional requirements according to three different design specifications and also to the number of relationships they have with each other. At the same time, a ranked order of importance for the packaging parts has been realised, considering the number of performed functions. The purpose of this method is to support the designers in focusing their attention on the most important packaging parts and, at the same time, giving them a clear idea of which are the most important functional requirements to be satisfied. This study has been focused on domestic household packaging, but the provided method can be extended to any particular packaging solution and its findings are still valid. According to the Design for Environmental perspective, the actual and the new resulting packaging solutions have been then compared through Life Cycle Assessment method. The results have shown the new packaging solution being able to cut down the environmental impacts, on average, of approximately 30%

In search for classification and selection of spare parts suitable for additive manufacturing: a literature review

This paper reviews the literature on additive manufacturing (AM) technologies and equipment, and spare parts classification criteria to propose a systematic process for selecting spare parts which are suitable for AM. This systematic process identifies criteria that can be used to select spare parts that are suitable for AM. The review found that there is limited research that addresses identifying processes for spare parts selection for AM, even though companies have identified this to be a key challenge in adopting AM. Seven areas for future research are identified relating to the methodology of spare parts selection for AM, processes for cross-functional integration in selecting spare parts for AM, broadening the spare parts portfolio that is suitable for AM (by considering usage of AM in conjunction with conventional technologies), and potential impact of AM on product modularity and integrality