ABSTRACT: In this paper, we present the results of an empirical study in the manufacturing industry of Germany, Austria and Switzerland with over 100 participants, mainly from the mechanical engineering, automotive and machine tool businesses. The questionnaire-based study yielded original findings in the area of assembly disruptions and the management thereof. Major results include that assembly disruptions are widespread in the industry and lead to extensive economic damages. The reasons, durations and locations of assembly disruptions as well as their character are explored and the need for a new concept of efficient, preventive assembly disruption management is derived.
To study the impact of multi vendor outsourcing on the performancIAEME Publication
This document summarizes a study on the impact of multi-vendor outsourcing in the automobile industry. The study found that:
1) Rejection levels increased at each stage of the supply chain, with the highest rejection rates found at tier 3 suppliers (those further down the chain). Statistical analysis confirmed rejection levels rose significantly with each additional outsourcing stage.
2) The proportion of certified suppliers decreased at lower tiers, from 100% certification at tier 1 to only 52% certification among tier 2 suppliers. More outsourcing equated to more non-certified suppliers in the supply chain.
3) Certification was found to impact quality, as non-certified suppliers had higher rejection rates
Economic analysis of lead time using value stream mapping (vsm) in company o...Jéssica M. Miloco
This document discusses using Value Stream Mapping (VSM) to analyze the economic impact of lead time in production processes for a capital goods company. VSM is a tool that maps the entire production process to identify waste and inefficiencies that increase lead time. The study uses VSM to examine a large Brazilian capital goods company with long lead times partly due to importing raw materials. It finds the company's cycle efficiency index is consistent with literature values, indicating potential for lead time and cost reductions through eliminating non-value-added activities.
Quality issues in outsourcing to China: Is it still a sustainable competitive...Ian McCarthy
Globalisation has made outsourcing to low-cost countries fashionable but firms face several challenges that fade outsourcing fashion.To survive in this outsourcing wave adopting proper sustainable strategy is needed.Using four case studies and four competitive strategies (‘‘Generic Strategies’’,‘‘Sandcone’’,‘‘Core Competences’’and ‘‘Value-Chain Analysis’’),this paper proposes sustainable
competitive advantage framework to over come quality issues in outsourcing to China.
Product costing in lean manufacturing organizationsAlexander Decker
This document discusses the drawbacks of traditional accounting methods when used in lean manufacturing organizations. It presents two alternative costing methods - Value Stream Costing and Features & Characteristics Costing - that are intended to better support lean manufacturing. Traditional methods can distort costs and fail to properly assess operational improvements in lean systems. Value Stream Costing aims to provide accurate cost information across the entire value stream to enhance decision making. Features & Characteristics Costing allows for more precise costing of individual products.
IRJET- Review Paper on Supply Chain Management of WindshieldIRJET Journal
This document discusses supply chain management of windshield production. It begins by defining supply chain management and its key components - planning, material requirements planning, production planning and control, and logistics. It then reviews several academic papers on supply chain management topics like frameworks, trends, challenges, and barriers in manufacturing organizations. Specifically, it examines how supply chain management can be applied to the construction industry. Finally, it discusses future opportunities to improve windshield production supply chain management through a customer focus, market analysis, and competition.
This document discusses how the implementation of advanced manufacturing technology (AMT) can impact organizational structure. It presents a framework showing that technology influences organizational structure at both operational and administrative levels, which then impacts employee jobs/tasks and firm performance. The framework suggests technology and structure should be aligned for superior performance. A study of 927 employees at 27 AMT firms in India revealed information on how existing structures need to change to be compatible with new technologies and improve productivity.
A systematic review of existing supply chain management definition, frameworkIAEME Publication
This document provides a review of existing supply chain management definitions, frameworks, and key factors. It begins with three definitions of supply chain management from various organizations. It then discusses the Supply Chain Operations Reference (SCOR) model framework in detail. Finally, it outlines several key factors in supply chain management, including logistics, planning, purchasing/sourcing, inventory management, and manufacturing techniques.
Companies’ perception toward manufacturing execution systems IJECEIAES
The use of information systems in manufacturing sector is very crucial to reach a high level of operational excellence and improve companies’ competitiveness. The use of such systems will definitely increase in the upcoming years, considering the digitalization strategies. Manufacturing execution systems gained a lot of attention in recent years due to showcased benefits in production management operations. Companies that adopted such systems witnessed an increase in process efficiency and enhancements with regards to cost savings and products quality. This paper seeks to analyze what makes the usage of manufacturing execution systems successful among manufacturing companies. We analyzed how the integration capabilities of such systems with other business applications and the company profile impact their usage and consequently the perceived benefits. A case study was conducted with 51 manufacturing companies and data were analyzed using partial least square structural equation modeling technique. The results confirmed the positive and significant impact of the company profile and solution integration capabilities on system usage. In addition, a ranking of solution modules importance for companies was also provided.
To study the impact of multi vendor outsourcing on the performancIAEME Publication
This document summarizes a study on the impact of multi-vendor outsourcing in the automobile industry. The study found that:
1) Rejection levels increased at each stage of the supply chain, with the highest rejection rates found at tier 3 suppliers (those further down the chain). Statistical analysis confirmed rejection levels rose significantly with each additional outsourcing stage.
2) The proportion of certified suppliers decreased at lower tiers, from 100% certification at tier 1 to only 52% certification among tier 2 suppliers. More outsourcing equated to more non-certified suppliers in the supply chain.
3) Certification was found to impact quality, as non-certified suppliers had higher rejection rates
Economic analysis of lead time using value stream mapping (vsm) in company o...Jéssica M. Miloco
This document discusses using Value Stream Mapping (VSM) to analyze the economic impact of lead time in production processes for a capital goods company. VSM is a tool that maps the entire production process to identify waste and inefficiencies that increase lead time. The study uses VSM to examine a large Brazilian capital goods company with long lead times partly due to importing raw materials. It finds the company's cycle efficiency index is consistent with literature values, indicating potential for lead time and cost reductions through eliminating non-value-added activities.
Quality issues in outsourcing to China: Is it still a sustainable competitive...Ian McCarthy
Globalisation has made outsourcing to low-cost countries fashionable but firms face several challenges that fade outsourcing fashion.To survive in this outsourcing wave adopting proper sustainable strategy is needed.Using four case studies and four competitive strategies (‘‘Generic Strategies’’,‘‘Sandcone’’,‘‘Core Competences’’and ‘‘Value-Chain Analysis’’),this paper proposes sustainable
competitive advantage framework to over come quality issues in outsourcing to China.
Product costing in lean manufacturing organizationsAlexander Decker
This document discusses the drawbacks of traditional accounting methods when used in lean manufacturing organizations. It presents two alternative costing methods - Value Stream Costing and Features & Characteristics Costing - that are intended to better support lean manufacturing. Traditional methods can distort costs and fail to properly assess operational improvements in lean systems. Value Stream Costing aims to provide accurate cost information across the entire value stream to enhance decision making. Features & Characteristics Costing allows for more precise costing of individual products.
IRJET- Review Paper on Supply Chain Management of WindshieldIRJET Journal
This document discusses supply chain management of windshield production. It begins by defining supply chain management and its key components - planning, material requirements planning, production planning and control, and logistics. It then reviews several academic papers on supply chain management topics like frameworks, trends, challenges, and barriers in manufacturing organizations. Specifically, it examines how supply chain management can be applied to the construction industry. Finally, it discusses future opportunities to improve windshield production supply chain management through a customer focus, market analysis, and competition.
This document discusses how the implementation of advanced manufacturing technology (AMT) can impact organizational structure. It presents a framework showing that technology influences organizational structure at both operational and administrative levels, which then impacts employee jobs/tasks and firm performance. The framework suggests technology and structure should be aligned for superior performance. A study of 927 employees at 27 AMT firms in India revealed information on how existing structures need to change to be compatible with new technologies and improve productivity.
A systematic review of existing supply chain management definition, frameworkIAEME Publication
This document provides a review of existing supply chain management definitions, frameworks, and key factors. It begins with three definitions of supply chain management from various organizations. It then discusses the Supply Chain Operations Reference (SCOR) model framework in detail. Finally, it outlines several key factors in supply chain management, including logistics, planning, purchasing/sourcing, inventory management, and manufacturing techniques.
Companies’ perception toward manufacturing execution systems IJECEIAES
The use of information systems in manufacturing sector is very crucial to reach a high level of operational excellence and improve companies’ competitiveness. The use of such systems will definitely increase in the upcoming years, considering the digitalization strategies. Manufacturing execution systems gained a lot of attention in recent years due to showcased benefits in production management operations. Companies that adopted such systems witnessed an increase in process efficiency and enhancements with regards to cost savings and products quality. This paper seeks to analyze what makes the usage of manufacturing execution systems successful among manufacturing companies. We analyzed how the integration capabilities of such systems with other business applications and the company profile impact their usage and consequently the perceived benefits. A case study was conducted with 51 manufacturing companies and data were analyzed using partial least square structural equation modeling technique. The results confirmed the positive and significant impact of the company profile and solution integration capabilities on system usage. In addition, a ranking of solution modules importance for companies was also provided.
The printing industry is the fourth largest manufacturing industry in Australia and third largest worldwide, employing over 104,000 people in Australia. The industry has undergone significant changes due to advancements in printing technology and integration with other technologies. This has virtually reinvented the industry and increased competition. Traditional printing has been impacted by substitute technologies like photocopying and the internet dampening demand. However, the industry is transitioning to provide holistic document lifecycle services. While offset printing remains important for large volumes, digital printing is growing and reducing the quality gap with offset. The future of printing relies on continued technology innovation and a shift to broader communication and data services.
This document summarizes a study on the internal lean manufacturing practices at apparel manufacturing companies in Jordan. The study aimed to identify the extent to which these companies practice five key internal lean manufacturing strategies: continuous flow production, short set-up time, statistical process control, employee involvement, and total production maintenance. A survey was distributed to managers at apparel companies in Jordan. The study found that the companies generally practice internal lean manufacturing strategies to a high extent, except for employee involvement which was rated average. Therefore, the researcher concluded that Jordanian apparel companies have strong potential to compete globally by further implementing lean practices.
A Broad Study on Lead Time Reduction using Value Stream Mapping Techniques in...IRJET Journal
This document summarizes a study on using value stream mapping techniques to reduce lead time in manufacturing industries. Value stream mapping is a lean tool that visually depicts the flow of materials and information currently and in the future state to identify and eliminate waste. The study reviews literature on applications of value stream mapping in various industries like electronics, automotive, and garment manufacturing. Implementing value stream mapping and other lean tools helped industries reduce lead time, work in process inventory, and improve productivity and throughput.
Multi agent systems in production planningJovenary Muta
This article provides an overview of multi-agent systems (MAS) in production planning and control. It defines key concepts of MAS including agents, control, organization, and communication. The article analyzes over 100 papers on MAS applications in supply chain and production systems. It finds that MAS show promise for improving flexibility and reactivity in manufacturing but that widespread adoption is inhibited by issues around coordination and integration.
This document discusses using simulation software to model and optimize a production line layout for a piston factory. It begins with background on simulation software and how it is used for facility layout planning. It then describes modeling the layout and production process of a piston factory in the Arena simulation software. The simulation is used to analyze material flow and optimize the layout to improve production rates by minimizing bottlenecks. The goals are to better understand how simulation can be applied to layout planning and prove its benefits for increasing efficiency in a factory setting.
This document discusses optimizing production time and productivity using lean manufacturing and overall equipment effectiveness (OEE). It analyzes OEE at a manufacturing company called ABM International. Calculations are shown to determine OEE based on experimental shift data and theoretical production data for ABM International over a year. The OEE was calculated to be 69.87% based on experimental data and 60.61% based on theoretical data, identifying opportunities to improve efficiency and reduce waste.
The document discusses facilitators for increasing after-sales service business, specifically focusing on marking hydraulic hose-assemblies in construction machines. After-sales business provides significant revenue potential, but most OEMs have not capitalized on this opportunity. The objective is to analyze the need for marking hose-assemblies and propose an efficient marking framework. Markings help customers order the right spare part and reduce downtime, but the permanence of the marking must be suitable for the machine's operating environment to avoid unnecessary costs.
7 qct optmisation in new product development detailed study on inter-links ...prjpublications
This document summarizes an article about optimizing quality, cost, and time (QCT) in new product development. It discusses how these three objectives are interrelated and often require trade-offs. It proposes using a systematic, analytical approach to quantify the interrelationships between objectives to help with trade-off decision making. This would assess how movement in one objective impacts others. For example, reducing development time could increase costs. The document also discusses using profitability metrics like profitability index, net present value, and payback period to evaluate trade-offs based on long-term profitability. Graphically representing cash flows can help assess trade-offs subject to the specific project's profitability targets.
Investigation for development of new tool in dfx shell through literature sur...iaemedu
This document discusses the need for a new tool called Design for TPM to help incorporate total productive maintenance considerations into equipment design. It notes that modifications are often made to equipment on the shop floor during TPM implementation, indicating that customer requirements for maintenance were not fully addressed at the design stage. The document reviews literature on TPM, design processes, reliability and maintainability considerations. It concludes that input from maintenance staff should be incorporated earlier in design to simplify maintenance tasks and reduce costs over the lifecycle of the equipment. A Design for TPM tool could help standardize how customer TPM needs are identified and addressed prior to equipment procurement.
(1) The document discusses critical success factors for implementing lean manufacturing in Vietnam manufacturing enterprises. It presents a lean manufacturing transformation model with six key dimensions: strategic initiatives, process management, change management, human resource management, situation management, and external management.
(2) The literature review examines definitions of lean manufacturing and discusses its goals of eliminating waste to reduce costs and improve quality, delivery, and flexibility. It also analyzes common indicators of successful lean implementation and discusses the concept of critical success factors.
(3) The article synthesizes critical success factors identified in previous research, finding the most common to be top management commitment, culture change, training, communication, teamwork ability, understanding lean tools, and continuous improvement
The study of scope and implementation of lean aspectsprjpublications
The document discusses the scope and implementation of lean aspects in the pharmaceutical industry. It begins with an introduction to lean strategies and their historical use in eliminating waste and improving efficiency. While lean has been successfully adopted in other industries, the pharmaceutical industry has been slow to implement it. The study aims to identify lean management principles that can be applied in the pharmaceutical manufacturing environment to improve quality and productivity while reducing costs. It also discusses conducting surveys of pharmaceutical companies to understand their current quality systems and openness to lean implementation. The goal is to determine how lean principles can enhance processes to achieve very high productivity, short lead times, and exceptional product quality.
PUBLIC DISTRIBUTION OF ESSENTIAL COMMODITIES IN PUNJABIAEME Publication
Public Distribution System (PDS) is poverty alleviation program and a direct state
intervention to ensure regular supply of essential consumer goods at cheap and
subsidized prices to deprived section so as to insulate them from impact of rising
prices of these goods and maintain the minimum nutritional status of population. PDS
is functioning quite efficiently under the joint coordination of both the Central and the
State Government from last five decades and Government of India is spending a huge
amount of money on this system to achieve food security. Punjab government started
its own Atta Dal Scheme under PDS program and NFSA (National Food Security) Act
covering more than half of its population to provide food supplies to the BPL
households at subsidized rates. However, very often PDS is being criticized for its
inefficiency to distributed the adequate and better quality goods to targeted strata of
society. The performance of Public Distribution System (PDS) depends on its reach
and potential to serve this deprived sections with entitled food commodities at
affordable prices on regular basis. Thus, the present study measured the public
distribution of essential commodities in Punjab by check out the different types of
ration cards and ration commodities and analyze the responses given by the
respondents of this study, about their satisfaction with quality, price and quantity of
these commodities distributed under the Public Distribution System.
Outsourcing: An air carrier's perspective on its' pros and consMersie Amha Melke
This document summarizes a research paper about the pros and cons of outsourcing from an air carrier's perspective. The paper analyzes reasons why airlines may outsource such as cost reduction. It also examines the transaction cost economics framework for evaluating outsourcing decisions. While outsourcing can reduce costs and allow airlines to focus on core functions, it may also reduce employee loyalty and oversight of critical maintenance activities. The paper concludes that outsourcing is useful for airlines but requires careful review to balance advantages and disadvantages.
Size and operational performance of manufacturing companies in pakistan using...Alexander Decker
This study uses data envelopment analysis to evaluate the efficiency of 49 manufacturing companies in Pakistan from 2008 to 2010. Three inputs (raw materials, staff expenses, and plant/machinery) and two outputs (net sales and earnings after tax) are used. Companies are categorized as large (assets over $100M), medium ($30-100M assets), or small (under $30M assets). The results show that small companies have the highest relative efficiency, and 2 large, 3 medium, and 5 small companies operate at the most productive scale size throughout the period.
Industrial Engineering Management E BookLuis Cabrera
The document discusses the history and evolution of industrial engineering management. It describes how operations research and management techniques developed in the 1960s and were applied to business problems using early computer technology. Through the 1970s-1980s, fields like distribution, logistics, supply chain management, and enterprise resource planning integrated operations research quantitative techniques. The development of computer languages, databases, internet technologies enabled enterprise resource planning software to automate business operations. Modern concepts now focus on cooperation between business partners using information sharing and technologies to reduce costs across the supply chain.
This document summarizes a study on the factors affecting productivity in terry towel manufacturing textile industries in Solapur, India. Through a survey of 164 textile SMEs, the study identified 8 key factors affecting productivity: 1) organizational structure and management commitment, 2) quality of inputs and processes, 3) employee training and motivation, 4) occupational health and safety, 5) manufacturing and dyeing processes, 6) use of renewable energy, 7) labor absenteeism and carelessness. The study used statistical analysis methods like factor analysis, reliability testing, and validity testing to identify these 8 factors from an initial list of 39 variables considered relevant based on literature review.
This document discusses using multiple criteria decision analysis methods like DEA and TOPSIS to evaluate the performance of steel companies. It outlines objectives to identify major steel industry players and attributes, employ DEA and TOPSIS for evaluation, collaborate the results using ERM-DT, and compare methodologies. Literature on steel industry performance evaluation and challenges are reviewed. The methodology section describes using DEA, a linear programming technique comparing each decision making unit to the best, and TOPSIS, which selects the alternative closest to the ideal solution.
11.econometric analysis of efficiency in indian cement industryAlexander Decker
This document summarizes a research article that analyzes total factor productivity performance and efficiency growth in India's cement industry from 1979-1980 to 2008-2009. It uses the Malmquist Data Envelopment Analysis approach to estimate productivity growth, technological change, and technical efficiency change over this period. Some key findings are:
1) Productivity in the cement industry accelerated during the post-reform period after 1991.
2) The industry experienced increases in technological progress but stagnation in technical efficiency.
3) Increasing technological change and non-responsive technical efficiency were mainly responsible for accelerating productivity growth.
4) Variables like gross mark-up, output growth, and foreign direct investment had a positive
This document summarizes a study on reducing breakdowns in a manufacturing industry through root cause analysis. The study analyzed breakdown data from the company over 8 months and identified the major breakdowns causing production losses as issues with the edge roller and vulcanization barrel. A cause-and-effect analysis identified specific root causes, such as belt deterioration and improper alignment checks for edge roller breakdowns. The analysis also identified improper pinion tightening as a root cause of chain slipping. Recommendations included using a higher grade belt for the edge roller and implementing proper alignment checking and a torque wrench for tightening to address the root causes and reduce breakdowns. Parallel improvements, such as replacing the edge roller's belt and pulley system with
The document proposes a modified version of the Manufacturing Cost Deployment (MCD) method called Project Cost Deployment (PCD) for analyzing engineer-to-order (ETO) production systems. The PCD introduces two key modifications: 1) replacing the concept of production stations with manual assembly macro-activities, and 2) introducing a new structure for classifying and analyzing losses specific to manual assembly tasks. The validity of the PCD approach is demonstrated through a real-world industrial application to a train wagon manufacturer. The results show that PCD can identify hidden losses, quantify wastes economically, and estimate the impacts of potential lean improvements in terms of efficiency and effectiveness.
This document discusses implementing lean philosophy in aircraft maintenance to eliminate waste. It first reviews literature on lean implementation in various industries. It then describes the problem environment of aircraft maintenance processes and provides an overview of lean philosophies, including defining value-adding, non-value-adding and necessary but non-value adding activities. It presents a case study of an aircraft industry in India and discusses observed non-value adding activities like frequent inspections increasing service time and long set-up times of components. Finally, it proposes using value stream mapping to visualize the current process and identify sources of waste to guide improving the future state.
This document discusses implementing lean philosophy in aircraft maintenance to eliminate waste. It reviews literature on applying lean principles in manufacturing. The author proposes using value stream mapping to visualize non-value added activities in a maintenance organization's processes. A case study of an aircraft industry applying lean is described. The paper concludes lean implementation can optimize maintenance operations with minimal investment.
The printing industry is the fourth largest manufacturing industry in Australia and third largest worldwide, employing over 104,000 people in Australia. The industry has undergone significant changes due to advancements in printing technology and integration with other technologies. This has virtually reinvented the industry and increased competition. Traditional printing has been impacted by substitute technologies like photocopying and the internet dampening demand. However, the industry is transitioning to provide holistic document lifecycle services. While offset printing remains important for large volumes, digital printing is growing and reducing the quality gap with offset. The future of printing relies on continued technology innovation and a shift to broader communication and data services.
This document summarizes a study on the internal lean manufacturing practices at apparel manufacturing companies in Jordan. The study aimed to identify the extent to which these companies practice five key internal lean manufacturing strategies: continuous flow production, short set-up time, statistical process control, employee involvement, and total production maintenance. A survey was distributed to managers at apparel companies in Jordan. The study found that the companies generally practice internal lean manufacturing strategies to a high extent, except for employee involvement which was rated average. Therefore, the researcher concluded that Jordanian apparel companies have strong potential to compete globally by further implementing lean practices.
A Broad Study on Lead Time Reduction using Value Stream Mapping Techniques in...IRJET Journal
This document summarizes a study on using value stream mapping techniques to reduce lead time in manufacturing industries. Value stream mapping is a lean tool that visually depicts the flow of materials and information currently and in the future state to identify and eliminate waste. The study reviews literature on applications of value stream mapping in various industries like electronics, automotive, and garment manufacturing. Implementing value stream mapping and other lean tools helped industries reduce lead time, work in process inventory, and improve productivity and throughput.
Multi agent systems in production planningJovenary Muta
This article provides an overview of multi-agent systems (MAS) in production planning and control. It defines key concepts of MAS including agents, control, organization, and communication. The article analyzes over 100 papers on MAS applications in supply chain and production systems. It finds that MAS show promise for improving flexibility and reactivity in manufacturing but that widespread adoption is inhibited by issues around coordination and integration.
This document discusses using simulation software to model and optimize a production line layout for a piston factory. It begins with background on simulation software and how it is used for facility layout planning. It then describes modeling the layout and production process of a piston factory in the Arena simulation software. The simulation is used to analyze material flow and optimize the layout to improve production rates by minimizing bottlenecks. The goals are to better understand how simulation can be applied to layout planning and prove its benefits for increasing efficiency in a factory setting.
This document discusses optimizing production time and productivity using lean manufacturing and overall equipment effectiveness (OEE). It analyzes OEE at a manufacturing company called ABM International. Calculations are shown to determine OEE based on experimental shift data and theoretical production data for ABM International over a year. The OEE was calculated to be 69.87% based on experimental data and 60.61% based on theoretical data, identifying opportunities to improve efficiency and reduce waste.
The document discusses facilitators for increasing after-sales service business, specifically focusing on marking hydraulic hose-assemblies in construction machines. After-sales business provides significant revenue potential, but most OEMs have not capitalized on this opportunity. The objective is to analyze the need for marking hose-assemblies and propose an efficient marking framework. Markings help customers order the right spare part and reduce downtime, but the permanence of the marking must be suitable for the machine's operating environment to avoid unnecessary costs.
7 qct optmisation in new product development detailed study on inter-links ...prjpublications
This document summarizes an article about optimizing quality, cost, and time (QCT) in new product development. It discusses how these three objectives are interrelated and often require trade-offs. It proposes using a systematic, analytical approach to quantify the interrelationships between objectives to help with trade-off decision making. This would assess how movement in one objective impacts others. For example, reducing development time could increase costs. The document also discusses using profitability metrics like profitability index, net present value, and payback period to evaluate trade-offs based on long-term profitability. Graphically representing cash flows can help assess trade-offs subject to the specific project's profitability targets.
Investigation for development of new tool in dfx shell through literature sur...iaemedu
This document discusses the need for a new tool called Design for TPM to help incorporate total productive maintenance considerations into equipment design. It notes that modifications are often made to equipment on the shop floor during TPM implementation, indicating that customer requirements for maintenance were not fully addressed at the design stage. The document reviews literature on TPM, design processes, reliability and maintainability considerations. It concludes that input from maintenance staff should be incorporated earlier in design to simplify maintenance tasks and reduce costs over the lifecycle of the equipment. A Design for TPM tool could help standardize how customer TPM needs are identified and addressed prior to equipment procurement.
(1) The document discusses critical success factors for implementing lean manufacturing in Vietnam manufacturing enterprises. It presents a lean manufacturing transformation model with six key dimensions: strategic initiatives, process management, change management, human resource management, situation management, and external management.
(2) The literature review examines definitions of lean manufacturing and discusses its goals of eliminating waste to reduce costs and improve quality, delivery, and flexibility. It also analyzes common indicators of successful lean implementation and discusses the concept of critical success factors.
(3) The article synthesizes critical success factors identified in previous research, finding the most common to be top management commitment, culture change, training, communication, teamwork ability, understanding lean tools, and continuous improvement
The study of scope and implementation of lean aspectsprjpublications
The document discusses the scope and implementation of lean aspects in the pharmaceutical industry. It begins with an introduction to lean strategies and their historical use in eliminating waste and improving efficiency. While lean has been successfully adopted in other industries, the pharmaceutical industry has been slow to implement it. The study aims to identify lean management principles that can be applied in the pharmaceutical manufacturing environment to improve quality and productivity while reducing costs. It also discusses conducting surveys of pharmaceutical companies to understand their current quality systems and openness to lean implementation. The goal is to determine how lean principles can enhance processes to achieve very high productivity, short lead times, and exceptional product quality.
PUBLIC DISTRIBUTION OF ESSENTIAL COMMODITIES IN PUNJABIAEME Publication
Public Distribution System (PDS) is poverty alleviation program and a direct state
intervention to ensure regular supply of essential consumer goods at cheap and
subsidized prices to deprived section so as to insulate them from impact of rising
prices of these goods and maintain the minimum nutritional status of population. PDS
is functioning quite efficiently under the joint coordination of both the Central and the
State Government from last five decades and Government of India is spending a huge
amount of money on this system to achieve food security. Punjab government started
its own Atta Dal Scheme under PDS program and NFSA (National Food Security) Act
covering more than half of its population to provide food supplies to the BPL
households at subsidized rates. However, very often PDS is being criticized for its
inefficiency to distributed the adequate and better quality goods to targeted strata of
society. The performance of Public Distribution System (PDS) depends on its reach
and potential to serve this deprived sections with entitled food commodities at
affordable prices on regular basis. Thus, the present study measured the public
distribution of essential commodities in Punjab by check out the different types of
ration cards and ration commodities and analyze the responses given by the
respondents of this study, about their satisfaction with quality, price and quantity of
these commodities distributed under the Public Distribution System.
Outsourcing: An air carrier's perspective on its' pros and consMersie Amha Melke
This document summarizes a research paper about the pros and cons of outsourcing from an air carrier's perspective. The paper analyzes reasons why airlines may outsource such as cost reduction. It also examines the transaction cost economics framework for evaluating outsourcing decisions. While outsourcing can reduce costs and allow airlines to focus on core functions, it may also reduce employee loyalty and oversight of critical maintenance activities. The paper concludes that outsourcing is useful for airlines but requires careful review to balance advantages and disadvantages.
Size and operational performance of manufacturing companies in pakistan using...Alexander Decker
This study uses data envelopment analysis to evaluate the efficiency of 49 manufacturing companies in Pakistan from 2008 to 2010. Three inputs (raw materials, staff expenses, and plant/machinery) and two outputs (net sales and earnings after tax) are used. Companies are categorized as large (assets over $100M), medium ($30-100M assets), or small (under $30M assets). The results show that small companies have the highest relative efficiency, and 2 large, 3 medium, and 5 small companies operate at the most productive scale size throughout the period.
Industrial Engineering Management E BookLuis Cabrera
The document discusses the history and evolution of industrial engineering management. It describes how operations research and management techniques developed in the 1960s and were applied to business problems using early computer technology. Through the 1970s-1980s, fields like distribution, logistics, supply chain management, and enterprise resource planning integrated operations research quantitative techniques. The development of computer languages, databases, internet technologies enabled enterprise resource planning software to automate business operations. Modern concepts now focus on cooperation between business partners using information sharing and technologies to reduce costs across the supply chain.
This document summarizes a study on the factors affecting productivity in terry towel manufacturing textile industries in Solapur, India. Through a survey of 164 textile SMEs, the study identified 8 key factors affecting productivity: 1) organizational structure and management commitment, 2) quality of inputs and processes, 3) employee training and motivation, 4) occupational health and safety, 5) manufacturing and dyeing processes, 6) use of renewable energy, 7) labor absenteeism and carelessness. The study used statistical analysis methods like factor analysis, reliability testing, and validity testing to identify these 8 factors from an initial list of 39 variables considered relevant based on literature review.
This document discusses using multiple criteria decision analysis methods like DEA and TOPSIS to evaluate the performance of steel companies. It outlines objectives to identify major steel industry players and attributes, employ DEA and TOPSIS for evaluation, collaborate the results using ERM-DT, and compare methodologies. Literature on steel industry performance evaluation and challenges are reviewed. The methodology section describes using DEA, a linear programming technique comparing each decision making unit to the best, and TOPSIS, which selects the alternative closest to the ideal solution.
11.econometric analysis of efficiency in indian cement industryAlexander Decker
This document summarizes a research article that analyzes total factor productivity performance and efficiency growth in India's cement industry from 1979-1980 to 2008-2009. It uses the Malmquist Data Envelopment Analysis approach to estimate productivity growth, technological change, and technical efficiency change over this period. Some key findings are:
1) Productivity in the cement industry accelerated during the post-reform period after 1991.
2) The industry experienced increases in technological progress but stagnation in technical efficiency.
3) Increasing technological change and non-responsive technical efficiency were mainly responsible for accelerating productivity growth.
4) Variables like gross mark-up, output growth, and foreign direct investment had a positive
This document summarizes a study on reducing breakdowns in a manufacturing industry through root cause analysis. The study analyzed breakdown data from the company over 8 months and identified the major breakdowns causing production losses as issues with the edge roller and vulcanization barrel. A cause-and-effect analysis identified specific root causes, such as belt deterioration and improper alignment checks for edge roller breakdowns. The analysis also identified improper pinion tightening as a root cause of chain slipping. Recommendations included using a higher grade belt for the edge roller and implementing proper alignment checking and a torque wrench for tightening to address the root causes and reduce breakdowns. Parallel improvements, such as replacing the edge roller's belt and pulley system with
The document proposes a modified version of the Manufacturing Cost Deployment (MCD) method called Project Cost Deployment (PCD) for analyzing engineer-to-order (ETO) production systems. The PCD introduces two key modifications: 1) replacing the concept of production stations with manual assembly macro-activities, and 2) introducing a new structure for classifying and analyzing losses specific to manual assembly tasks. The validity of the PCD approach is demonstrated through a real-world industrial application to a train wagon manufacturer. The results show that PCD can identify hidden losses, quantify wastes economically, and estimate the impacts of potential lean improvements in terms of efficiency and effectiveness.
This document discusses implementing lean philosophy in aircraft maintenance to eliminate waste. It first reviews literature on lean implementation in various industries. It then describes the problem environment of aircraft maintenance processes and provides an overview of lean philosophies, including defining value-adding, non-value-adding and necessary but non-value adding activities. It presents a case study of an aircraft industry in India and discusses observed non-value adding activities like frequent inspections increasing service time and long set-up times of components. Finally, it proposes using value stream mapping to visualize the current process and identify sources of waste to guide improving the future state.
This document discusses implementing lean philosophy in aircraft maintenance to eliminate waste. It reviews literature on applying lean principles in manufacturing. The author proposes using value stream mapping to visualize non-value added activities in a maintenance organization's processes. A case study of an aircraft industry applying lean is described. The paper concludes lean implementation can optimize maintenance operations with minimal investment.
This document describes a simulation program developed to monitor and improve the performance of a production system. The program calculates Overall Line Effectiveness (OLE) metrics to identify weaknesses in a line with multiple interconnected machines. It was applied to a case study of a bathtub manufacturing company with 6 departments. Data showed significant time losses from issues like breakdowns, setups, idle time, and rejects. The simulation software helped analyze this data and identify areas for improvement, increasing the OLE value from 46.84% to 68.94% after implementing recommended changes.
This document discusses enhancing productivity in manufacturing industries by using an adjustable multi-spindle attachment to machine multiple T-slots simultaneously. It begins by providing background on productivity improvement techniques and how manufacturers are seeking to get closer to customers and operate more responsively. The attachment was designed to machine three T-slots at once on milling machine tables or press machine bolster plates, reducing the machining time to 1/3 of the original time and increasing output. Diagrams of the adjustable multi-spindle attachment and how it mounts on machines are included, along with discussions of traditional single-spindle machining techniques and how this attachment improves upon them by completing multiple cuts at once.
This document provides an overview of World Class Manufacturing (WCM) techniques and their implementation at an automotive company in Italy. It discusses that WCM aims to continuously improve production performance through eliminating waste. The key aspects of WCM discussed are its 10 technical and 10 managerial pillars implemented through a 7 step process. The document also reviews the literature on WCM and discusses its goals of increased productivity, quality, flexibility and communication between management and employees.
This document summarizes a case study on how two engineering industries improved business processes by applying Product Lifecycle Management (PLM) systems. The case studies found that PLM systems helped with data capture and reuse, improved communication and teamwork, and enhanced product and process management and visibility. Benefits included reduced disruption, faster response to changes, improved knowledge sharing, streamlined processes, and better project status monitoring. The studies indicate a strong relationship between PLM application and positive business process development.
Decision support systems and their role in rationalizing the production plansAlexander Decker
This document discusses using decision support systems and linear programming models to optimize production planning at a tire factory in Najaf, Iraq. It presents the research problem, objectives, and data collected from the factory. A mathematical model is applied using linear programming to maximize profits based on constraints of available resources. The model results show the most profitable tire sizes to produce and determines shadow prices and surplus raw materials. Overall, the document examines how quantitative decision support tools can help managers optimize production plans.
Evaluation of Total Productive Maintenance Implementation in a Selected Semi-...IJMER
Manufacturing industries around the world spend a lot of money on buying new equipment
to increase production but a little is done to get hundred percent output from the machine. However,
because of increased competency levels and demand of quality products at lower costs, buying latest
equipment is not a solution unless it is fully utilized. Therefore machine maintenance and in general,
implementing an appropriate maintenance strategy has become increasingly important for manufacturing
companies to accomplish these requirements. Total productive maintenance (TPM) has become one of the
most popular maintenance strategies to ensure high machine reliability since it is regarded as an integral
part of Lean Manufacturing. Performance evaluation is the most important aspects in the field of
continuous improving of the production process and overall equipment effectiveness (OEE) is one of the
justified performance evaluation methods that is popular in the manufacturing industries to assess the
machine’s effectiveness and performance. In this concern, this research work has been conducted in a
selected semi-automated manufacturing industry to study and evaluate the implementation of autonomous
maintenance and planned maintenance pillars of TPM. After the OEE measurement, it has been
benchmarked with the world class OEE. Pareto and statistical analysis of downtimes were performed to
show the most affecting downtime factors hierarchically. Based on the obtained results, maintenance
management and production planning have been suggested to improve their maintenance procedures and
the productivity as well.
This document describes a simulation model developed to calculate Overall Equipment Effectiveness (OEE) for a generic production line. The model takes input data from XML files generated by an optimization model that minimizes costs based on factors like work in progress inventory and machine idle time. Both crisp and fuzzy models are implemented to calculate availability, performance, quality, and overall OEE. The fuzzy model uses Mamdani inference with triangular membership functions. Simulation results in VB and Excel are presented and compared to world class standards. Goal seek and scenario manager tools are used to determine input parameter changes needed to meet standards. The model provides a way to evaluate a production line's efficiency and identify areas for improvement.
Finding the relation between make or buy decisions and profitabilityIAEME Publication
This document summarizes a research paper that examines the relationship between make-or-buy decisions and profitability for batch manufacturing industries. The paper reviews literature showing mixed results on the impact of outsourcing on firm performance and profitability. It then describes a survey conducted of batch manufacturing industries to understand their make-buy trends, factors considered in make-buy decisions, and the impact on firm profitability. The goal is to provide guidance to manufacturing industries on make-buy decision-making and how it can impact profitability.
International Journal of Computational Engineering Research (IJCER) is dedicated to protecting personal information and will make every reasonable effort to handle collected information appropriately. All information collected, as well as related requests, will be handled as carefully and efficiently as possible in accordance with IJCER standards for integrity and objectivity
Checking the activities and Performance Management in the Automotive IndustryIRJET Journal
1. The document discusses production planning and control in the automotive industry. It analyzes problems with executing the planned production sequence and maintaining the planned sequence through the different production stages.
2. It suggests that uncertainties between planning the master production schedule and implementing it can cause deviations from the planned production sequence. This makes it difficult to predict component needs and deliver finished goods to customers on time.
3. The document proposes monitoring production at key points to track adherence to the planned sequence. It also recommends improving coordination with suppliers to better support the planned sequence and meet customer delivery times.
Servitization: service is the future of manufacturingABN AMRO
Servitization refers to the process of manufacturing companies increasingly offering services in addition to or instead of traditional product sales. This transition allows companies to generate additional revenue from services and provide better value to customers. While challenging, servitization offers significant potential for increased revenue and higher profit margins compared to traditional product sales alone. Fully realizing this potential requires overcoming growing pains as investments in new services are made and a culture shift occurs throughout the entire organization to focus on customer service.
QEAD Rev:03 ver 01 9th July 2017 Template A 1
F/QAP/021/001
College of Engineering
Course Work
Name of the programme B.Eng (CAME/POM/COE/EIE/EPE/TE)
Name of Module with Code Industrial Studies (MHH624713)
Level/Semester & AY 4/Semester B & 2018-2019
Name of the Module
Leader/Tutor
Mr Motilal Lakavat, Dr Haris Kadir Mohammed,
Dr.M Mutaz Mirza, Ms.Shetha Daniel, Dr.Priay Brat
Dwivedi, Dr.Syed Murtuza
Coursework Type Assignment
Assessment weightage 30%
Type and date of submission Online submission 16-05-2019
Ref# 71
Student Name 140150 Amani Mohammed Ali Al Ajmi
Aim To develop an understanding of overall concepts of various
Industrial management functions.
Learning Outcomes On completion of this module, the student should be able to:
1. Describe the main decision areas of marketing,
marketing policy as applied to goods/products.
2. Analyze management accounts and appraise capital
investments.
3. Demonstrate the concept of the manufacturing system
and apply group technology philosophy in industry.
4. Describe the underlying principles of production planning
and control, and evaluate inventory costs.
5. Demonstrate the principles of forecasting and predict
customer demand.
6. Describe the principles of management and explain the
effective utilization of human resources.
7. Demonstrate the principles of industrial maintenance and
product reliability and apply Monte Carlo simulation
technique to evaluate the performance of systems.
QEAD Rev:03 ver 01 9th July 2017 Template A 2
F/QAP/021/001
Tasks
Section A (Theory – 45 Marks)
Q1. Present scenario of Oman market in the automobile industry, each student has to select
one product with a complete analysis of the local market and analyze the brands available
in the Oman market. Study any one product in detail and carry out the survey and provide
the answers for the following task;
(a) Critically evaluate the product mentioning all the details of it. (Name of the product,
specifications of the product, and manufacturers details etc.,) 7Marks
(Using your own sentences with 300 words approx.)
(b) Identify which brand of the product is the market leader in the Oman market and
discuss what market strategies made the brand as the market leader 8Marks
(Using your own sentences with 400 words approx.)
Q2. Discuss the Marketing Mix (4 Ps) being followed by the company in question 1 and how
it is effective in increasing sales. Identify the present stage of the product and discuss the
strategies for the company to implement in order to maintain the strength of the sales.
(Using your own senten.
The document discusses a survey of experts on composite simulation. It finds that automotive and aerospace are dominant industries for application, with component failure/crash and material description as top areas. Material models are seen as the most significant technology. High R&D demands exist for material models, failure prediction, service life, and manufacturing processes. Researchers see above average needs for research in these areas.
DEMATEL (siglas en inglés de Decision Making Trial and Evaluation Laboratory) es una técnica desarrollada en 1972 por Fontela y Gabus en el Centro de Investigación de Ginebra del Battelle Memorial Institute. Se utiliza para analizar la interdependencia (relación o influencia) entre componentes, variables o atributos de un sistema complejo, identificar aquellos que son críticos y estudiar sus relaciones causa-efecto, utilizando un diagrama de relaciones de
DEMATEL (siglas en inglés de Decision Making Trial and Evaluation Laboratory) es una técnica desarrollada en 1972 por Fontela y Gabus en el Centro de Investigación de Ginebra del Battelle Memorial Institute. Se utiliza para analizar la interdependencia (relación o influencia) entre componentes, variables o atributos de un sistema complejo, identificar aquellos que son críticos y estudiar sus relaciones causa-efecto, utilizando un diagrama de relaciones de DEMATEL (siglas en inglés de Decision Making Trial and Evaluation Laboratory) es una técnica desarrollada en 1972 por Fontela y Gabus en el Centro de Investigación de Ginebra del Battelle Memorial Institute. Se utiliza para analizar la interdependencia (relación o influencia) entre componentes, variables o atributos de un sistema complejo, identificar aquellos que son críticos y estudiar sus relaciones causa-efecto, utilizando un diagrama de relaciones de DEMATEL (siglas en inglés de Decision Making Trial and Evaluation Laboratory) es una técnica desarrollada en 1972 por Fontela y Gabus en el Centro de Investigación de Ginebra del Battelle Memorial Institute. Se utiliza para analizar la interdependencia (relación o influencia) entre componentes, variables o atributos de un sistema complejo, identificar aquellos que son críticos y estudiar sus relaciones causa-efecto, utilizando un diagrama de relaciones de
EMATEL (siglas en inglés de Decision Making Trial and Evaluation Laboratory) es una técnica desarrollada en 1972 por Fontela y Gabus en el Centro de Investigación de Ginebra del Battelle Memorial Institute. Se utiliza para analizar la interdependencia (relación o influencia) entre componentes, variables o atributos de un sistema complejo, identificar aquellos que son críticos y estudiar sus relaciones causa-efecto, utilizando un diagrama de relaciones de
DEMATEL (siglas en inglés de Decision Making Trial and Evaluation Laboratory) es una técnica desarrollada en 1972 por Fontela y Gabus en el Centro de Investigación de Ginebra del Battelle Memorial Institute. Se utiliza para analizar la interdependencia (relación o influenci
Implementation of Lean Manufacturing Tools in Garment IndustryIJLT EMAS
For any Company’s economy, the industry cost,
production time, total quality management and waste reduction
have great impact. The investments consumed by the company
by eradicating non value added production work and time are
very important. Focusing on these points Lean Manufacturing
tools, a Japanese strategy, is implemented in this work. An
apparel industry was studied and the bottleneck areas were
identified through Value Stream Mapping (VSM). The
bottleneck areas were identified and eliminated by implementing
line balancing and parallel working section. The implementation
of kaizen resulted in reduction of cycle time by 48.7%.
Drying of agricultural products using forced convection indirect solar dryerIRJESJOURNAL
Abstract:- Drying of three agricultural products namely potato slices, onion slices and whole grapes was done using an indigenously designed and fabricated forced convection indirect solar dryer and under open sunlight. The diurnal variation of temperature, relative humidity in the solar dryer was also compared with the ambient temperature and relative humidity during March and April 2017 for all the three products. The study showed increase of temperature and lower humidity inside the drying chamber at different time interval. Hourly moisture loss for all the three agricultural products in the drying chamber and open sun drying was also compared and the percentage of moisture loss in the drying chamber was found to be higher compared to open sun drying for all the products. The mass of water removed for all the three products in the drying chamber was also found to be higher than the open sun drying. Results of the study showed that forced convection indirect solar dryer is better than the open sun drying method for drying the agricultural products more efficiently.
The Problems of Constructing Optimal Onboard Colored RGB Depicting UAV SystemsIRJESJOURNAL
Abstract:-The problems of constructing optimal adaptive onboard color RGB depictingUAV systems have been analyzed. The problem of optimal formation of color signals of RGB color system has been formulated and solved by implementing the adaptive flight mode of UAVs containing an onboard imaging system. An adaptive UAV mode with an imaging system on board is proposed, which consists of adaptive changes in flight altitude depending on the wavelength of the received color signal. As a result of the optimization of the proposed operating mode of the UAV imaging system, an analytic formula for adaptive device control has been obtained. Recommendations have been given on the practical implementation of the proposed method.
Flexible Design Processes to Reduce the Early Obsolescence of BuildingsIRJESJOURNAL
Abstract:- This work intends to analyze the processes of flexibility to improve the adaptability to the users and to define some strategies to delay building obsolescence. Some approaches that address the architectural flexibility processes are studied to understand the rapid transformation of user lifestyles and changes in needs and performance building requirements. Obsolescence is often characterized by the lack of flexibility in the structure and walls, as well as services that change rapidly according to the different uses of buildings. This poses a threat to the built environment, since a large number of buildings are demolished having still years of useful life. In this way, different types of obsolescence are analyzed, focusing on some structural, economic, functional and social aspects of the construction and the use of buildings, seeking the capacity to design and produce adaptive buildings that are more resilient to obsolescence. Thus, some concepts of flexibility and flexible process are presented to promote adaptability in buildings. However, flexibility is a complex process, a long way to achieve adaptability to the built environment and the changing needs of users. The method used in this analysis takes into account the diversity of the design process, making some considerations about the interrelation of the social, functional and technical aspects. Finally, some conclusions about the design methods faced by a flexible approach process can lead to more useful and adaptable spaces for future transformations in order to extend the life cycle and prevent early obsolescence of buildings.
Study on Performance Enhancement of Solar Ejector Cooling SystemIRJESJOURNAL
Abstract: Cooling sector is dominating by vapor compression cooling sector which uses refrigerant which are harmful to environment. The solar ejector cooling system is alternative for vapor compression cycle which uses solar energy to give heat to the generator, which is a viable method for heat generation. The solar ejector cooling system not only fulfills cooling requirement but also helps in energy conservation and protection of environment. It reduces the generator work and decrease the throttling losses. Maintenance requirement and cost is low for ejector cooling system .In this paper, theoretically study is done on enhancement of the performance of solar ejector cooling system. Various system configuration are presented with detailed design. This system still needed a lot of research work to make it alternative for vapor compression cycle based cooling system completely.
Flight Safety Case Study: Adi Sucipto Airport Jogjakarta - IndonesiaIRJESJOURNAL
Abstract: Adi Sucipto Airport-Jogyakarta is an airport with enclave civil status or as TNI-AU airbase (civilian airport within the military area) has limited infrastructure with Azimuth Runway 09-27, has no RESA (Runway End Safety Area). The calculation results using Acceptable Safety Level (ASL) standard 1 x 10-7 shows that the probability of accident risk at wet runway condition is greater than in dry condition. Runway Excursion occurs at the airport, especially when the runway is wet and overrun due to hydroplaning and the plane deviates from the center of runway as well as the aircraft wheels are in contact with ground or obstacle surface outside the runway. It means the thicker layer of water above the runway will cause increased risk of accidents on the runway. This is why standing water should be immediately removed from the runway as quickly as possible. Mitigation efforts need to be done simultaneously with recovery by adding RESA and other preventive efforts in order to water patch and standing water does not exceed 2 mm and apply the mandatory of SOP consistently at the airport.
A Review of Severe Plastic DeformationIRJESJOURNAL
ABSTRACT: This article reviews about Ultrafine grained (UFG) materials processed by Severe Plastic
Deformation. From the period of 1950’s, the researchers made a fountain stone for this technique. Over the last
decades, this SPD technique experienced an enormous growth among the research field. There was a
development of different methods of SPD, production of various materials by SPD with improved and
interesting results based on our requirement. Moreover, different post processing techniques will also help to
enhance the property of the SPD processed material. This paper reviews the overall development of this
technique, various methods of SPD, discussed about the enhancement of the properties and finally concluded
with some specific challenges and issues faced by the modern researchers. It may be helpful to those who wants
specialise in bulk nanomaterials produced by SPD.
Annealing Response of Aluminum Alloy AA6014 Processed By Severe Plastic Defor...IRJESJOURNAL
Abstract: In this paper the study of micro structural stability during annealing with respect to time of conventionally grains (CG) and ultrafine-grained (UFG) of Aluminum AA6014 i s carried out. It has been observed that, the effect of the second phase magnesium-silicon particles in the CG and UFG AA6014 samples leads to a rapid hardness which increases from 40HV10 to 70HV10 within 7 days. Artificial aging shows that the material hardness even increased after 20 hours of annealing at 180°C. In total 30 hours of annealing, the hardness arrives at its maximum and then reduces due to the formation of Mg2Si precipitates, which rise in size and change their coherency. The precipitates cannot efficiently pin the dislocations and act as barriers to the dislocation motion which indicate an overall decrease in the hardness. It also has been found that the ultrafinegrained AA6014 alloy loses its thermal stability at approximately 200°C and recrystallized at 300°C. Thermal stability is strongly dependent on the material purity, second phase particles and/or oxide particles which may break up during rolling and lead to some dispersion strengthening.
Evaluation of Thresholding Based Noncontact Respiration Rate Monitoring using...IRJESJOURNAL
Abstract: - A noncontact method for respiration rate monitoring using thermal imaging was developed and evaluated. Algorithms to capture images, detect the location of the face, locate the corners of the eyes from the detected face and thereafter locate the tip of the nose in each image were developed. The amount of emitted infrared radiation was then determined from the detected tip of the nose. Signal processing techniques were then utilised to obtain the respiration rate in real-time. The method was evaluated on 6 enrolled subjects after obtaining all ethical approvals. The evaluations were conducted against two existing contact based methods; thoracic and abdominal bands. Results showed a correlation coefficient of 0.9974 to 0.9999 depending on the location of the ROI relative to the detected tip of the nose. The main contributions of the work was the successful development and evaluation of the facial features tracking algorithms in thermal imagining, the evaluation of thermal imaging as a technology for respiration monitoring in a hospital environment against existing respiration monitoring systems as well as the real time nature of the method where the frame processing time was 40 ms from capture to respiration feature plotting.
Correlation of True Boiling Point of Crude OilIRJESJOURNAL
Abstract :- The knowledge of the crude boiling point is very important for the refining process design and optimization. In this project the aim is to find the correlation of true boiling points. The study will be very useful in crude transportation and downstream operations. Correlation is tried to obtain by testing a number of crude oil samples from heavy to light. The comparisons of boiling point of different crude samples obtained is tried to compare with already existing correlations. Framol, Destmol and Riazi’s, these three correlation models have taken. The result showed that comparison of three correlation models and which is more accurate.
Combined Geophysical And Geotechnical Techniques For Assessment Of Foundation...IRJESJOURNAL
Abstract: This study was carried out to assess the subsurface conditions around the school of technology complex in Lagos State Polytechnic, Ikorodu, using integrated geophysical and geotechnical techniques. The site lies within the Sedimentary terrain of southwestern Nigeria. Allied Ohmega Resistivity meter was used for data collection of 1-D and 2-D resistivitymeasurement while WinResist software and Dipro software were used for the processing respectively.The results of the vertical electrical sounding indicate that the depth to basement values ranges between 27.6 and 39.5m. The 2D resistivitysurvey has provided valuable information on the lateral and vertical variation of the layer competent for erecting foundation of engineering structures. The CPT probed an average depth of 4.8m and has identified material of very high shear strength associated with dense sand materials. The correlation of the three techniques used revealed similar soil layering consisting of topsoilsandy clay, coarse sand and sand.A mechanically stable coarse sand material was discovered as weathered layer which indicates high load bearing capacity suitable for foundation in the area and can support massive structures.
Abstract:- research stands out because it is provided by the model of Al-Mobaideen (2009) critics to analyze for the governance of information and communications technology (ICT) at the National University of Chimborazo factors which raises the factors such as: strategies and policies, infrastructure and networks, financing and sustainability, and institutional culture that should be taken into account if desired govern the successful integration of ICT in the school. The study is exploratory, the almost total lack of previous studies on Governance of ICT integration at the University. It is concluded that there is a set of organizations with addresses IT markedly different roles in their duties with regard to its orientation to administrative, academic and research. The University has failed to define the strategic role of ICT in their academic, because there is no objective referred to IT academia in 2013-2016 pedi, but also because there is not a pedi-oriented IT the formation. The limited effectiveness of IT organizations in academic activities is provided by the low rate of use of educationalplatformsb_learning.
Gobernanzade las TIC en la Educacion SuperiorIRJESJOURNAL
Abstract:-Se destaca la investigación debido a que se da a conocer mediante el modelo de Al-Mobaideen (2009) los factores críticos a analizar para la gobernanza de las Tecnologías de la información y la Comunicación (TIC) en la Universidad Nacional de Chimborazo donde plantea los factores como:estrategias y políticas, infraestructura y redes, financiación y sostenibilidad, y cultura institucional, que se debe tomar en cuenta si se desea gobernar la integración exitosa de las TIC en la institución educativa. El estudio es exploratoria, por la poca presencia de estudios previos sobre Gobernanza de la integración de las TIC en la Universidad. Se concluye que existe un conjunto de organismos con direcciones de TI con roles notoriamente diferenciados en sus funciones con respecto a su orientación a procesos administrativos, académicos y de investigación. La Universidad no ha logrado definir el rol estratégico de las TIC en su desarrollo académico, porque no existe ningún objetivo referido a TI para el ámbito académico en el PEDI 2013-2016, sino porque además, no se cuenta con un PEDI de TI orientado a la formación. La poca eficacia de los organismos de TI en actividades académicas se da a conocer por la baja tasa de uso de plataformas educativas b_learning.
The Analysis and Perspective on Development of Chinese Automotive Heavy-duty ...IRJESJOURNAL
Abstract: In recent years, under the influence of both China's domestic market demand and emissions standard improvement, Chinese manufacturers put great effort on the research and design of automotive heavy-duty diesel engine. This paper analyzes the technical parameters of heavy duty diesel engine in 11 / 13L displacement section and introduces its performance. At the same time, combined with the development of foreign heavy-duty diesel engine, the future development direction of Chinese heavy-duty diesel engine is forecasted.
Research on The Bottom Software of Electronic Control System In Automobile El...IRJESJOURNAL
Abstract: With the development of science and technology, car replacement faster and faster. The development of the automotive industry has a contradiction, on the one hand, the speed of upgrading the car technology can not keep up with the speed of the performance requirements of the car, on the other hand, the country's automobile exhaust emission standards become more stringent. In addition, the depletion of oil resources led to the rise in gasoline prices, the traditional car is facing a crisis. Considering the situation of gas fuel resource structure and supply situation in China, it is feasible to promote gas fuel engine[1].However, the pollution caused by the car has become one of the major pollution sources in the urban environment and the atmospheric environment, and this trend continues to deteriorate[2].Therefore, alternative energy vehicles and hybrid cars is the main direction of development, and any improvement in the car will be car electronics and software replacement for the premise. On the one hand, natural gas as an alternative to gasoline, with its low prices, excellent combustion emissions, the relative sustainable development and other characteristics of more and more car manufacturers favor;On the other hand, the mainstream of the automotive electronic control unit ECU software development to AUTOSAR structure, low power consumption, functional safety for the development direction. Based on the actual development of natural gas engine control unit, the structure and function of ECU software are studied with reference to AUTOSAR software design standard. This paper studies the structure of the application of the software layer of the electronic control system and the main control strategy under the various conditions of the structure, and puts forward the underlying software resources needed by the application layer software. This paper analyzes the internal and peripheral resources of Infineon XC2785x microcontroller and designs hardware abstraction layer software and ECU abstraction layer software. The current characteristics of the jet valve driven by the natural gas multi-point injection engine were investigated. Automotive electronics technology has been widely used in modern vehicles which, and gradually become the development of new models, improve the performance of the key technical factors[3] .
Evaluation of Specialized Virtual Health Libraries in Scholar Education Evalu...IRJESJOURNAL
Abstract:- The aim is to evaluate the impact on academic training with specialized virtual health libraries (databases and catalogs) available in Institutions of Scholar Education, because there is uncertainty about the appropriate use of these libraries. The research was conducted on the databases available on 2 universities during the academic period August 2015 - February 2016. Using criteria and indicators for evaluating virtual libraries, model quality of university libraries based on fuzzy techniques, Bibliometric and criteria for virtual libraries in health. The study had the participation of 188 students from two universities or groups. The research reveals that for the first group and the second group almost always (60.45%) find the information, the (57.2%) have relevance to the topic, access (45.8%) once a month, and Elseiver and BiblioMedica are the most commonly used, however, mostly ie (78.55%) use traditional libraries versus (58.2%) which are virtual. Descriptive analysis was performed using the software SPSSv20. This experience allows us to confirm that the use of libraries contributes discreetly in academic education, therefore, it requires training plans, reference guides, strengthen the socialization of this resource, free access from anywhere.
Linking Ab Initio-Calphad for the Assessment of the AluminiumLutetium SystemIRJESJOURNAL
Abstract: First-principles calculations within density functional theory (DFT) were used to investigate intermetallics in the Al-Lu system at 0 K. The five compounds of the system were investigated in their observed experimental structures. Thermodynamic modelling of the Au–Lu system was carried out by means of the CALPHAD (calculation of phase diagrams) method. The liquid phase and the intermetallic compounds Al3Lu, Al2Lu, AlLu, Al2Lu3 and AlLu2 are taken into consideration in this optimization. The substitutional solution model was used to describe the liquid phase. The five compounds are treated as stoichiometric phases. The enthalpies of formation of the compounds were found by the ab initio calculations and used in the optimization of the phase diagram.
Thermodynamic Assessment (Suggestions) Of the Gold-Rubidium SystemIRJESJOURNAL
Abstract: Thermodynamic modellings of the Au–Rb system was carried out by means of the CALPHAD (calculation of phase diagrams) method. The liquid phase and the intermetallic compounds Au5Rb, Au2Rb, AuRb and Au7Rb3 and Au3Rb2 (new compounds) in addition to the compound AuRb2 (suspected compound) are taken into consideration in this optimization. The substitutional solution model was used to describe the liquid phase. The six compounds are treated as stoichiometric phases. The enthalpies of formation used in these optimizations were calculated within ab-initio method in precedent work
Elisa Test for Determination of Grapevine Viral Infection in Rahovec, KosovoIRJESJOURNAL
Abstract: Vineyard in Kosovo is estimated to have a great economic potential. There are thousands of hectares of vineyards that contribute to the economic potential of Rahovec by expanding the cultivation area year by year. The vines are affected by a number of viral diseases or pathologies similar to them, which significantly have an impact against the plant life and their production. Therefore, this study was conducted in several farms in Rahovec to determine whether there is a presence of viral infection in the vines. Application of Das-Elisa, Protein A-DAS and Antigen Direct Binding - DASI verified the final identification of viral infection in the collected material. The yellow colour reaction shown on the plate showed the positive result of the Elisa assay for viruses GFLV, ArMV, GLRaV-1, GLRaV-2, GLRaV-3, GVA and GVB in varieties Vranac, Smederevka, Prokup, Afuzali, Grocaka, Demir Kapi, Plovdina, Melika, Zhillavka. The use of specific antibodies will enable the examination of viral diseases in plant materials collected from vineyards and will be oriented to their phytosanitary status.
Abstract. Ensuring of permanent and continuous working process of oil-gas and field equipment alongside with the other factors, depends also on reliability of sealing units. A problem of deterioration modeling of a sealing element of a packer including into an oil field equipment complex is considered in this paper.
Determining Loss of Liquid from Different Types of Mud by Various Addictives ...IRJESJOURNAL
Abstract :- Filtration is used in many industries to separate water from the solid. It is important to find fluid loss in drilling, cementing, fracturing, and almost every other type of downhole treatment design. The filter cake characterization is very essential for well selection of drilling fluid problems and formation damage. Therefore this study is taken up to experimentally investigate the effect of different concentrations of CMC, Starch, Wood fibers, Soda ash, Caustic soda, Bentonite and Barite on filtration loss and formation damages. Three different samples are used in this study at different concentration and a comparison is made. Although the discussion presented here is confined to fluid loss during drilling. Water-based drilling mud’s including Bentonite is wellknown and is being widely used in the petroleum industry. Among the important functions of water-based drilling fluid were to form filter cake on the wall of the well bore, prevent water leakage, and maintain the stability of the well wall. The properties of the water-based drilling fluid, such as the rheology and filtration loss, are affected by the fluid loss additive. Polymers, which are nontoxic, degradable, and environment friendly, are the best choice to be used as drilling fluids additives.
Prediction of Electrical Energy Efficiency Using Information on Consumer's Ac...PriyankaKilaniya
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Assembly Disruptions – Empirical Evidence in the Manufacturing Industry of Germany, Austria and Switzerland
1. International Refereed Journal of Engineering and Science (IRJES)
ISSN (Online) 2319-183X, (Print) 2319-1821
Volume 6, Issue 3 (March 2017), PP.15-25
www.irjes.com 15 | Page
Assembly Disruptions – Empirical Evidence in the Manufacturing
Industry of Germany, Austria and Switzerland
Johannes Wagner1
, Peter Burggräf², Matthias Dannapfel3
, Carsten Fölling4
1,3,4
(ChairOfProduction Engineering, RWTH Aachen University, Germany)
² (Chair OfInternational Production Management And Engineering, University Of Siegen, Germany)
ABSTRACT: In this paper, we present the results of an empirical study in the manufacturing industry of
Germany, Austria and Switzerland with over 100 participants, mainly from the mechanical engineering,
automotive and machine tool businesses. The questionnaire-based study yielded original findings in the area of
assembly disruptions and the management thereof. Major results include that assembly disruptions are
widespread in the industry and lead to extensive economic damages. The reasons, durations and locations of
assembly disruptions as well as their character are explored and the need for a new concept of efficient,
preventive assembly disruption management is derived.
Keywords:Assembly disruptions, disruption management, empirical study
I. INTRODUCTION
In order to succeed in the competition enforced by the growing globalization of markets, companies
face the urgent need to increase flexibility as well as to ensure on-time delivery and to minimize their
production costs [1] [2]. A key element of the minimization of production costs is a decrease of assembly costs
in spite of simultaneously increasing quality, complexity and customization requirements [3] [4]. A main issue
to be addressed for the reduction of production costs and for a secure on-time order completion are disruptions
occurring during the assembly process. According to LEHMANN, a disruption is every kind of unintentional
deviation from the usual assembly process [5].SCHWARTZadds staff, materials, information or orders as root
causes for different kinds of assembly disruptions[6].
According toABUMAIZAR AND SVESTKA, disruptions include machine breakdowns, lacks of material,
rush orders and cancelled orders [7]. Although a lot of information about disruption management can be found
in the literature and the problem of disruptions is often described, only few empirical studies regarding this issue
have been carried out in the production industry. Except studies by LEHMANN and WUENSCHER, which date
back several years, little quantification of assembly disruptions can be found in the existing literature. [5] [8]
The study aims to answer three main questions. The first question regards the current situation of
companies in the production industry induced by assembly disruptions. Secondly, the study intends to examine
the question of how disruptions occur and how they can be characterized. The third question regards disruption
management approaches that are already applied in the industry. The study structure has been designed with the
purpose of supporting the answer to these questions.
II. PRESENTATION OF THE STUDY DESIGN
In order to fill the date gaps regarding quantified assembly disruptions by describing the reasons for
assembly disruptions as well as their impacts and to validate solution hypotheses, an empirical study has been
conducted. The study has been carried out in the form of a web-based survey. Participants from Germany,
Austria and Switzerland were questioned against the background of several hypotheses within the online-
questionnaire. The study design is structured in three consecutive modules. The sample of the study is presented
and characterized in the first section. The second module deals with the problem description before some
applied solution approaches are presented in the third section (Fig. 1).
Fig. 1Study Design: Modules of the questionnaire
The results of this study are presented in the following.
Sections of the Study
Sections of the Study
Applied Solution
Approaches
Characterization of the
Sample
Problem Description
2. Assembly Disruptions – Empirical Evidence in the Manufacturing Industry of ….
www.irjes.com 16 | Page
1%
21% 24% 26%
10% 11% 8% 0%1% 1%
3%
31%
18%
29%
12%
5%
0%
10%
20%
30%
< 10 10 - 50 51 - 100 101 - 500 501 - 1,000 1,001 -
10,000
10,001 -
50,000
> 50,000
Assembly Total
1%
21% 24% 26%
10% 11% 8% 0%1% 1%
3%
31%
18%
29%
12%
5%
0%
10%
20%
30%
< 10 10 - 50 51 - 100 101 - 500 501 - 1,000 1,001 -
10,000
10,001 -
50,000
> 50,000
Assembly Total
III. PRESENTATION OF THE STUDY SAMPLE
The first part of the questionnaire is intended to characterize the sample of this study. The sample
includes 101 participants from numerous companies from Germany, Austria and Switzerland, many of which
are internationally operating. The participants hold high positions such as plant manager, production or
assembly manager. Due to the large scope of this study, significant results have been derived.
The largest proportion of the participants’ companies can be assigned to the mechanical engineering
respectively plant engineering industry, automotive industry and machine tool industry. Other participants work
for companies in the electrical and aviation industry.
Fig. 2 Represented industries1
On average, almost 13,000 members of staff are employed in each of these companies, with an average
of about 7,600 employees in the area of assembly. The largest company in the sample employs 360,000
employees. Some other companies employ around 100,000 members of staff.
To characterize the participating companies in terms of their economic situation, the annual turnover
has been taken as a measure (year 2014). Two percent of the participants state an annual turnover between 2 and
10 million €, 21 % between 10 and 50 million € and 77 % above 50 million €.
Fig. 4 Annual turnover
1
If figures do not add up to 100 %, this is due to rounding differences. This applies to several figures in this paper.
43%
16%
14%
26%
Mechanical/ Plant
Engineering
Automotive industry
Machine tool industry
Other
77%
21%
2%
> 50 million €
10 - 50 million €
2 - 10 million €
Fig. 3 Number of staff [FTE] in the assembly and in the entire company
3. Assembly Disruptions – Empirical Evidence in the Manufacturing Industry of ….
www.irjes.com 17 | Page
It can be derived from these numbers that about one fourth of the sample are ranked among small or
medium-sized enterprises (SMEs) which are characterized by an annual turnover below 50 million € based on
the SME definition by the European Commission. [9]
The participants further describe the degree of standardization of their companies’ products. Only few
characterize their products as completely standardized, whereas 39 % classify their products as mainly
standardized, 29 % as mainly customized and 24 % as customized.
Fig. 5 Degree of standardization of the products
A large diversity can be recognized in the companies’ assembly output volumes in 2014. The range
reaches from less than ten to more than a million assembled units per year.
Fig. 6 Assembly volumes [units per year]
The forms of assembly organizations named by the participants reach from group assemblies to
production line assemblies, which shows a wide range of assembly practices throughout the represented
industries and companies.
Fig. 7 Assembly forms
7%
39%
29%
24%
Only Standardized
products
Mainly standardized
products
Mainly customized
products
Customized products
2%
11%
14%
17%
14%
8%
10%
3%
21%
< 10
11-50
51-200
201-1,000
1,001-10,000
10,001-50,000
50,001-500,000
500,001-1,000,000
> 1,000,000
49%
43%
41%
35%
33%
10%
Group assembly
Flow assembly
Onsite assembly
Row assembly
Production line assembly
Other
Which assembly form do you apply in your
company?
4. Assembly Disruptions – Empirical Evidence in the Manufacturing Industry of ….
www.irjes.com 18 | Page
IV. CURRENT DISRUPTION SITUATION IN INDUSTRIAL ASSEMBLY
In the second part of the survey, the participants were confronted with questions to analyze whether
their companies suffer from assembly disruptions. Further questions aimed at characterizing the disruptions
regarding where and how they arise, their duration, whether they can be predicted or avoided and how they are
monitored and documented in the companies.
In the beginning, the participants were asked to rate their approval ofthe statement "Assembly
disruptions cause economic losses for our company, e.g. due to additional costs or delays in delivery."
Fig. 8 Rating of economic losses caused by assembly disruptions
It can be seen in Fig. 8that the vast majority of companies (97 %) agree or strongly agree with the
statement, which proves that assembly disruptions are a severe economic problem for most companies in the
production industry. With these significant results, this study confirms prior findings from the literature, which
attest the economic impact of disruptions in the assembly (e.g. [3]).
In the following, the reasons for assembly disruptions in the participating companies were analyzed in
a question allowing multiple answers. As can be seen inFig. 9, 92 % of the participants state to have material
deficiencies causing disruptions. 54 % respectively 65 % of the participants ascribe assembly disruptions to
lacks of capacity and information. Another 19 % name technological problems, environmental influences and
quality problems as further reasons.
Fig. 9 Reasons for assembly disruptions
Similar results were obtained by LEHMANN in 1992. In his study, which was carried out in a sample of
16 companies, he inter alia evaluated which kind of assembly disruptions occurred. 63 % of the disruptions
examined by him were reducible to material-related problems and 18 % respectively 19 % to lacks of capacity
and information. [5] The figures differ since LEHMANN evaluated a sample of single disruptions which did not
generate multiple answers. Nevertheless, the basic statement endures.
The areas where disruptions can be detected in the companies were investigated next with multiple
answers allowed. 95 % of the participants experience disruptions in the final assembly, 73 % in the pre-
assembly and only 25 % in a field or onsite assembly. The last value might be due to the fact, that most
industrial companies finish their assembly in their own plant, not on the site of the later usage of the product. No
participant states not to experience disruptions at all.
0% 3%
16%
81%
Strongly
disagree
Disagree Agree Strongly
agree
“Assembly disruptions cause economic losses
for our company, e.g. due to additional costs or
delays in delivery.“
92%
54%
65%
19%
0%
Material deficiencies
Lacks of capacity
Lacks of information
Other
No disruptions
“Disruptions in our assembly are
reducible to ... .“
5. Assembly Disruptions – Empirical Evidence in the Manufacturing Industry of ….
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89%
77%
11%
19% 5%
long (> 4h)
short (< 4h)
Strongly agree Agree Disagree Strongly disagree
Influence of the duration of assembly disruptions on the participants’ evaluation of economic
losses induced by these disruptions
Fig. 10 Areas of disruptions
Again, the data collected by LEHMANN substantiate these results. He found that the majority (62 %) of
the examined disruptions in his study arose in the final assembly, 28 % in the pre-assembly and 10 % in a field
or onsite assembly. [5]
LEHMANN further worked out the duration of the regarded disruptions. In his sample, 48 % of the
disruptions lasted longer than four hours, whereas a small majority of the disruptions (52 %) lasted for a shorter
period of less than four hours. [5]
The results of our study show that the duration of disruptions has decreased significantly compared
with his findings. 65 % of the sample characterize the average duration of their assembly disruptions as “short
(< 4 hours)” and only 35 % as “long (> 4 hours)”.
Fig. 11 Average duration of assembly disruptions
These findings suggest that the majority of assembly disruptions that companies have to deal with only
last for a relatively short time.
The importance of the duration of occurring disruptions can be measured by the induced economic
losses. It was found that participants who describe their assembly disruptions as “long (> 4h)” rather tend to
agree to the fact that assembly disruptions cause economic losses than those who describe their disruptions as
“short (< 4h)”.
Fig. 12 Evaluation of economic losses due to assembly disruptions depending on their duration
In the next question, the participants were confronted with the statement "Theoretically predictable or
even avoidable disruptions occur in our assembly.”as this information about a disruption can be beneficial in
terms of finding promising disruption management solutions. The answers show that a high proportion of
assembly disruptions can be predicted and therefore potentially avoided. 72 % of the participants agree
(24 % strongly) to the statement whereas 28 % disagree (2 % strongly).
73%
95%
25%
0%
Pre-assembly
Final assembly
Field/ onsite assembly
No disruptions
“Disruptions in our assembly occur in the
following areas... .“
35%
65%
long (> 4h) short (< 4h)
“The average duration of a disruption in our
assembly is ... .“
6. Assembly Disruptions – Empirical Evidence in the Manufacturing Industry of ….
www.irjes.com 20 | Page
Fig. 13 Assembly disruptions that can be predicted or even avoided
The repetition of assembly disruptions over time in a similar way is likely to increase the predictability
of assembly disruptions. Thus, the proposition “In our assembly, disruptions occur which repeat in a similar
way.” was presented in the survey in order to enquire the level of repetition with which disruptions arise. 79 %
of the participants confirm that disruptions repeating in a similar way can be found in their assembly (33 %
strongly) whereas 21 % disagree with the statement.
Fig. 14 Similar repetition of disruptions
These results suggest that a high proportion of assembly disruptions is caused by lasting problems
instead of random environmental influences. The reduction of the frequency of disruptions has been described
as a critical element of a successful disruption management in the literature before (e.g. [10]). This underlines
the significance of these findings, as the recognition of repeating disruptions is a promising approach to this aim.
A profound knowledge and an explicit documentation of processes respectively parts, that are critical
with regard to assembly disruptions, are described as the groundwork for a successful disruption management in
the literature [3]. Therefore, the participants were asked for their degree of consent with the statement "Critical
processes respectively parts are known and explicitly documented in our company.”
Fig. 15 Knowledge and documentation of critical processes and parts
The results reveal a potential for improvement regarding the monitoring of the elements of the
assembly process that are vulnerable to disruptions.
In the last question of the second part of the questionnaire the proposition "Due to limited planning
capacities, not all processes respectively parts in our company can be monitored regarding possible future
2%
26%
48%
24%
Strongly
disagree
Disagree Agree Strongly
agree
"Theoretically predictable or even avoidable
disruptions occur in our assembly.“
0% 21%
46%
33%
Strongly
disagree
Disagree Agree Strongly
agree
"In our assembly, disruptions occur which
repeat in a similar way.“
7%
42% 38%
13%
Strongly
disagree
Disagree Agree Strongly
agree
"Critical processes respectively parts are
known and explicitly documented in our
company.“
7. Assembly Disruptions – Empirical Evidence in the Manufacturing Industry of ….
www.irjes.com 21 | Page
disruptions.” was presented in order to determine a possible reason for why the monitoring of processes is still
worthy of improvement.
Fig. 16 Restrictions to the monitoring of processes due to limited planning capacities
The results as shown in Fig. 16 suggest that limited planning capacities inhibit a complete monitoring
of processes.
V. DISRUPTION MANAGEMENT APPROACHES AND EVALUATION BY
PARTICIPANTS
The third part of the questionnaire addresses solutions and improvement approaches the participants
already apply in their companies within the scope of assembly disruption management.
The first question in this part deals with methods respectively tools applied in the represented
companies in order to eliminate or to deal with disruptions. Multiple answers were allowed and a diversity of
practices has been identified. 74 % of the participants state that a spontaneous respectively intuitive approach to
handling disruptions is applied in their companies. 73 % indicate to have defined escalation stages in place and
68 % try to prevent disruptions based on experiences. Reactive respectively preventive IT-based disruption
management are named by 62 % respectively 53 % of the participants. Only 26 % indicate the keeping of a
disruption logbook. Further 9 % name individual methods including specialized teams or processes in their
disruption management.
Fig. 17 Methods and tools applied within the scope of assembly disruption management
In the following question, the participants were asked to evaluate the average utility of their methods
and tools applied to reduce disruptions and their impacts with regard to the belonging cost incurrence. Although
the majority (64 %) consider the utility of their approaches to be (rather) high, the remaining 36 % reveal
efficiency problems in the current disruption management of their companies.
6% 21%
40%
32%
Strongly
disagree
Disagree Agree Strongly
agree
"Due to limited planning capacities, not all
processes respectively parts in our company can
be monitored regarding possible future
disruptions.“
74%
73%
68%
62%
53%
26%
9%
Spontaneous/ intuitive handling of occurring
disruptions
Defined escalation stages depending on the
severity of occurring disruptions
Prevention based on the experiences of the staff
Reactive, IT-based disruption management
Preventive, IT-based disruption management
Keeping of a disruption logbook
Company specific approach
8. Assembly Disruptions – Empirical Evidence in the Manufacturing Industry of ….
www.irjes.com 22 | Page
Fig. 18 Evaluation of the average utility of methods and tools within the disruption management
In order to differentiate this evaluation depending on the applied methods within the disruption
management, the correlation between selected disruption management approaches and the evaluation of their
utility has been measured.
Fig. 19 Correlation of applied disruption management approaches and the evaluation of their utility
A significantly higher share of high evaluations can be found among those with a preventive disruption
management approach compared with reactive or even spontaneous approaches. In other words, companies,
which focus on preventing assembly disruptions are more satisfied with the efficiency of their efforts than other
companies, which handle assembly disruptions in a reactive manner.
In order to further investigate the differences between these different approaches, the participants were
asked how they evaluate the potential of preventive disruption management (e.g. [3]) in contrast to reactive
disruption management (e.g. [11], [12]). Although a high proportion of participants evaluates their reactive
approaches to be successful within disruption management before, a significant majority (88 %) of all study
participants assesses the potential of a preventive disruption management higher than that of the reactive
approach.
Fig. 20 Evaluation of the potential of preventive disruption management in comparison with reactive disruption management
Next, the participants were asked to give their opinion on whether their resources could be used more
efficiently and disruptions could be prevented if there was transparency about actually critical processes
respectively parts. The majority (87 %) agrees with this proposition whereas only 13 % disagree.
2%
34%
48%
16%
low rather low rather high high
3% 40%
27%
30%
45%
48%
40%
12%
25%
30%
Spontaneous/ intuitive handling of
occurring disruptions
Reactive, IT-based disruption
management
Preventive, IT-based disruption
management
low rather low rather high high
Evaluation of the utility of selected methods respectively tools to reduce disruptions and their
impacts with regard to the belonging cost incurrence
0% 12%
50%
38%
low rather low rather high high
9. Assembly Disruptions – Empirical Evidence in the Manufacturing Industry of ….
www.irjes.com 23 | Page
Fig. 21 Transparency about critical processes and parts
Based on this question, it was investigated to which extent the participants’ consent with the statement
"If there was transparency about actually critical processes respectively parts, our resources could be used
more efficiently and disruptions could be prevented.” is depending on their knowledge and documentation of
critical processes respectively parts (Fig. 15).
Fig. 22 Influence of the knowledge and documentation of critical elements on the efficiency of the use of resources and the
possible prevention of disruptions
It can be derived fromFig. 22, that the consent with the proposition increases with the knowledge of
critical process elements and with their explicit documentation.
Rephrasing this finding in simple terms, the companies, which know and document critical processes,
realize that resources can be used more efficiently and disruptions can be prevented. Those who do not have the
transparency do not share this view, as it is a hypothetical question for this part of the sample.
For a quantification of the anticipated benefits through the transparency of critical processes
respectively parts, the participants were asked to estimate the saving potential in the case of transparency in
relation to the total assembly costs. The boxplot method has been applied in order to compute a measure of
dispersion of the participants’ ratings without including the extreme potential outliers [13]. Fig. 23displays in a
boxplot the range of estimations ignoring the highest outliers (50 %, 80 %, 80 %), which are symbolized by
circles. The average estimate amounts 15.2 %, suggesting a significant economic potential in the monitoring of
process elements critical to disruptions. 59 % of the participants estimated this potential between 10 % and 30 %
and the range of estimations reached from 1 % up to 80 %.
1% 12%
51%
36%
Strongly
disagree
Disagree Agree Strongly
agree
"If there was transparency about actually
critical processes respectively parts, our
resources could be used more efficiently and
disruptions could be prevented.“
2%
14%
12%
8%
27%
86%
51%
49%
27%
34%
43%
46%
unknown and not documented
rather unknown and not documented
rather known and documented
known and documented
Strongly disagree Disagree Agree Strongly agree
Agreement with the statement that resources could be used more efficiently and disruptions
could be prevented due to transparency about actually critical processes/ parts depending on
the knowledge and documentation of critical processes
10. Assembly Disruptions – Empirical Evidence in the Manufacturing Industry of ….
www.irjes.com 24 | Page
Fig. 23 Rating of the cost reduction potential of total assembly costs presented in a boxplot
It has been shown, that not all processes can be monitored due to limited planning capacities (compare
Fig. 16). The next proposition was presented with the aim to examine, if at least an ongoing monitoring
respectively treatment of critical processes respectively parts was possible. The consent of 79 % of the
participants shows, that these critical process elements can be monitored or treated with regard to disruptions.
Fig. 24 Possibility of an ongoing monitoring respectively treatment of actually critical processes
This suggests that a promising approach for assembly disruption management might be to focus on
identifying these disruption-critical factors and concentrating prevention efforts on them.
VI. CONCLUSION AND OUTLOOK
An empirical study in the manufacturing industries of Germany, Austria and Switzerland with more
than 100 participants has been performed in 2015 and 2016 with the aim to reveal new statistical data and
findings with regards to assembly disruption management. Not only is the topic of disruptions widespread in the
assembly of industrial companies in large parts of Europe, but it also causes massive economic damages to these
companies.
It was confirmed that a high number of disruptions can theoretically be forecasted or even prevented,
and that many disruptions reoccur in an exact or similar way as before. This leads to the question on why
companies do not prevent disruptions. The study reveals that the planning capacities are not sufficient to deal
with every disruption and process in the same way, but that the critical processes have to be focused. Even in the
case of only dealing with critical processes the saving potentials amount to about 15 % of overall assembly
costs.
Based on these results, an approach for efficient preventive disruption management is being developed
by the authors, which has been first described conceptually in 2015 and is being refined to be published in
2017 [3].
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0,0
10,0
20,0
30,0
40,0
50,0
60,0
70,0
80,0%
%
%
%
%
%
%
%
%
1% 20%
48%
31%
Strongly
disagree
Disagree Agree Strongly
agree
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feasible for actually critical processes
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11. Assembly Disruptions – Empirical Evidence in the Manufacturing Industry of ….
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