Teaching operations management using a 'pseudo'-scientific approach

The purpose of this paper is to explore a theory led approach to teaching operations and supply chain management that has emerged from the analysis of seminal operations management developments and case research. This research identified common operations construct relationships encompassing variation, uncertainty, buffering mechanisms and trade-offs which are used to provide a common basis for explaining these developments, linking established theory with current professional practice. The construct relationships are further shown to comprise three distinct but coordinated strategies that provide a useful framework for case evaluatio

Evaluating demand driven MRP: a case based simulated study

This study evaluates the assumption underpinning Material Requirements Planning (MRP), buffer management and DDMRP before analysing the case company and evaluating the potential benefits, utilizing simulated data from the existing ERP system. The purpose of this research is to evaluate DDMRP in the context of improving the performance of a printing ink manufacturing company. The main issues the company is facing using a traditional MRP system include poor due-date performance, stock levels not corresponding to the actual market needs and overall system instability leading to inefficiencies. The findings indicate the potential of DDMRP to improve system stability and product availability

Last planner and critical chain in construction management: comparative analysis

This paper endeavours to compare the Last Planner System of production control and the Critical Chain production management method. This comparison is carried out in the context of construction management. The original prescription and the evolution of the practice are examined regarding both approaches, and the similarities and differences are noted. Based on these considerations, gaps in the two approaches are identified and the potential of a synthesis of them is explored

Questioning the relentless shift to offshore manufacturing

The last 20 years has seen a relentless shift to offshore manufacturing as retailers chase ever-lower labor costs. The results of this strategy can now be evaluated and we propose that some adjustments are in order. We analyze the case of a North American apparel manufacturer (Griffin Manufacturing, Inc.) that has successfully emerged from a period of major change with a strong and strategic position in the apparel supply chain. This case study documents Griffin’s survival through evolution in capabilities, technology, and especially attitude. The Griffin case study suggests that keeping a portion of the manufacturing onshore at an agile, quick response factory is cost effective: it increases sales and improves margins. However, the new relationship between the parties is much more complex and requires commitment on both sides

Systematic innovation and the underlying principles behind TRIZ and TOC

Innovative developments in the design of product and manufacturing systems are often marked by simplicity, at least in retrospect, that has previously been shrouded by restrictive mental models or limited knowledge transfer. These innovative developments are often associated with the breaking of long established trade-off compromises, as in the paradigm shift associated with JIT & TQM, or the resolution of design contradictions, as in the case of the dual cyclone vacuum cleaner. The rate of change in technology and the commercial environment suggests the opportunity for innovative developments is accelerating, but what systematic support is there to guide this innovation process. This paper brings together two parallel, but independent theories on inventive problem solving; one in mechanical engineering, namely the Russian Theory of Inventive Problem Solving (TRIZ) and the other originating in manufacturing management as the Theory of Constraints (TOC). The term systematic innovation is used to describe the use of common underlying principles within these two approaches. The paper focuses on the significance of trade-off contradictions to innovation in these two fields and explores their relationship with manufacturing strategy development

Reinterpreting Fisher's coordinated strategies: a longitudinal case study

Purpose: Much has been written about the need to align the supply chain with the product/market but it has proved, elusive especially in response to a supply change transitions. This paper reviews the established theoretical models before considering how the realignment process can be better supported in the light of a longitudinal study. Design/methodology/approach: This paper uses a single apparel case where data was gathered over a five year period involving multiple site visits, management interviews and archival data across three echelons of the supply chain. Repeated visits enabled the collection of contemporary evidence and the development and testing of the causal relationships. This case was part of a multi case research project that explored the causal relationship between variation, uncertainty, performance trade offs and buffering mechanisms (time, capacity and inventory). Findings: The case analysis demonstrates how established theory and causal reasoning can be used to explain the trade off oscillations that characterized this case. As with earlier studies, local cost considerations predominated, interspersed with strategic countermeasures. Fisher's (1997) concept of coordinated strategies is shown to provide an effective means of clarifying the trade off implications of the transition in support of proactive realignment. This concept is discussed in relation to other cases and literature before proposing how this could be developed and used as a basis for further research. Practical implications: Supply chain redesign is of growing importance and with it the need to more effectively manage such transitions. This paper clarifies the need for supply chain orientation and offers means of clarifying the implications of such transitions to management. Originality/value: This paper provides case evidence of the underlying operations management issues and the associated analysis

New concept in brazing metallic honeycomb panels

Aluminum oxide coating provides surface which will not be wetted by brazing alloy and which stops metallic diffusion welding of tooling materials to part being produced. This method eliminates loss of tooling materials and parts from braze wetting and allows fall-apart disassembly of tooling after brazing

The strategic integration of agile and lean supply

Lean supply is closely associated with enabling flow and the elimination of wasteful variation within the supply chain. However, lean operations depend on level scheduling and the growing need to accommodate variety and demand uncertainty has resulted in the emergence of the concept of agility. This paper explores the role of inventory and capacity in accommodating such variation and identifies how TRIZ separation principles and TOC tools may be combined in the integrated development of responsive and efficient supply chains. A detailed apparel industry case study is used to illustrate the application of these concepts and tools