Horacio Soriano-Meier

A model for evaluating the degree of leanness of manufacturing firms

Clarifies the concept of lean manufacturing and what it comprises. Commences with a review of the lean production literature and, specifically, existing models that identify the variables and component elements of lean production firms. Presents a research instrument for measuring the degree of leanness possessed by manufacturing firms. Research questions were developed and incorporated into structured survey questionnaires for both manufacturing directors and managing directors that enabled a quantitative assessment to be made for the various components of leanness. The survey was completed by over 30 firms in the UK ceramics tableware industry and so represents a comprehensive overview of the state of play in that sector. The figures derived allowed for hypotheses testing and a quantitative analysis. Presents selected results and conclusions from the current survey to illustrate the application and usefulness of the instrument. Argues that, though developed specifically for the tableware industry, the research instrument can be adapted for use in other industries.

Lean Production, Market Share and Value Creation in the Agricultural Machinery Sector in Brazil

By adopting Lean Manufacturing firms wants to see the value created in its results at the bottom line. The agricultural machinery and implements sector in Brazil had experienced in Lean and saw its results affected by the program. Using an established analytical model, the paper tests three hypotheses: H1: firms with a high degree of management commitment to the program simultaneously support this commitment with investments in support of the plant infrastructure and problem-solving groups; H2: firms that adopt lean principles have made changes in the direction of these principles; H3: firms that made continuous investments in plant infrastructure in to support lean principles have better performances. All hypotheses H1, H2 and H3 were fully accepted and corroborated.

Overall equipment effectiveness (OEE) and process capability (PC) measures: A relationship analysis

Purpose – Overall equipment effectiveness (OEE) and process capability (PC) are commonly used and well‐accepted measures of performance in industry. These measures, however, are traditionally applied separately and with different purposes. The purpose of this paper is to investigate the relationship between OEE and PC, how they interact and impact each other, and the possible effect that this relationship may have on decision making.Design/methodology/approach – The paper reviews the OEE and PC background. Then, a discrete‐event simulation model of a bottling line is developed. Using the model, a set of experiments are run and the results interpreted using graphical trend and impact analyses.Findings – The paper demonstrates the relationship between OEE and PC and suggests the existence of a “cut‐off point” beyond which improvements in PC have little impact on OEE.Practical implications – PC uses the capability indices (CI) to help in determining the suitability of a process to meet the required quality s...

The development of a lean park homes production process using process flow and simulation methods

Purpose – Continuous process flow is a prerequisite of lean systems as it helps to reduce throughput times, improve quality, minimize operational costs, and shorten delivery times. The purpose of this paper is to empirically demonstrate the application of a methodology that combines a time‐based study, discrete‐event simulation and the trial and error method to enable a leaner process through more efficient line balancing and more effective flow for a park homes production process. This method is replicable across other contexts and industry settings.Design/methodology/approach – The paper reviews the UK park homes production industry and, specifically, a major factory that builds these homes. It compares the factory method to traditional on‐site construction methods. An empirical study of production times was carried out to collect data in order to analyse the current workload distribution and the process flow performance of the park homes production process. Finally, seven discrete‐event simulation mode...

A DMAIRC approach to lead time reduction in an aerospace engine assembly process

Purpose – Problem solving and continuous process improvement are key elements to achieve business excellence. Many problem solving and process improvement methodologies have been proposed and adopted by organisations, with DMAIC being the most widely used. The purpose of this paper is to present an empirical application of a modified version of DMAIC which enabled a world-class organisation to achieve an optimum reduction in the lead time of its aerospace engine assembly process. Design/methodology/approach – The paper reviews the most commonly used problem solving and process improvement methodologies and specifically, DMAIC, its variations and limitations. Based on this, it presents define, measure, analyse, improve, review, control (DMAIRC). Finally, DMAIRC is empirically applied through a case study, in a world-class manufacturing organisation. Findings – The results obtained from the case study indicate that DMAIRC is an effective alternative to achieve the maximum improvement potential of a process....

An integrated methodology to prioritise improvement initiatives in low volume-high integrity product manufacturing organisations

Purpose – Several authors have proposed different approaches to help practitioners deal with the complexity of prioritising improvement projects and initiatives. However, these approaches have been developed as “generic” methods which do not consider the specific needs, objectives and capabilities of different industries and organisations. The purpose of this paper is to present an integrated methodology that prioritises improvement projects or initiatives based on two key performance objectives, cost and quality, specifically important for low volume‐high integrity product manufacturers.Design/methodology/approach – The paper reviews some of the most commonly used prioritisation methods and the theory and logic behind the proposed prioritisation methodology. Then, the prioritisation methodology is empirically tested, through a case study, in a world class manufacturing organisation.Findings – The results obtained from the case study indicate that the integrated methodology proposed in this paper is an ef...

The role of the physical layout in the implementation of lean management initiatives

Purpose – The purpose of this paper is to investigate the impact of layout configurations in a hospital on the implementation of lean management initiatives, to include different units of care. The research concentrated on the impact, the physical distance between dependent units could have on staff perception, use of staff time, time spent in the system by patients, and performance.Design/methodology/approach – The research examined the relationship between clinical units allocated within Northampton General Hospital and their internal providers. In addition, an adapted version of the SERVPERF questionnaire was used to measure the quality perception of staff.Findings – The transit distances from each clinical unit to their internal providers have: a negative relationship with the staff quality provision of care; a positive relationship with the time the patient spends in the system; and no discernable direct correlation with performance.Practical implications – These findings will help hospital managers ...

Exploring the application of quality improvement programmes and ISO standards in the Indian marble mining sector

In this era of globalisation, as competition intensifies, providing quality products and services has become a competitive advantage and a need to ensure survival. To ensure such competitive advantage, organisations of different industries around the world have implemented several quality improvement programmes like ISO, TQM and Six Sigma. This paper explores the application of quality improvement programmes in the marble mining industry of India. A questionnaire survey was designed, validated and distributed to 52 Indian marble organisations. A total of 35 responses were obtained and analysed using descriptive statistics. Then, since the literature review and preliminary results of the questionnaire indicated ISO as the most popular quality improvement approach in this sector, an exploratory case study was conducted in Indias leading marble mining company to gain more in-depth information about the application of ISO in this particular industrial sector. The results revealed that the marble mining industry of India lacks far behind in relation to other industries of this country, with ISO 9000 being the most popular quality improvement approach. The results also provide evidence of the degree of awareness, implementation issues and results achieved through the ISO implementation in this industry.

Empirical production management enquiry as an expatriate researcher

This paper explores the myriad methodological, practical and cultural challenges experienced by foreign researchers when conducting empirical management research overseas. It also provides a methodological solution to address many of the issues in the form of a research instrument which enables systematic and rigorous data collection via a combination of face-to-face interviews and survey, together with general observation. The paper builds upon an extensive study which deployed two survey instruments to obtain key information from senior and middle level managers respectively within the UK tableware industry. The survey was complemented with semistructured interviews and observational intervention via random plant visits. This methodology generated significant and extensive data sets, this paper reflects upon the issues and lessons learnt. The use of a mixed methodology combining survey, interview and observational techniques, provided an enriched qualitative dimension to empirical research that could not have been obtained by using a survey alone. The proposed methodology has wide application and can be deployed beneficially by expatriate researchers.