Alan Davies

Identifying the characteristics for achieving sustainable manufacturing companies

Purpose - The purpose of this paper is to identify the qualitative characteristics that can make manufacturing companies more robust and hence become economically sustainable in this globally competitive environment. The characteristics identified will form the foundations for defining a new manufacturing management perspective to both academics and industrialists. Design/methodology/approach - Through a comprehensive case study approach the author initially analyses the developmental cycle of the subject company and then identifies the key characteristics which enabled the company to become economically sustainable and survive in a changing environment in which it operates. The paper opens with a brief academic analysis of sustainability literature available before developing the case study. Findings - Traditional business improvement strategies such as Lean and Agility which many companies initially follow in an attempt to become more robust and economically stable, allow companies to deliver bottom-line savings in production terms although their effectiveness depends upon the volume and demand profile of their products. Through the case study outlined in this paper however, it outlines a combined approach towards the application of Lean as a primary means of reducing operating costs alongside the simultaneous implementation of product innovation strategies which allows the company to break into new markets as a means to achieving long term economic sustainability and making it more robust to market changes. The development of a business within a business is described as an effective mechanism towards achieving business sustainability. Research limitations/implications - The paper proposes a novel approach to achieving economic sustainability within a business and can be of benefit to the wider industrial and academic community. The development of work around a single company has its obvious limitations and it is crucial that further work with a range of companies in the area of business sustainability is key to developing a comprehensive set of sustainability characteristics. Practical implications - The paper outlines a simple sustainability framework and proposes a set of qualitative characteristics for the development of an economically sustainable manufacturing company. The development of a comprehensive case study with a subject company also directs and enables other companies of similar size and style to apply a similar approach and to achieve economic sustainability in an efficient and effective manner through reducing production costs, minimising company failure and increasing business efficiency and effectiveness. Originality/value - The development of a set of sustainability characteristics is aimed at tackling directly the issues of economic sustainability is proposed and is considered by the authors as one of a kind. The case study approach also provides for a framework towards the implementation of sustainable manufacturing operations within companies.

An empirical analysis of Lean six sigma implementation in SMEs - a migratory perspective

Purpose – The purpose of this paper is to investigate the migratory nature of Lean Six Sigma (LSS) implementation and adoption in manufacturing-based SMEs in the UK. The companies were surveyed at two points over a five-year period. These periods were before and after the 2008 recession point. This being done in order to identify the level of LSS adoption as a result of the tougher economic climate that has prevailed since 2008. Design/methodology/approach – Analysis is carried out on a sample of 96 manufacturing SMEs from a range of manufacturing sectors in the UK. Data were gathered from company CEOs via a triangulated method of questionnaire, direct observation and interviews. Findings – The paper provides research information into the characterisation, compatibility and innovativeness of SMEs towards LSS implementation and goes on to provide an implementation classification system and characterises the dynamical nature of LSS development in manufacturing SMEs. Research limitations/implications – The f...

A note on ‘Modified Hamiltonian chain: a graph theoretic approach to group technology’ after S. K. Mukhopadhyay, K. Ramesh Babu and K. V. Vijai Sai

This note examines and compares a methodology devised by Mukhopadhyay et al. 2000 (Mukhopadhyay, S.K., Ramesh Babu, K. and Vijai Sai, K.V., Modified Hamiltonian chain: a graph theoretic approach to group technology. Int. J. Prod. Res., 2000, 38, 2459–2470) and offers possible solution approaches to a potential problem identified by the authors.

A flow direction weighting scheme for facility layout in cellular manufacturing

Purpose – The purpose of this paper is to re-examine the solution methodology to the facility grouping problem in group technology originally outlined by Mukhopadhyay et al. The aim of this re-examination is to attempt to resolve some of the problems associated with the original solution methodology and to provide the system designer with an improved technique for the creation of an efficient initial system design solution. Cellular manufacture by its very nature requires work-part transfer both within a machine cell and in some instances between machine cells. By utilising a design methodology which seeks to minimise work-part transfer, these non-value but cost adding tasks are kept to a minimum, thereby providing a faster throughput time and lower operational costs for companies who use cellular manufacturing systems in their production operations. Design/methodology/approach – In approach, the technique advocated parallels the possible alternative solution method suggested by John et al. to resolve the problem of edge ranking ties which exists in the original Mukhopadhyay et al. solution technique. Presented and discussed in this contribution is a revised flow direction weighting scheme (FDWS) which simplifies the solution input data requirements and overcomes a perceived disadvantage in the earlier scheme outlined by John et al. The methodology outlined in the paper is subsequently evaluated for its generic nature, applicability and effectiveness via the use of previously published synthetic production data, and the findings compared to the results determined by several alternative approaches to the problem. Findings – The development and application of the FDWS to cellular manufacturing system design is outlined in the paper and the usefulness of the technique is subsequently examined and compared to the results found for several competing methods. The approach provides for the identification of improved solutions to the test problems examined in both of the earlier contributions by Mukhopadhyay et al., and John et al. In addition, the results show that irrespective of the assessment criteria used, the FDWS technique provides solutions that are comparable to or better than the alternative approaches examined. Originality/value – The proposed FDWS technique further contributes to the existing knowledge base on cellular manufacturing system design. It can provide good initial solution guidance for manufacturing system designers and thereby reduce the time required to achieve an acceptable and cost efficient design for a cellular production system.

Reducing turn-round variability through the application of Six Sigma in aerospace MRO facilities

Purpose – The purpose of this paper is to outline the application of a Six Sigma (SS) methodology as a means of reducing supply chain risk in aerospace maintenance repair and overhaul (MRO) functions. In this contribution the LSS method is used to estimate the economic impact on the selection of the most appropriate maintenance strategy pertaining to aircraft display units (DUs) as well as providing a reduction in turn round time (TRT) variation of the DUs. Design/methodology/approach – The paper develops a SS approach which includes the development of the Monte Carlo technique as a mechanism to identify the most cost effective MRO strategy whilst simultaneously reducing variability in TRT servicing of the DUs. This application enabled the authors to obtain further proof of concept and also to apply a number of focused quality improvement techniques to systematically reduce TRT variation. Findings – An effective development of the SS approach is proposed and the effectiveness of the method is subsequently...

A weighted similarity coefficient technique for manufacturing facility design

Purpose - Using the weighted similarity coefficient (WSC) technique in the design of manufacturing facilities provides the system designer with a suitable method for the creation of efficient manufacturing cells. The formation of such well designed machine cells will then hopefully ensure that the achievable cost reduction benefits, in terms of lower operational costs incurred via the transfer of components between machines, are obtained by companies that wish to use cellular manufacturing in their approach to production operations. The aim of this paper is to outline and evaluate the application of a particular WSC equation to the formulation and design of cellular manufacturing systems. Design/methodology/approach - By using a pragmatic approach, the paper chronicles the design and development of a particular weighted similarity coefficient as a means of defining a possibly useful methodology for cell design in manufacturing systems. The technique outlined is subsequently evaluated for its generic nature, applicability and effectiveness via the use of previously published synthetic production data and a comparison with the results of several alternative approaches. Findings - The development of the proposed weighted similarity coefficient to manufacturing cellular design is outlined in the paper and the appropriateness of the technique is subsequently evaluated in order that the benefits obtainable by its use to a host organisation are highlighted. In addition, the results show how the approach can lead to useful improvements in cellular manufacturing performance if adopted by manufacturing system designers and implemented in their designs. Practical implications - The design, development and application of the WSC proposed and its use in manufacturing cellular design provides a simple yet highly effective approach to achieving useful improvements in production system performance through improved work-part transfer efficiency and associated cost savings. The paper offers practising manufacturing managers and engineers a technique whereby manufacturing cell productive efficiency and output can be improved whilst at the same time achieving a reduction in operational costs. Originality/value - The paper focuses on the proposed WSC technique which contributes to the existing knowledge base on production cell design and may also provide impetus, guidance, support and encouragement for designers to achieve improved output performance and reduced costs in their manufacturing system designs.

Achieving sustainability in manufacturing via organisational and operational learning

The contribution contained in this paper focuses on providing a possible framework or approach in respect of how manufacturing companies can economically introduce environmentally friendly practices to their production operations, whilst at the same time encouraging organisational and operational learning with the aim of eventual evolution of the firm into an eco-efficient concern. A key premise associated with the approach advocated is economical organisational and operational learning over time, thus providing a sequential movement of the company through various stages of cultural change and technological capability to eventually achieve eco-efficiency in its production activities. At each stage in the process, it is suggested that a balance must be maintained between on the one hand, a reduction in operational economics consistent with on the other hand, an improvement in the environmental sustainability of company activities. To that end, some previously suggested monitoring metrics are examined in the text for their efficacy and economic rapport via hypothetical examples of how they might be applied in practice to monitor movement towards industrial–environmental sustainability.

Defining a bearing replacement strategy using Monte Carlo methods

Purpose – The purpose of this paper is to propose a bearing replacement strategy which employs the Monte Carlo simulation method. In this contribution the method is used to estimate the economic impact on the selection of a particular bearing change strategy. The simulation demonstrates that it is possible to identify the most cost-effective approach and thus suggests a suitable bearing replacement policy, which in turn allows engineers to develop the appropriate maintenance schedules for their company. Design/methodology/approach – The paper develops the Monte Carlo method through a case study approach. Three case studies are presented. The first study is detailed and chronicles the design, development and implementation of the Monte Carlo method as a means of defining a bearing replacement strategy within a subject company. The second and third cases outline the application of the Monte Carlo method in two different environments. These applications made it possible to obtain proof of concept and also to further prove the effectiveness of the Monte Carlo simulation approach. Findings – An effective development of the Monte Carlo approach is proposed and the effectiveness of the method is subsequently evaluated, highlighting the benefits to the host organization and how the approach led to significant improvement in machinery reliability through a bearing replacement strategy. Practical implications – The design, development and implementation of a bearing replacement strategy provide a simple yet effective approach to achieving significant improvements in system reliability and performance through less downtime and greater cost savings. The paper offers practising maintenance managers and engineers a strategic framework for increasing productive efficiency and output. Originality/value – The proposed bearing replacement strategy contributes to the existing knowledge base on maintenance systems and subsequently disseminates this information in order to provide impetus, guidance and support towards increasing the development companies in an attempt to move the UK manufacturing sector towards world-class manufacturing performance.

Corporate strategy development via numerical situation analysis

Purpose – Using the numerical situation analysis (NSA) technique in the development of corporate strategy provides senior managers with a suitable methodology for the creation of alternative strategic options. Subsequently, it may be used to evaluate those options for possible selection and implementation by the company concerned. In addition, the technique provides a graphic temporal point description of an organisations strategic situation. Consequently, the aim of this paper is to outline the technique of NSA via a hypothetical example and thereby illustrate its use in practice. Design/methodology/approach – By using a paradigm approach, the paper indicates the correct application of the NSA technique as a means of defining and evaluating alternative strategic options within a manufacturing company. As proposed, the methodology also permits several graphic illustrations of the strategic situation to be drawn, along with a scheme for monitoring the effectiveness of an adopted strategy. Findings – The e...

Manufacturing process flow improvements using simulation and sustainable manufacturing

Simulation techniques are important tools that are used by businesses to guide decision-making, identify problems and provide solutions. This paper examines the adoption of simulation models and lean manufacturing techniques into the manufacturing line of a company in order to improve the process flow and reduce waste. A number of simulation models were built for the purpose of replicating the manufacturing line of the company. Attempts were made on the models to improve the process flow and reduce waste by reallocation of labour and machine resources through the use of Witness simulation statistics, Yamazumi charts and cross supporting, and flow charts. The waste generated due to machine breakdowns was explored and resolved through proactive engineering solutions which were proposed to repair the major breakdowns. An assessment of the waste generated by the transportation of components was carried out and multiple solutions were identified through the use of simulation models. The simulation results show that a rearrangement of resources, through the use of simulation and lean manufacturing techniques, yielded advantageous economical results for the company in terms of an increase in output by 18%, a reduction in waste by 10%, and an improvement in process flow leading to better throughout. Further, it could be seen that the breakdowns of machines and the transportation of components resulted in losses to the revenues of the company which could have been avoided by using the suggested proactive solutions.