Model of information system for support of management of industrialenterprises

Na osnovu istraživanja u ovoj disertaciji i implemetiranog softverskog rešenja za podršku upravljanju industrijskim preduzećima utvrđeno je da sama implementacija ERP sistema nije dovoljna, i da su potrebni MES sistemi koji pružaju informacije u realnom vremenu koje pomažu da se donese odluka u cilju unapređenja proizvodnih sistema i omogućuju kontrolu nad svim elementima proizvodnog procesa, prema osnovnim načelima LEAN proizvodnje i TQM.Based on the research in this dissertation and implementation оf software solution for support of management of industrial enterprises it was found that implementation of ERP systems is not sufficient, and it is necessary implementation of MES systems which provide real-time information for making a decision for improvement of the production system and enable control of all elements of the manufacturing process, according to the basic principles of LEAN production and TQM

Integrated modelling approach in support of change-capable PPC strategy realisation

The increasing demand for customization, reduced time to market and globalization are the real challenges for today’s manufacturing enterprises (MEs). Therefore MEs can reduce these competitive pressures by becoming more and more change-capable. The agile and lean manufacturing philosophies must complement the application of reconfiguration techniques. However, choosing and applying the best philosophies and techniques are far from being well understood and well structured processes because most MEs deploy complex and unique configurations of processes and resource systems, and seek economies of scope and scale in respect of a number of 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 next generation MEs. This paper discusses research aimed at developing and prototyping a model-driven environment for the design, optimization and control of enterprises with an embedded capability to handle various types of change in an example of a production planning and control (PPC) scenario. The developed environment supports the engineering of common types of strategic, tactical and operational process found in many MEs. Also reported are initial findings of manufacturing case study work in which coherent multi-perspective models of a specific ME have facilitated process reengineering and associated resource system configuration and interoperation. In order to understand the system prior to realisation of any PPC strategy, multiple process segments of organisations need to be modelled. The paper considers key PPC strategies and describes a novel systematic approach to create coherent sets of unified models that facilitate the engineering of PPC strategies. Case study models are presented with capability to enable PPC decision making processes in support of complex organisation design and change (OD&C). The paper outlines key areas for future research including the need for research into unified modelling approaches and interoperation of partial models in support of complex OD&C

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

Process improvement in BAe Systems and the wider aerospace sector

Purpose: To research the change management processes used to implement ‘world class’ improvements in a major aerospace company, BAE SYSTEMS, and to propose a model for process improvement in the wider aerospace sector. Design/methodology/approach: The research was undertaken as a longitudinal study over a period of five years. A variety of research methodologies were used at various stages of the research including action research and observation. Semi-structured and unstructured interviews were used to gather qualitative data along with documentary evidence of the processes being used. Findings: There are three key findings. Firstly, an understanding of the production stages in the aerospace sector: future project; new product; sustain and return to work. Secondly details of a matrix-based approach and the issues regarding its implementation in a large organisation are discussed. Thirdly, a generic set of principles to aid process improvement in the aerospace sector is proposed. Research limitations/implications: Given that the study is based in one company, there are issues regarding the generalisation of the results. A potential further research project would entail the implementation of the proposed generic principles in another aerospace organisation. Practical implications: For BAE SYSTEMS, this research project aided their understanding of the issues involved in rolling out a process improvement program in a large organisation.Originality/value: Until recently, most of the research into process improvement had either been universalistic or aimed at another type of industry, such as the automotive industry. This research helps to address the specific needs of the aerospace industry

The role of a manufacturing execution system during a lean improvement project

Observation is a key aspect within a Lean improvement project. The project team starts from scratch and analyses the current situation by walking through the production process. During the last decade, the digitization of manufacturing operations has had its share of attention. Different kinds of software tools collect and analyze real-time data and turn them into valuable knowledge to support and optimize manufacturing operations. These systems are commonly referred to as Manufacturing Execution Systems (MES). The historical data – incorporated in these systems – can be used to support or validate the Lean efforts. As MES enforces the standard way of working on the production floor, it is also crucial to (re)align the system with the Lean improvements. A case study within a food and beverage company illustrates this dual role of an MES during a Lean improvement project

The Complementarity of Lean Thinking and the ISA 95 Standard

Although Lean and Information Technology both pursue the same objectives, their complementarity remains an open issue. The literature on this topic provides divergent opinions. Lean advocates state it is preferable for employees to search for the information they need, as and when they need it, rather than configuring software to provide them with information that is repeated at predetermined times. IT proponents consider Information Technology as a useful tool to support lean practices, for example to deal with complex issues in real-time. This paper gives an overview of the opinions. In addition the process models of lean and ISA 95 are matched. The underlying research question is: does the ISA 95 standard give an appropriate framework to support lean practices; such as Visual Management, Kanban, Value Stream Mapping, Six Sigma, … A preliminary conclusion on their complementarity is made and further research is mentioned. An experimental mock-up must be set up to test the lean compatibility of existing Manufacturing Execution Systems (MES). Many vendors state that their software supports lean practices but fail to validate this theory thoroughly. By putting the software to the test in a simulated environment, the leanness of the software can be evaluated

Applying Lean and MES toward Smart Manufacturing - Application of a Thai Automotive Company

Lean, manufacturing execution systems (MES), and Smart manufacturing are of different disciplines. The objective of this study is to explore the integrated application of these three disciplines. This study conducts a field observation and interview of a selected car wheel frame manufacturer in Thailand to generate five applications. The extended technology acceptance model (TAM2) and overall equipment effectiveness (OEE) are applied to verify the effectiveness of the case company. This study’s results show that MES facilitates production transparency and increases the firm’s ability to focus on value-added activities. Employees can predict potential issues and proactively eliminate them. Improved transparency also enhances employee ownership, enabling employees to independently problem solve and implement improvements before an issue arises

Sistemas de informação na indústria 4.0 : mecanismos de apoio à transferência de dados para conhecimento em ambientes Lean

The paradigm that presently emerges in the organizational context, known as Industry 4.0 (I4.0) or Fourth Industrial Revolution, promises to bring principles of connectivity and flexibility to the companies that embrace it. Industry 4.0 enhances the efficiency in adapting in real time to the customers’ requirements, through the establishment of an intelligent shop floor capable of answering in a flexible and customized way to market changes. However, during the last three decades, it is known that the adoption of the Lean philosophy was absorbed by the industrial environment, with results that proved to be exuberant, considering the simplicity of the tools. In this way, the I4.0 implementation must be prepared to preserve the existing manufacturing systems, proceeding, whenever possible, to upgrade them on a Lean excellence basis. It is said that information systems will be decisive in the foundation of the I4.0 paradigm. Of these, MES systems, with greater connection to the shop floor, will tend to be aligned with existing practices, contributing, through their connectivity, to the introduction of knowledge management practices and data visualization mechanisms. In the specification and architecture phase of these systems, understanding the processes will be crucial. Thus, their documentation is an organizational pillar, with BPMN and UML being able to guide it. However, and in addition to its usefulness in the processes’ mapping, BPMN is also likely to be applied in capturing tacit knowledge, which can be a foundation for the constitution of knowledge repositories, impacting organizational excellence. It is in this context that the present work is implanted, aiming at the creation of guidelines and mechanisms that facilitate the implementation of I4.0 strategies in Lean industrial environments. The adopted methodology first went through an exhaustive literature review, in order to find possible bilateral effects between I4.0 technologies and lean tools. Then, the development of some applications aligned with the I4.0 paradigm, as a technological engine, and the Lean philosophy, as a tool for eliminating waste and / or creating value, was contemplated. From the various development experiences in an industrial context and considering the evidence reported in the literature, this study proposes a Lean 4.0 framework oriented to the shop floor.O paradigma que atualmente emerge no contexto organizacional, conhecido como Indústria 4.0 (I4.0) ou Quarta Revolução Industrial, promete trazer princípios de conectividade e flexibilidade às empresas que a adotam. A Indústria 4.0 potencia a eficácia no ajuste em tempo real aos requisitos dos clientes, através da constituição de um chão de fábrica inteligente e capaz de responder de forma flexível e customizada às mudanças do mercado. Contudo, durante as últimas três décadas, sabe-se que a adoção da filosofia Lean foi absorvida pelo meio industrial, com resultados que se demonstraram exuberantes, tendo em conta a simplicidade das ferramentas. Deste modo, a implementação I4.0 deve ser feita no sentido da preservação dos sistemas de manufatura já existentes, procedendo, desde que possível, ao seu upgrade numa base de excelência Lean. Conta-se que os sistemas de informação serão decisivos na fundação do paradigma I4.0. Destes, os sistemas MES, com maior conexão ao chão de fábrica, tenderão a ser alinhados com as práticas já existentes, contribuindo, através da sua conectividade, para a introdução de práticas de gestão do conhecimento e mecanismos de visualização de dados. Na fase de especificação e arquitetura destes sistemas, o entendimento dos processos será crucial. Assim, a documentação dos mesmos é um pilar organizacional, estando o BPMN e a UML capazes de a orientar. Porém, e a somar à sua utilidade na ilustração de processos, o BPMN está igualmente passível de ser aplicado na captação de conhecimento tácito, o que por si pode ser uma base para a constituição de repositórios de conhecimento, contribuindo para a excelência organizacional. É neste contexto que o presente trabalho se insere, tendo como objetivo a criação de linhas orientadoras e mecanismos que facilitem a implementação de estratégias I4.0 em ambientes industriais Lean. A metodologia adotada passou, primeiramente, por uma exaustiva revisão da literatura, por forma a encontrar possíveis efeitos bilaterais entre tecnologias I4.0 e ferramentas lean. De seguida, contemplou-se o desenvolvimento de alguns aplicativos alinhados ao paradigma I4.0, enquanto motor tecnológico, e à filosofia Lean, enquanto ferramenta de eliminação de desperdícios e/ou criação de valor. Das diversas experiências de desenvolvimento em contexto industrial e considerando as evidências reportadas na literatura o presente estudo propõe uma framework Lean 4.0 orientado ao chão de fábrica.Mestrado em Engenharia e Gestão Industria