Improvement in planning and resource management for an automotive company’s parts feeding system

The increasing sophistication of the automotive market and the constant change in customer requirements increases companies’ concern to ensure efficient internal logistic flows in line with Just-In-Time philosophy and Lean principles, to deal with wastes and variability. Variability arises from the growing differentiation of products, from the adoption of multi and mixed model assembly lines, and from the uncertainty in customer demand resulting from the worldwide outbreak of COVID-19. Considering the automotive supplier company as research subject, several problems were found to be compromising the efficiency of one of its in-plant parts’ feeding systems, the most critical problem being the lack of planning and management of resources (human and material) needed to perform the logistic service. Through Action-Research methodology stages, the actions taken culminated in the development of a simulation and decision-support tool for the component supply system resource management and efficiency improvement. The simulations made revealed reliable and adjusted results of workload and workforce to face the variations in customer demand and the existing product mix. After the tool creation, resource planning and balancing was no longer based on managers experience and empirical knowledge only but based on scientific knowledge: concise and reliable data from information systems, measurements, study of times, and literature review on in-plant milk run systems, lean, just-in-time and continuous improvement techniques.info:eu-repo/semantics/publishedVersio

Knowledge creation and visualisation by using trade-off curves to enable set-based concurrent engineering

The increased international competition forces companies to sustain and improve market share through the production of a high quality product in a cost effective manner and in a shorter time. Set‑based concurrent engineering (SBCE), which is a core element of lean product development approach, has got the potential to decrease time‑to‑market as well as enhance product innovation to be produced in good quality and cost effective manner. A knowledge‑based environment is one of the important requ irements for a successful SBCE implementation. One way to provide this environment is the use of trade‑off curves (ToC). ToC is a tool to create and visualise knowledge in the way to understand the relationships between various conflicting design parame ters to each other. This paper presents an overview of different types of ToCs and the role of knowledge‑based ToCs in SBCE by employing an extensive literature review and industrial field study. It then proposes a process of generating and using knowledg e‑based ToCs in order to create and visualise knowledge to enable the following key SBCE activities: (1) Identify the feasible design space, (2) Generate set of conceptual design solutions, (3) Compare design solutions, (4) Narrow down the design sets, (5) Achieve final optimal design solution. Finally a hypothetical example of a car seat structure is presented in order to provide a better understanding of using ToCs. This example shows that ToCs are effective tools to be used as a knowledge sou rce at the early stages of product development process

Principles for aerospace manufacturing engineering in integrated new product introduction

This article investigates the value-adding practices of Manufacturing Engineering for integrated New Product Introduction. A model representing how current practices align to support lean integration in Manufacturing Engineering has been defined. The results are used to identify a novel set of guiding principles for integrated Manufacturing Engineering. These are as follows: (1) use a data-driven process, (2) build from core capabilities, (3) develop the standard, (4) deliver through responsive processes and (5) align cross-functional and customer requirements. The investigation used a mixed-method approach. This comprises case studies to identify current practice and a survey to understand implementation in a sample of component development projects within a major aerospace manufacturer. The research contribution is an illustration of aerospace Manufacturing Engineering practices for New Product Introduction. The conclusions will be used to indicate new priorities for New Product Introduction and the cross-functional interactions to support flawless and innovative New Product Introduction. The final principles have been validated through a series of consultations with experts in the sponsoring company to ensure that correct and relevant content has been defined

Enablers and Constraints in Implementing Lean Manufacturing: evidence from Brazilian SMEs

Lean Manufacturing has revolutionized the global manufacturing environment at an unprecedented rate. In scholarly and managerial literature, many works have reported that Lean Manufacturing is a very efficient approach and a straightforward way towards process improvements, in terms of productivity and value adding activities ratio. However, many studies on Lean Manufacturing have highlighted many problems in its implementation. The analysis carried out within the research project is aimed to the factors enabling or constraining the Lean Transformation of a firm’s production system, along with the most relevant tools or practices to be applied. The research methodology used is the so-called “Normative Delphi” with a panel formed by 32 experts coming from 16 Brazilian SMEs. Our results are partially consistent with what has already been discussed in the literature and we found that the most relevant tools/practices are: value stream mapping, 5S methodology, and Kaizen (Gemba walks); the top three enabling factors are: knowledge and sponsorship of senior management, focus on continuous improvement, and employee development fostered by the company; finally, the main critical constraints are: little support from the top management, resistance to change by middle management, and poor or non-qualified Lean training activities

Work Organisation and Innovation

[Excerpt] Innovations in work organisation have the potential to optimise production processes in companies and improve employees’ overall experience of work. This report explores the links between innovations in work organisation – under the broader label of high performance work practices (HPWPs) – and the potential benefits for both employees and organisations. It draws on empirical evidence from case studies carried out in 13 Member States of the European Union where workplace innovations have resulted in positive outcomes

Work Organisation and Innovation - Case Study: LHT, Germany

[Excerpt] Lufthansa Technik AG (LHT) provides aircraft-related technical services to a worldwide customer base comprising airlines, aircraft leasing companies, maintenance organisations, and operators of business and VIP aircrafts. Besides the maintenance, repair, and overhaul (MRO) services that form the organisation’s core business, activities also include development and production activities, as well as logistics

Creating Social Value within the Delivery of Construction Projects

The purpose of this paper is to present the current knowledge surrounding social value and show how lean approach supports social value realisation in the delivery of construction projects. A critical literature review was adopted, to gather the current knowledge surrounding social value from mainstream management sciences, construction management and lean literature. A total of 70 studies were critically reviewed. The study reveals that the separation theory propagated by Friedman, (1962), tends to separate social value from economic value, thus making organisations care less about delivering social value. The study found that there is still no clear or single criterion for measuring social value delivered and there is a dearth of scholarly publications on social value especially in construction management literature. The investigation shows that lean production approach has the potentials to enable construction organisations to conceptualise the community and the physical environment where they operate as customers, which contributes to the delivery of social value objectives in construction projects. This study conceptualises the community and the physical environment around where the construction project is executed as customers using lean production approach and shows that the Transformation, Flow & Value view support smooth workflow which enhances the achievement of social value objectives. This creates a new insight into how social value can be realised in construction project delivery. This study extends the on-going debate around the need for social value in construction project delivery and contributes to construction management and lean construction literature on social value. Future studies could build on this to obtain empirical data and develop an approach/method that would support the evidencing of social value delivery in construction projects

Collaboration in Design – Justification, Characteristics and Related Concepts

The purpose of this article is to understand the academic landscape on collaboration in design, its characteristics and related concepts for promoting collaboration within in the project based production systems. We aim to answer to the following three questions: How to define collaboration in design and why individuals need to collaborate during design? What characterizes effective collaboration in design? Which concepts support the development of collaboration in design? For shedding light on this subject, a literature review is conducted and applicability to Architecture, Engineering and Construction industry and project delivery are discussed. In this study, it was found that collaboration is a complex phenomenon, which explains the diversity of views and many complimentary concepts in organizational and design literature. Collaboration requires the management of material and knowledge boundaries, in order to develop common goals, processes and product. Lean construction concepts, methods and tools have helped the teams to develop collaborative design and construction practices

Training: an inhibitor of innovation in the automotive supply chain?

Have training programmes become the new Taylorism: allowing OEMs to exercise control over their smaller suppliers and unconsciously preventing these SMEs from innovating, diversifying and growing to become competitive rivals? At the Lisbon Council in March 2000, European government leaders set themselves the target of making the European Union the “most competitive and dynamic knowledge-based economy in the world, capable of sustained economic growth …” within ten years. Human resources are central to the creation and transmission of knowledge and a determining factor in the European automotive industry's potential for innovation. This research seeks to clarify whether the new skills that are being promoted across the supply chain are truly enablers for competitiveness and innovation. As currently practised they may be providing a less effective response to the Lisbon Agenda, i.e. increasing the distribution of skills without the depth that allows companies to become potentially innovative. For SMEs to be encouraged to grow, to be innovative and so be truly competitive, they need training support. The training may be designed just to tackle short term skills needs. It may be designed to instil the demonstrable best practice of its customer and lean manufacturing is an eminent example of this type. Training must also be designed in the context of where the SME aspires to be, to allow the SME to mature and develop. This research has highlighted the risk when externally promoted and funded training potentially constrains the potential for innovation and the Lisbon goals.Peer reviewe