Ways to Circular and Transparent Value Chains

The purpose of this paper is to increase the knowledge about the implementation of circularity and other sustainability approaches in value chains. The objective is to develop roadmaps for the implementation of digital Circular manufacturing (CMA) and Social-life cycle (S-LCA) assessments in Textile and Clothing (TC) value chains. Implementing these digital assessments in TC value chains can increase their transparency, by validating that product manufacturing safeguards worker wellbeing and the environment. TC is one of the sectors with most critical social and environmental impacts. The roadmaps were developed through a Design Science methodology, combining: i) case studies to understand the practical problem, ii) literature study on CMA and S-LCA to develop the roadmaps, and iii) action research to iteratively apply the roadmaps to the cases and refine them with participants in an EU project, representing the entire TC value chain. The EU project is developing digital sustainability assessments with Blockchain functionality for increased data trustworthiness. This study aims to contribute to theory, practice, and public policies by providing a validated overview of the status, barriers, goals, and systematic activities for the implementation of CMA and S-LCA in TC value chains and for increased sustainability.publishedVersio

Scheduling for Flexible Production: A Case Study of Production Leveling Under Volume Constraints

Flexible manufacturing systems in high-mix low-volume segments offer many challenges in terms of planning and scheduling. The complexity of these systems often requires a systemic approach for which humans are the perfect actors. However, computer systems can support scheduling tasks more effectively due to their capacity to synthesize large amounts of data. This paper describes a system developed for the flexible manufacturing of wooden doors with a wide range of product configurations. This paper proposes a rule-based scheduling method for high-mix production. The method was applied and validated at a wooden door producer. Based on the company's production schedule for a given week, a scheduling program was developed that suggested minor rearrangements for production leveling. As the rule-based approach makes the decisions verifiable, the program was validated at the producer, through a case study of production leveling under volume constraints. The results include the complete elimination of changeovers and the stabilization of throughput, which improved the precision of the delivery time. The producer is integrating the program into their production planning and control system. Thus, the results suggest that the proposed method can be useful for scheduling high-mix low-volume production, and merits further validation in similar environments.acceptedVersio

Toyota Kata for continuous improvement; an action research project in the construction industry

Purpose: The purpose of this study is to investigate how Toyota Kata can be effectively applied in the engineer-to-order (ETO) manufacturing within the construction industry. The objective is to identify the critical success factors (CSFs) for the Toyota Kata implementation in this environment and to develop a continuous improvement (CI) method – based on Toyota Kata and adapted to the ETO manufacturing within the construction industry. Design/methodology/approach: An action research (AR) approach was applied, which includes a participatory form of inquiry and learning from both intended and unintended outcomes, while simultaneously building up scientific knowledge about successful implementation of Toyota Kata. Findings: All the CSFs in the AR project are addressed by the earlier literature, thus confirming the existing body of knowledge. Moreover, the existing knowledge was arguably extended through the modified Toyota Kata as an approach for CI. New elements regarding how to run the small experiments by extending the core team with personnel who work with the problem on a daily basis. Originality/value: This research addresses a gap identified in the literature regarding how Toyota Kata can be adapted to the ETO manufacturing within the construction industry. It also presents an overview of CSFs for the Toyota Kata implementation in this environment.acceptedVersio

Applying the fundamentals of TPS to realize a resilient and responsive manufacturing system

Concepts like the Toyota Production System (TPS) and Quick Response Manufacturing (QRM) are often presented as alternative manufacturing methods or strategies suited for different manufacturing conditions. QRM is depicted as a Job-shop alternative (low volume-high mix) to TPS, and TPS is viewed as a method best suited for high volume-low mix environments. However, the realities of manufacturing organizations today are that they operate in a mass-customization environment with high total volumes to achieve economies of scale, and high variability due to the widening of choices available to customers. Which means that manufacturers must produce an infinite number of variants to serve individual customer needs, on a limited number of production lines, emphasising the need for both efficiency and responsiveness. In this paper we present preliminary findings from two Norwegian manufacturing companies who are applying the concepts of TPS to realize a resilient and responsive manufacturing system through a process of action learning. Instead of rigidly adopting the best practices developed by others, the companies are building flexible manufacturing systems through discovering their own paths towards improved quality, greater flexibility, and shorter lead-times - by finding and facing their challenges and engaging everyone in forming solutions, together.publishedVersio

Quick-Scan – Towards a Strategy for Responsive and Resilient Value Chains

To remain competitive in today’s increasingly dynamic and complex environments, manufacturing enterprises must build resilience to respond to changes quickly. As such, lean production has provided firms with an alternative to "fat and lazy" mass production. In addition, Quick Response Manufacturing has been presented as a credible supplement to lean production, specifically in High Mix, Low Volume environments. Drawing on practical insights from two case studies, we present a Quick-Scan method as an initial step towards creating resilient and responsive value chain strategies. The approach combines manufacturing critical-path time mapping from Quick Response Manufacturing with Gemba-based discovery and learning from Lean - to find, face, and frame real problems, and thereafter form solutions together with managers and front-line personnel. The method has been adopted in both cases as a means of revitalizing operations with the intention of enabling more effective delivery of customer-specific products.publishedVersio

Occupational Protection against Exposure to Radioactive Sources and Electromagnetic Fields in the Offshore Petroleum Industry

The objective of the Master Thesis has been to provide an overview of the radioactive sources and Electromagnetic fields (EMF), existing on offshore petroleum installations from the Norwegian continental shelf (NCS). It has also been of interest to describe how offshore workers handle these radiation sources, which are the associated health hazards and which are the most efficient protection measures against exposure. The report contains a literature research of the most recent national and international publications relevant for the topic; a collection of interesting data from the literature study, from the interviews of various experts within Health, Safety and Environment, and from a workshop where the participants have shared their personal experiences with radiation protection offshore. Moreover, the literature research also provides an overview of important radiation concepts, of measuring units used in the assessment of exposure, of statutory requirements and means of identifying and prioritising protection measures. The thesis is accompanied by two digital databases that have been created in conjunction with the data collection realised. One of the databases provides the mapping of radioactive sources used in the offshore petroleum industry, while the other one includes a similar mapping for the EMF. Both of the databases contain significant information from the literature study and from the workshop attended about: the properties of almost 40 mapped radiation sources, efficient protection measures and interesting practical experiences. Moreover, the databases have been sent to experts for quality assurance and new inputs. Furthermore, the results from the data collection have been thoroughly discussed in order to highlight the most critical radiation sources on the NCS and efficient barriers against exposure. The results show that among the most hazardous radioactive sources on the NCS there are: industrial radiography, well logging by use of neutron and gamma radiation, installed gauges, intelligent pigs , radiotracers, as well as the natural occurring radioactive material (NORM) formed in gas and oil equipment. EMF are divided into: Static magnetic fields (SMF), Extremely low frequency electric and magnetic fields (ELF) and Radiofrequency electromagnetic fields (RF). Among the most important sources of ELF, there are: generators, low and high voltage transformers, low-voltage switch gear room, the drive space, as well as power supply cables to or from the shore. RF sources highlighted in the studied literature and by experts are: the X-band and S-band maritime radars and the Radio Link communication antennas, while strong SMF are generated by powerful electric motors. Protection measures against exposure to radioactive sources are based on restricting as much as possible the total dose people receive throughout their lives and thus, the likelihood of developing cancer and genetic damages. Most of the barriers are related to radiation protection principles like: maximising the distance from the radiation source (radiation doses decrease rapidly with the square of the distance), minimising the exposure time and shielding the source. Moreover it is particularly important to avoid inhaling or ingesting radioactive material, such as NORM dust. Barriers against exposure to ELF are mainly based on avoiding acute biological effects, such as the excitation of muscle and nerve cells, with possible but nevertheless, uncertain impact on e.g. the development of Alzheimer s. Protection measures are also aimed at avoiding health effects such as the increased risk for leukaemia caused by long term exposures to high magnetic fields. A possible long term biological effect of strong SMF, is their impact on the expression of certain genes, primarily in mammalian cells. Most of the barriers against exposure to ELF and SMF are based on the radiation protection principles of maximising the distance from the source and minimising the exposure time, since the level of exposure to EMF decrease also with the square of the distance. Strong magnetic fields are normally difficult to shield. Protection measures against exposure to RF are related to biological effects such as tissue damages after a temperature increase in the body of 1-2 oC, caused by extremely high exposure levels. There are several hypotheses about the RF s exact short term and long term health effects but none of them is well established. Thus, most of the barriers are based on a precautionary strategy, and they are primarily related to the principle of minimising the exposure time to avoid tissue heating, maximising the distance from the source, and to design solutions such as directing the transmission of antennas away from manned areas. Radiation protection is a wide subject, thus, there are many possible recommendations one could give with respect to efficient protective measures. One strategy that applies for both radioactive sources and for EMF is: to use radiation sources only if they are justified and to restrict the exposure levels as much as reasonably achievable. Apart from keeping in mind these three factors: distance, time and shielding against the radiation source, one should always make sure that workers have adequate training and that there is maintained a good level of communication, experience exchange and risk awareness within the organisation and across the industry. Moreover, priority should be given to design and organisational barriers at the source and the use of personal protective equipment must be always considered as a last resort

Enablers and inhibitors of Industry 4.0: results from a survey of industrial companies in Norway

Since 2011 when it was announced, Industry 4.0 has inspired a series of governmental and private programs worldwide. Nevertheless, it is an emerging research field and the academia calls for further explorative research, including on the enablers and inhibitors of Industry 4.0 implementation at national level. This paper addresses this topic based on a cross-sectional analysis of data collected through a two-step survey of 49 companies in Norway, 13 suppliers to the Oil and Gas industry and 36 from different manufacturing industries. The findings contribute primarily to the Training and Continuing Professional Development priority area in Kagermann et al. (2013)

A Production Transfer Procedure Based on Risk Management Principles

Purpose This paper aims to develop a procedure for preparing production transfers based on risk management principles. The procedure should help companies reduce the amount of supply chain disruptions during transfers and achieve their outsourcing/offshoring objectives. Design/methodology/approach The procedure was developed during a three-year Design Science study. First, a literature review and case studies were conducted to frame the research problem. Second, a preliminary procedure was developed based on preventive risk mitigation actions from the production transfer literature. Third, the procedure was implemented during an electronics-offshoring case and refined during workshops with the sender and receiver’s transfer personnel. Fourth, during a seminar, transfer practitioners verified the procedure by applying it to outsourcing/offshoring cases with which they had experience. Findings Most of the preventive actions were evaluated as relevant for the transfers the procedure was applied to, regardless of industry and relocation type. Moreover, the electronics-offshoring case showed that the success of a production transfer not only depends on the physical, knowledge and supply chain transfers, as presented in earlier research, but also on the administrative transfer and on the organisation, project and quality management actions. This paper also attempts to enhance the production transfer literature by clarifying transfer risk management. Practical implications The procedure can be used during the production transfer phase as a preparation procedure. Moreover, it informs the decision-making process during the relocation-decision and supplier-selection phases. Originality/value To the authors’ knowledge, this is the first production-transfer-preparation procedure based on risk management principles