James Tannock

A review of neural networks for statistical process control

This paper aims to take stock of the recent research literature on application of Neural Networks (NNs) to the analysis of Shewharts traditional Statistical Process Control (SPC) charts. First appearing in the late 1980s, most of the literature claims success, great or small, in applying NNs for SPC (NNSPC). These efforts are viewed in this paper as useful steps towards automatic on-line SPC for continuous improvement of quality and for real-time manufacturing process control. A standard NN approach that can parallel the universality of the traditional Shewhart charts has not yet been developed or adopted, although knowledge in this area is rapidly increasing. This paper attempts to provide a practical insight into the issues involved in application of NNs to SPC with the hope of advancing the use of NN techniques and facilitating their adoption as a new and useful aspect of SPC. First, a brief review of control chart analysis prior to the introduction of NN technology is presented. This is followed by an examination and classification of the NNSPC existing literature. Next, an extensive discussion of implementation issues with reference to significant research papers is presented. Finally, after summarising the survey, a set of general guidelines for future applications of NNs to SPC is outlined.

A neural network approach to characterize pattern parameters in process control charts

Abnormal patterns on manufacturing process control charts can reveal potential quality problems due to assignable causes at an early stage, helping to prevent defects and improve quality performance. In recent years, neural networks have been applied to the pattern recognition task for control charts. The emphasis has been on pattern detection and identification rather than more detailed pattern parameter information, such as shift magnitude, trend slope, etc., which is vital for effective assignable cause analysis. Moreover, the identification of concurrent patterns (where two or more patterns exist together) which are commonly encountered in practical manufacturing processes has not been reported. This paper proposes a neural network-based approach to recognize typical abnormal patterns and in addition to accurately identify key parameters of the specific patterns involved. Both single and concurrent patterns can be characterized using this approach. A sequential pattern analysis (SPA) design was adopted to tackle complexity and prevent interference between pattern categories. The performance of the model has been evaluated using a simulation approach, and numerical and graphical results are presented which demonstrate that the approach performs effectively in control chart pattern recognition and accurately identifies the key parameters of the recognized pattern(s) in both single and concurrent pattern circumstances.

The optimisation of neural network parameters using Taguchi’s design of experiments approach: an application in manufacturing process modelling

Neural networks have been widely used in manufacturing industry, but they suffer from a lack of structured method to determine the settings of NN design and training parameters, which are usually set by trial and error. This article presents an application of Taguchi’s Design of Experiments, to identify the optimum setting of NN parameters in a multilayer perceptron (MLP) network trained with the back propagation algorithm. A case study of a complex forming process is used to demonstrate implementation of the approach in manufacturing, and the issues arising from the case are discussed.

TQM Best Practices: Experiences of Malaysian SMEs

Abstract The progress of TQM in SMEs, particularly in developing countries, is a significant research issue at present. This paper presents some of the most important findings of three case studies, undertaken at SME companies in Malaysia. The companies comprise medium-scale automotive parts and plastics manufacturers, and a smaller food manufacturing company. Each company case provides insights into the issues facing SMEs, who are trying to develop more advanced quality management approaches. The case studies involved structured interviews with top management at each company, based on the award criteria of the Malaysian Quality Management Excellence Award (QMEA). The case study analysis illustrates that the companies studied have adopted distinct approaches to the implementation of TQM, which could be shared by other SMEs. Some of the key issues that have been addressed by the case study companies can be summarized as: effective top management commitment, an effective steering committee engaged in policy and planning management, real employee involvement, employee rewards and skills development. The issues of benefits perceived, barriers and quality progress of the companies are also presented in the paper.

The development of total quality management in Thai manufacturing SMEs

Total quality management (TQM) has been applied widely in developed countries, and now appears to many as a precursor of the broader concept of business excellence. By contrast, in developing countries ISO 9000 series standards have been the focus of quality management development, and TQM is a new and challenging concept. TQM companies are rare, and with few exceptions are subsidiaries of larger multinational organisations. Examines the progress of four Thai SMEs attempting to implement TQM over a two‐year period, assisted by a facilitator and a “model company”. Relevant literature is briefly reviewed and issues of particular relevance to SMEs discussed. The efforts, problems, barriers and progress of the companies are described. The relative success of the companies was found to be related in large part to management and information issues, which are discussed.

Supply chains and supply networks: distinctions and overlaps

Purpose – Although supply chain management is now an established field, the distinction between supply chains and supply networks is relatively immature and requires further investigation. The purpose of this paper is to clarify the distinction between supply chains and supply networks. Design/methodology/approach – Based on a review of the literature and assisted by input from academic experts during a relevant supply chain management workshop, this paper critiques seminal and extant theoretical developments in the field of supply chain management. Findings – The main contribution of this paper is the development of an outline classification of relevant dimensions where the concepts of supply chain and supply network are compared and their distinctive features are highlighted. The paper identifies strategic opportunities emanating from considering both the supply chain and supply network, and the associated levels of engagement with active and inactive members in terms of, inter alia, complexity, members...

The training of neural networks to model manufacturing processes

Neural networks have been increasingly used in various areas of manufacturing. Modelling of manufacturing processes, to allow experimentation on the model, is one of the areas in which successful applications have been reported. Most literature in this area is focused on network results. This paper concentrates on methods for training neural networks to model complex manufacturing processes. It summarises the use of neural network for process modelling in the past decade and provides some detailed guidelines for network training. A case study of a complex forming process is used to demonstrate a real implementation case in industry, and the issues arising from this case are discussed.

Building the extended enterprise: key collaboration factors

Purpose – The purpose of this paper is to explore supply chain collaboration issues in the extended enterprise (EE) to develop a more complete understanding of the nature and effectiveness of collaboration in the transition towards, but also within, the EE paradigm.Design/methodology/approach – The paper presents results from a three‐company case study focusing on the civil aerospace industry, with all companies taking part in an EE. The research involved obtaining and systematically analysing a diversity of interview data and company documents to assist in the development of theory, which was subject to a systematic validation process.Findings – The authors propose a taxonomy, which, first, assists in understanding the transition towards the EE and supports a distinction between sets of factors that affect the effectiveness of collaboration, termed the “contractual” and “engaging” factors. Second, it assists in understanding the dynamic, complex nature of the EE paradigm and suggests a further breakdown ...

A decision aid for selecting improvement methodologies

Competitive pressures increasingly force companies to consider the adoption of new business improvement methodologies. The multi-criteria decision aid described in this article provides managers with a comprehensive set of selection criteria, within a structured and formalized evaluation process. The decision aid employs multiple criteria decision-making (MCDM) methods and is underpinned by a selection framework which aims to promote rational decision-making and assists decision-makers to structure their evaluation process, compile useful information and reach a consensus decision with confidence. This article describes the theoretical background to the development of both selection framework and decision aid and explains the operation of the decision aid. A case example of a multi-national company is used to illustrate the operation of the decision support process. Practical testing of the decision aid provides evidence of its feasibility, usability, and utility. The article concludes by discussing how this approach can help managers make more rational decisions, when deciding to adopt new improvement methodologies.

A study of TQM implementation in Thailand

Describes research which has been carried out using case‐study analysis to investigate how three Thai companies have adopted TQM. As Japanese and US companies are major investors in Thailand, one purpose of the study was to compare approaches to TQM implementation between three ownership categories: Thai, Japanese, and US‐owned companies operating in Thailand. A framework of TQM implementation developed from change management theory has been adopted for this study. The methodology used involved structured interviews with key staff throughout the selected organisations. The data collected were analysed for content using interview phrase‐matching. This method of analysis proved effective and can form the foundation for an in‐depth understanding of TQM implementation. The case study analysis illustrates that the companies studied have adopted distinct approaches to the implementation of TQM, which are described and placed in the context of the theoretical framework. Also describes the common characteristics of the TQM company which were found in the companies investigated.