Maria Kollberg Thomassen

Global supply chain control systems: a conceptual framework for the global control centre

The operation of global supply chains is challenging due to the complexity in product and information flows, diversity in sites, localisation and processes and the information processing needed for coordination and control. In order to be competitive, manufacturing supply networks should strive to use information to create transparent and visible demand patterns and to create an efficient balance of supply and demand by an integrated and coordinated manufacturing planning and control system. In this article, a framework for developing global control centres (GCCs) is presented that includes a global control model, performance measurement system, information and communications technology (ICT) and organisation of roles and responsibilities. The framework has been further tested in a company for realising a GCC. The main challenges for realisation include control issues, information handling and ICT and management of change and organisational resistance.

A Strategic Approach for Automation Technology Initiatives Selection

Despite the rapid development of new manufacturing technologies, a large portion of adoptions fail to achieve expected benefits. Existing models for technology selection are criticized for requiring large computations, and for being time consuming and difficult to use. This paper presents a strategic approach to support decision-makers in automation technology selection that is efficient and easy to apply in practice. It involves technology strategy decisions, process and technology analyses, technology/process ranking and considerations on investment and implementation. The approach has been developed through literature reviews and close collaboration with two case companies, utilizing the action research method. Its use is illustrated in an ongoing automation project at a world leading supplier of plastic pipes systems.

A New Value Stream Mapping Approach for Engineer-to-Order Production Systems

Companies seeking to implement lean practices in engineer-to-order environments experience major difficulties due to a high degree of non-standard products and non-repetitive processes. Current lean methods need to be further developed to be more efficiently applied in manufacturing environments with high variety and complexity. This paper presents a new approach for value stream mapping adapted to engineer-to-order production systems. The approach combines the classic value stream mapping approach with recent works dealing with lean methods in high mix and complex production systems. Also, it proposes a stronger focus on the choice of location of the customer order decoupling point compared to previous research.

Front-End/Back-End Integration in Mass Customization: Challenges and Opportunities

Many mass customization challenges can be ascribed to insufficient integration of front-end (e.g., customer choice navigation processes, product configuration, user interfaces, and customer behavior patterns) and back-end (e.g., order management, purchasing and production planning and control) systems. To succeed as a mass customizer, customer/manufacturer integration is critical. This paper provides in-depth insights to integration challenges and opportunities based upon a case study of four manufacturing companies. For solution space and product development, high uncertainty in new idea generation, lack of systematic product and solution space development, and limited knowledge of what is the “right” solution space are identified as challenges with opportunities for improvement. Regarding choice navigation, many companies have limited direct contact with end customers due to sales through dealers and resellers. Associated inefficient information flows are another challenge. The companies acknowledge opportunities related to advisory support during the sales process, as well as enhanced external collaboration with, e.g., complementary actors. With respect to back-end systems, inefficient information flows also occur here. This, in combination with a large number of freestanding ICT systems, results in cumbersome production planning and execution. This is complicated even more by incorrect basic data. Finally, there are major opportunities in automatic visualization and efficient utilization of key information from the entire value chain. In addition to outlining several directions for further research, the paper provides in-depth, company-based insights to key integration development areas, which managers may use when developing their own mass customization practices.

The Importance of Choice Navigation in Starting Configurator Projects

Choice navigation can support customers in identifying their own solutions while minimizing complexity and the burden of choice. Product configurators are used as an interactive tool to help customers in this process. For companies aiming to develop a configurator from scratch, there are many hurdles. Particularly for SMEs, there are additional challenges, such as shortage of resources, experience, and knowledge in developing a viable configurator tool. In this paper, we explore the process of designing choice navigation through a product configurator tool. We review existing methodologies and propose a new process model. Empirical data come from a case study of three SMEs embarking on the process of establishing a choice navigation tool. The proposed model is developed in the context of the research project CustomR. The new process model is cyclic and customer-driven and aims to develop need-based configurators (as opposed to a linear, technology-driven, and function-based approach). The paper reports on challenges and success factors from an ongoing configurator development project.

Information Support for Supplier Kit Preparation

Information support in kit preparation is critical for the design of efficient kitting systems. Existing literature is dominated by studies that address in-house kitting and order picking support in warehouse settings and that are based upon laboratory experiments. This study explores critical aspects of information support for kit preparation outsourced to partners in the supply chain based upon empirical evidence of a web application for kitting adopted in a real-life case of a manufacturer and a supplier. Detailed insights to kitting efficiency, information sharing and user acceptance are presented. Critical aspects are identified primarily related to the relationship and interaction between companies, quality of information sharing, usefulness, parts identification efficiency, and joint improvement and development efforts. This work highlights the importance of considering supply chain information sharing in outsourced kitting.

Challenges in Choice Navigation for SMEs

As mass customization is becoming a more widely adopted business strategy, not only large companies but also SMEs are beginning to adopt mass customization. Previous research suggests that in order to become a successful mass customizer, companies must hold three fundamental capabilities: solution space development, choice navigation, and robust process design. Since mass customization often requires complex systems related to these three capabilities, this is often resource consuming and can thus be challenging for SMEs due to the smaller scale compared to traditional mass customizers. This paper analyzes six cases of SME mass customizers, by describing and comparing the challenges they have been faced with implementing mass customization. This paper focuses specifically on the capability choice navigation and thus addresses the expected benefits and challenges these companies have encountered in relation to product selectors, product configurators, or other systems used for matching customer requirements with selection within the company’s product variety.

Mass Customization Challenges of Engineer-to-Order Manufacturing

Companies in engineer-to-order (ETO) manufacturing environments that seek efficiency gains through adopting a mass customization strategy meet major challenges. Current research on the implementation of mass customization (MC) in companies traditionally has a strong focus on the transition from mass production, and few studies only involve settings characterized by high variety and low volume production. The purpose of this study is to bring further detail to major areas of concern when adopting mass customization principles in ETO manufacturing. A literature review of mass customization and ETO was carried out, and principles for mass customization implementation were tested in a case company. The study revealed that major issues of MC in ETO are interdependent across several decision areas and involve manufacturing as well as engineering and design phases. This paper provides more in-depth insights to practical consequences of implementing MC in ETO manufacturing.

A Framework for Lean Flow in Turbulent High-Variety Low-Volume Manufacturing Environments

Value stream mapping (VSM) is a widely applied method for manufacturing systems design in repetitive and stable industries. A literature review of challenges and modified solutions for lean flow in high-variety low-volume (HV/LV) value streams is carried out. The solutions are categorized according to manufacturing turbulence level. The review shows that existing VSM solutions take their starting point in the original VSM principles and incorporate other relevant works only to a limited extent. Based upon the review, a coherent framework with revised VSM principles that that can be used to develop lean flow in HV/LV environments with medium and high turbulence levels is proposed.

Comparing Techniques for Selecting Automation Technology

Automation of industrial processes is a necessary step towards the Industry 4.0 vision. There are several justification techniques available that can help to improve chances for success in automation projects. A literature review on justification techniques and their usefulness is carried out. Based on the review, a set of criteria for evaluating justification techniques are developed. A case study is carried out in a company with an ongoing manufacturing system development project that includes decisions regarding processes and technologies that require a systematic evaluation and justification. Two justification techniques were selected and tested in the development project. The tests show that both justification techniques provide good support for the technology acquisition process. Strengths and weaknesses of the tested techniques are highlighted. The study suggests that the choice of method should depend on the type of acquisition process of a company, especially with respect to technology strategy, competences, and supplier relations.