Maurizio Bevilacqua

Development of a sustainable product lifecycle in manufacturing firms: a case study

This study discusses a methodology for integrating Design for Environment (DfE) and life cycle assessment (LCA) techniques both into new product development and into the process of redesigning a set of existing products. The article explains the reasons for developing DfE in general, and pays particular attention to a specific, chosen product, a class of electrical distribution boards, to illustrate the concept. The main process steps in the development of the DfE are outlined, and the development of a LCA that satisfies the requirements of the ISO 14040 standard is illustrated. A major benefit of the DfE methodology proposed in this work is the possibility to use LCA data both during new product development and when modifying old products, with the aim of continuously reducing the overall environmental impact of products during their life cycle. This improvement cycle begins with the attempt to find new design solutions (for assembly and set-up in the case of electrical distribution boards), continues with the calculation of the enviromental break even point (BEP) and with the assessment of the BEP for the expenses incurred by the client. On the basis of these calculations and bearing in mind the technical specifications required by the clients and the work environment in which the product will be used, the designers will be able to make the most efficient choices from both the environmental and the economic point of view.

From Traditional Purchasing to Supplier Management: A Fuzzy Logic-based Approach to Supplier Selection

Making a decision requires the consideration of possible alternatives and then selecting the optimal one. This selection process generally relies quite considerably on subjective judgement. The intrinsic difficulty of any decision is increased by the unavailability of precise or complete information. This kind of problem exists when selecting the most appropriate supplier and it is worsened when purchasing managers are willing to adopt advanced approaches to supplier selection and auditing whereby less traditional criteria are considered. In fact, when dealing with such factors as the suppliers effort to implement total quality management principles, its capacity to adapt flexibly to changes in the customers requirements, its technological profile, its capacity to operate in a just-in-time supply perspective and its organisational culture, the subjective and qualitative dimensions of the purchasers judgements become paramount. In this paper, we develop a system for supplier selection using fuzzy logic. Fuzzy logic enables us to emulate the human reasoning process and make decisions based on vague or imprecise data. The approach seems to be particularly effective in reducing the uncertainty inherent in the determination of the relative importance (weight) given to the different criteria and in determining the impact of each alternative supplier on the attributes considered.

Identifying manufacturing flexibility best practices in small and medium enterprises

Most of previous research on manufacturing flexibility has been conceptual by nature and finalized to build analytical models and only a small percentage of the studies have focused on empirical observations of actual industrial practice. In this study, we applied a DEA‐based methodology to identify small and medium‐sized enterprises (SMEs) that operate on the frontier of manufacturing flexibility practice. Data were obtained via a questionnaire survey that considered seven basic dimensions of manufacturing flexibility. Subsequently, discriminant analysis was carried out to delineate which contextual factors and managerial aspects characterize the firms that have reached the “best practice” status. Finally, on‐site investigation was carried out with the “excellent” firms to better delineate their organizational and strategic profile.

Design for environment as a tool for the development of a sustainable supply chain

In this work, design for environment (DfE) methodologies have been used as a tool for the development of a more sustainable supply chain. In particular by combining life‐cycle assessment (LCA) techniques and by using the quality function deployment (QFD) multi‐criteria matrices, an ‘environmental compromise’ can be reached. In this work, the QFD matrices have been developed in a new way using an iterative process that involves the whole supply chain starting from the product life‐cycle, taking into consideration the machines that make the product and their components. This methodology is compatible with the requirements of the various stakeholders, suppliers, manufacturers and clients, involved in the supply chain. To assess the validity of the proposed approach a specific supply chain was studied concerning packaging systems for liquid food substances (beverage cartons). Firstly all the stages which are most critical from the environmental point of view in the supply chain of packaging systems were identified and assessed. The starting point for the analysis of environmental aspects and impacts which characterise the supply chain was LCA, which proved to be useful for the identification and the environmental assessment of the various stages in a packaging system. Through the use of ‘iterative QFD’ it is possible to arrive at a definition of the engineering characteristics of all the machinery which is involved in the supply chain. In particular in this work the authors have tried to identify the critical points in the design of those machines which either make the beverage cartons or are involved in the filling process.

Industrial and occupational ergonomics in the petrochemical process industry: A regression trees approach

This work is an attempt to apply classification tree methods to data regarding accidents in a medium-sized refinery, so as to identify the important relationships between the variables, which can be considered as decision-making rules when adopting any measures for improvement. The results obtained using the CART (Classification And Regression Trees) method proved to be the most precise and, in general, they are encouraging concerning the use of tree diagrams as preliminary explorative techniques for the assessment of the ergonomic, management and operational parameters which influence high accident risk situations. The Occupational Injury analysis carried out in this paper was planned as a dynamic process and can be repeated systematically. The CART technique, which considers a very wide set of objective and predictive variables, shows new cause-effect correlations in occupational safety which had never been previously described, highlighting possible injury risk groups and supporting decision-making in these areas. The use of classification trees must not, however, be seen as an attempt to supplant other techniques, but as a complementary method which can be integrated into traditional types of analysis.

CLASSIFICATION OF OCCUPATIONAL INJURY CASES USING THE REGRESSION TREE APPROACH

Occupational safety and illness surveillance has made a great effort to spread a safety culture to all workplaces and a great deal of progress has been made in finding solutions that guarantee safer working conditions.This paper analyses occupational injury data in order to identify specific risk groups and factors that in turn could be further analyzed to define prevention measures. A technique based on rule induction is put forward as a non-parametric alternative tool for analyzing occupational injury data which specifically uses the Classification And Regression Tree (CART) approach. Application of this technique to relevant work-related injury data collected in Italy has been encouraging. Data referring to 156 cases of injury in the period 2000–2002 were analyzed and lead to the factors that most affect work-related injuries being identified. According to the literature, up to the time of writing computer-intensive non-parametric modeling procedures have never been used to analyze occupational injuries. The aim of this paper is to use a real world application to illustrate the advantages and flexibility of applying a typical non-parametric epidemiological tool, such as CART, to an occupational injury study. This application can provide more informative, flexible, and attractive models identifying potential risk areas in support of decision-making in safety management.

DATA MINING FOR OCCUPATIONAL INJURY RISK: A CASE STUDY

The management of occupational injury is of strategic importance in a company from the organizational, engineering and economic point of view. This work is an attempt to apply data mining techniques to data regarding accidents in a medium-sized refinery. Several techniques were adopted in order to identify the important relationships between risk level and immediate/root causes and corrective actions. As a Data Mining technique were tested: Negative Binomial Regression (NBR), Chi-Squared Automatic Interaction Detection (CHAID); Exhaustive CHAID; Classification And Regression Trees (CART); Quick, Unbiased, Efficient Statistical Tree (QUEST), Artificial Neural Network (ANN) and Neuro-Fuzzy Systems (FIS). The comparison carried out in this study shows through a real application the flexibility and advantages of using the neuro-fuzzy network, a typical soft computing tool. Using these innovative techniques to analyse injury data this study aims to: • obtain a classification of input data according to their importance and/or influence on the risk level in injuries; • assess how a variation in one or more pieces of input data can effect occupational injury and subsequently carry out a sensitivity analysis concerning the probability, the consequences and risks of the injurie events; The analyses carried out indicated important relationships between the variables, providing useful decision-making rules which can be followed when adopting measures for improvement.

An application of BPR and RCM methods to an oil refinery turnaround process

This works reports on the application of business process re-engineering (BPR) methods to a specific stage in the maintenance activities of the API refinery in Falconara Marittima (AN), i.e. the scheduled annual turnaround. The aim of the study was to analyse the process as it was always implemented up until the year 2001, identifying any related problems and inconsistencies, and then describe the re-engineering of this process, assessing and emphasising the changes involved and pinpointing further opportunities for improvement. Using the synergies provided by the simultaneous adoption of management policies and maintenance management methods enables considerable changes to be made with a view to the production of servicing plans that ensure a greater reliability at the lowest possible cost. The annual turnaround process was modelled using the AIØ WIN software, which supports the IDEFØ method.

Value stream mapping in project management: A case study

This article describes the application of value stream mapping to analyze and redesign the way of managing the materials procurement stage of a project. A framework based on integrated definition (IDEF) methodology, the stream analysis approach, activity-based costing, and discrete event simulation is presented. The stream analysis approach is used to analyze, diagnose, and manage process changes represented using an IDEF model. A dynamic simulation is used to evaluate the impact of the changes considered, to support the analysis of the process, and to model the performance of the proposed process. The overall methodology is demonstrated by applying it to a company whose core business is the design and construction of offshore oil rigs. The company specializes in engineering, procurement, and construction projects and has an annual portfolio of about six projects. Many of these projects have common features in terms of design and components, and they are all also characterized by a short “time to delivery.” For this reason, this study was aimed at assessing the possible effects that the application of new materials management policies could have on reducing both project completion time and the resources required.

Relationships between Italian companies’ operational characteristics and business growth in high and low lean performers

Purpose n n n n nThe purpose of this paper is to analyze relationships between operational characteristics and business growth in Italian manufacturing companies comparing high lean performers (HLPs), which are companies with a high degree of application of lean practices, and low lean performers (LLPs). This analysis aims at highlighting the effect of the implementation level of lean practices on operational characteristics of Italian companies and, as a consequence, on business growth. n n n n nDesign/methodology/approach n n n n nA classification in “LLPs” and “HLPs” of Italian manufacturing industries has been developed in order to measure the company’s degree of application of lean practices. A survey was carried out, and a combination of cluster analysis and multi-group structural equation path model was developed in order to answer research hypotheses. n n n n nFindings n n n n nResults suggest that HLPs are characterized by a greater number of employees and a larger turnover. The operational characteristics that contribute to the business growth owing to the introduction of lean practices are as follows: the range of different finished products managed, the delivery reliability, and speedy response to warranty claim. No differences between HLPs and LLPs in terms of business growth have been highlighted when companies vary the batch size, reduce the medium production time, reduce the percentage of finished products which are subject to claim, and increase the percentage (of turnover) of R&D investment. The study highlights that “LLPs” companies are apparently capable of changing their production schemes and adjusting themselves better for customizing their products. n n n n nPractical implications n n n n nCompanies that aim at implementing lean practices should focus their attention on practices that affect the operational characteristics that contribute to the business growth. Moreover, because of the complexity and effort for the implementation of certain lean practices connected to supplier, workforce, quality, and production efficiency, these practices are more suitable only for large firms with enough resources. n n n n nOriginality/value n n n n nAs an attempt to offer strategic and operational perspective on Italian lean practices implementation, this study examined how the degree of application of the different lean practices has an impact on operational and companies’ performance. Hence, even if the present study is limited to the Italian manufacturing companies, it could be a representative of companies that are operating in developed countries that are facing the so-called “anemic growth.”