Gionata Carmignani

A new value stream mapping approach for complex production systems

In this paper, an innovative framework to apply Value Stream Mapping to products with complex Bill of Materials is presented. Value Stream Mapping is one of the best tools to map a process and to identify its main criticalities. Unfortunately, it can be effectively applied to linear systems only. When the manufacturing process is complex with flows merging together, Value Stream Mapping cannot be used straightforwardly. Thus, the main objective of this work is to solve this limitation so that lean production can be enhanced in complex systems too. The proposed approach is based on seven iterative steps and integrates Value Stream Mapping with other tools typical of industrial engineering. The basic idea is to execute a preliminary analysis to identify the ‘critical production path’ using the Temporized Bill of Material. Then, improvements are made considering all possible sharing with other secondary paths as possible constraints. Once the critical path has been optimized, a new path may become critical. Thus, the analysis proceeds iteratively until the optimum is reached and the Work In Process level has decreased under a desired value. A case study taken from a real setting environment is finally presented to assess the validity of the methodology proposed here.

An integrated structural framework to cost-based FMECA: The priority-cost FMECA

The Failure Mode, Effects and Criticality Analysis (FMECA) methodology is a widely recognized tool for the study and reliability analysis of a design or process. Many authors in the field have emphasized the usefulness of this particular method as well as its limitations. In particular, there are two main criticisms regarding the Risk Priority Number (RPN) method of calculation and the extreme difficulty in considering the variable of the corrective action cost in the analysis. The main scope of this work is to present a new integrated approach, named priority-cost FMECA (PC-FMECA), in order to exceed these limits. Making reference to a paper by Braglia [MAFMA: multi-attribute failure modes analysis. Int J Qual Reliab Manage 2000; 17(9)], this study proposes a method which allows for the calculation of a new RPN and the introduction of the concept of Profitability taking into consideration the corrective action cost. The study is divided in three fundamental phases: critical analysis of the FMECA model, proposal and development of the PC-FMECA and presentation of an implemented case study in the automotive field.

AHP‐based evaluation of CMMS software

Purpose – To provide a structured methodology to permit an optimal selection of the best suited Computer Managed Maintenance System (CMMS) software within process industries.Design/methodology/approach – The analysis has been executed adopting a multi‐attribute decision making methodology, namely the analytic hierarchic process (AHP) technique. A specific hierarchic structure has been defined considering 46 criteria outlined via questionnaires and interviews with administration, production and maintenance managers of several industries. To improve the effectiveness of the methodology, AHP has been coupled with a sound sensitivity analysis.Findings – The application of the proposed approach allows the maintenance practitioners to concentrate on a limited subset of CMMS applications and to compare their actual capabilities in order to select the right one, rather than considering only their purchase cost.Practical implications – The methodology enables decision makers to restrict the selection process to a ...

Supply chain and quality management: The definition of a standard to implement a process management system in a supply chain

Purpose – The purpose of this paper is to present the results of a research for developing a standard to implement a process management system in a whole supply chain.Design/methodology/approach – To gain this aim, the research has been developed in two parts. The quality management part has the objective to select the reference model to develop the standard. The supply chain management (SCM) part has, instead, the objective to select the drivers and the main processes that the standard have to manage. The evaluation of the results of these parts has permitted to define the proposed standard.Findings – A modified interpretation of ISO 9001:2000 norm is proposed permitting: to improve the ISO 9001 standard to the general requirements for a whole process approach; to extend and to apply the ISO 9001 concepts, that address quality aspects within a single organization, to a whole supply chain; and to facilitate the introduction of the modern principles and techniques of SCM. Finally, the standard to implement...

Process‐based management: A structured approach to provide the best answers to the ISO 9001 requirements

Purpose – The purpose of this paper is to provide a structured method to apply process management approach following ISO 9001:2000 requirements, clause 4.1.Design/methodology/approach – The content of this paper is focused on the detailed analysis of the fourth clause of the 2000 edition of norm ISO 9001, and it presents an articulated procedure which can be undertaken by any organization in order to give the best answers to the requirements therein.Findings – The method described consists in eight steps, with a top‐down approach going from the definition of the macro‐processes of the organization to the definition of the single stages which constitute the activities. An approach to implement quality objectives deployment is implemented. In order to better explain the methodology, a case study is used.Originality/value – Indeed, it is thought that the content of the fourth clause of ISO 9001, and in particular of paragraph 4.1, represents one of the most important innovations brought in by the new edition...

Data classification and MTBF prediction with a multivariate analysis approach

Abstract The paper presents a multivariate statistical approach that supports the classification of mechanical components, subjected to specific operating conditions, in terms of the Mean Time Between Failure (MTBF). Assessing the influence of working conditions and/or environmental factors on the MTBF is a prerequisite for the development of an effective preventive maintenance plan. However, this task may be demanding and it is generally performed with ad-hoc experimental methods, lacking of statistical rigor. To solve this common problem, a step by step multivariate data classification technique is proposed. Specifically, a set of structured failure data are classified in a meaningful way by means of: (i) cluster analysis, (ii) multivariate analysis of variance, (iii) feature extraction and (iv) predictive discriminant analysis. This makes it possible not only to define the MTBF of the analyzed components, but also to identify the working parameters that explain most of the variability of the observed data. The approach is finally demonstrated on 126 centrifugal pumps installed in an oil refinery plant; obtained results demonstrate the quality of the final discrimination, in terms of data classification and failure prediction.

Lean thinking in the luxury-fashion market: Evidences from an extensive industrial project

Purpose – The capability to overcome tradeoffs among costs, quality and time has become a must in high-margin businesses too. Lean thinking may be a solution, but applications in the luxury-fashion market are still rare. In order to shed light on this apparent contradiction, the purpose of this paper is to identify the key features of the luxury-fashion market that may act as barriers for the adoption of lean principles. Next, based on the results of this preliminary analysis, the paper tries to verify, if and how, lean principles can be properly reinterpreted, so as to properly fit the requirements of this market. Design/methodology/approach – Due to the operating nature of lean, an empiric approach was followed. From the evidences gathered during a lean project of a world-wide company, critical elements of the luxury-fashion market were identified and used as criteria to select, among lean tools, the most appropriate ones. Lastly, selected tools were integrated in a structured framework (for lean implem...

A QFD‐based technique to select and manage reverse e‐auctions

Purpose – In the 1990s, reverse e‐auctions were designed to be a widely used procurement tool due to the dramatic cost reduction. However, the current usage is more limited than expected, because e‐auctions do not always produce the benefits expected and firms have great difficulty in deciding the right tool to use in the negotiation. The aim of this paper is to propose a methodology for a useful utilization of the reverse e‐auctions.Design/methodology/approach – This paper suggests a method based on the quality function deployment (QFD) technique to help purchasing managers to choose how and when they should use e‐auctions to buy a new product or service.Findings – The approach proposed is structured as a tree and developed in three steps: choice between traditional negotiation and e‐auction; choice between the different typologies of e‐auction (open, secret, and in sealed envelope); and, finally, choice of the specific characteristics of the e‐auction to guarantee an optimal negotiation outcome.Practica...

Lean Supply Chain Model and Application in an Italian Fashion Luxury Company

Since many years the lean production paradigm has found many applications in a lot of different organizations. The necessity, for every organization, to reduce wastes and to make more efficient the way to operate has become a dogma. However, there are many cases of failure in the implementation of lean methodology that can be found in the literature. These failures are due to the fact that the techniques and tools of lean production must be accompanied by a careful analysis of the market environment, the product, the field in which the organization operates and not least the characteristics of the supply chain. The field of fashion and luxury has very particular characteristics in the way of realizing the products along the supply chain. Therefore, it is necessary to establish the appropriate methods and techniques to implement the methodologies of lean production. In this paper an structured approach for the development of a lean management project is presented highlighting what are the characteristics of this particular sector. Thanks to the application and integration of the principles of Lean Production and Total Quality Management it was possible to line up the suppliers craftsman production with the management requirements of the luxury industry, in order to obtain a better interaction between the actors of supply chain, higher product quality and maximize productivity. A case study, applied in a major Italian company in the fashion industry, is reported to validate the proposed approach.

Modified QFD and problem‐solving techniques integrated approach implementing corrective actions: a case study in an Italian manufacturing plant

The ISO 9001:2000 and Total Quality Management models impose that organizations adopt structured procedures to implement corrective and preventive actions. In this paper, a structured framework to solve a non-conformity in a product or in a process, selecting the best corrective actions, is proposed. Some problem-solving techniques are applied in a structural method (i) to find the problem (product or process non-conform), (ii) setting the problem (using data-collecting instruments), (iii) analyzing the problem (with techniques such as Pareto charts, histograms, stratification analysis) and (iv) searching possible alternative solutions. Then, a modified quality function deployment technique is applied to evaluate and to classify the alternative solutions with respect to three different parameters (benefit, cost and impact). The framework has been developed to select and implement corrective actions in an Italian manufacturing plant. The case study is presented in this paper. However, the proposed approach is applicable in many other contexts. Copyright