The customer is always right [customer focused manufacturing]

Only if we satisfy our customers will we stay in business, and only if we can deliver customer focused manufacturing at an acceptable cost level, can we afford to stay in business. The author explores the various IT strategies available to companies in meeting the challenges of the future     

The Information Technology Productivity Paradox Revisited: A Theoretical and Empirical Investigation in the Manufacturing Sector

The lack of empirical support for the positive economic impact of information technology (IT) has been called the IT productivity paradox. Even though output measurement problems have often been held responsible for the paradox, we conjecture that modeling limitations in production-economics-based studies and input measurement also might have contributed to the paucity of systematic evidence regarding the impact of IT. We take the position that output measurement is slightly less problematic in manufacturing than in the service sector and that there is sound a priori rationale to expect substantial productivity gains from IT investments in manufacturing and production management. We revisit the IT productivity paradox to highlight some potential limitations of earlier research and obtain empirical support for these conjectures. We apply a theoretical framework involving explicit modeling of a strategic business unit's (SBU)1 input choices to a secondary data set in the manufacturing sector. A widely cited study by Loveman (1994) with the same dataset showed that the marginal contribution of IT to productivity was negative. However, our analysis reveals a significant positive impact of IT investment on SBU output. We show that Loveman's negative results can be attributed to the deflator used for the IT capital. Further, modeling issues such as a firm's choice of inputs like IT, non-IT, and labor lead to major differences in the IT productivity estimates. The question as to whether firms actually achieved economic benefits from IT investments in the past decade has been raised in the literature, and our results provide evidence of sizable productivity gains by large successful corporations in the manufacturing sector during the same time period.     

Why bad forecasts can be good for business...[demand forecasting]

In order for companies to be more responsive to actual customer demand, some degree of forecasting is necessary. In a study on supply chain improvement, the results indicate the importance of demand forecasting. The study show that manufacturers need to create a model of the near future, their demand forecast, to enable them to best configure their supply chain's resources. Forecasting is as important as ever, even as companies seek to become as responsive as possible. New software tools help companies make forecasting less of a black art and more of a scientific process. However, it is key that judgement is used to assess what the software proposes and collaboration, also enabled through software and the Internet, helps involve all key stakeholders to create a robust forecast that the business can work to.     

Creating agile supply chains

An agile business needs an agile supply chain. Quick response to customer demand, the ability to customise and the need to provide multiple variants for profitable customer niches are all increasingly required by many companies. Yet as manufacturers inexorably move their sourcing of components and low value-added operations offshore, to lower cost countries, so their supply chains increase in both distance and complexity. Many companies are faced with the challenge of providing an agile response to customers and yet operating a lean operation across an extended global supply chain. This is a challenge that needs a solution beyond the abilities of simply judgement, the telephone and spreadsheets. Companies need to utilise the power of Internet-enabled software to provide visibility across their global supply chain and to help them optimise it. In particular the new generation of supply chain optimisation software offers companies the ability to gain visibility and optimisation across their supply chains, at significantly reduced ownership costs compared to earlier systems     

六西格玛管理在模具生产品质中的应用

六西格玛为一套系统的业务改进方法体系,旨在持续改进企业业务流程,实现顾客满意的管理方法。使用六西格玛管理对由模具生产出的产品品质进行研究,可以很好地控制模具产品的重要尺寸,降低模具生产成本,提高生产率,缩短周期,降低废品率。     

Ahp model for the selection of partner companies in virtual enterprises

Rising product variety and complexity, shorter time frames to respond, and the continual need to gain new capabilities through innovativeness force the trend of outsourcing to be replaced by strategic alliances, where enterprises or individuals work together towards a common goal and share their responsibilities as well as their profits. Recent developments in information technology have enabled relatively inexpensive, reliable and fast networking to support such alliances in real time. In this context, the virtual enterprise (VE) represents an appropriate cooperation alternative and competitive advantage for the enterprises. VE is a temporary network of independent companies -- suppliers, customers, even rivals -- linked by information technology (IT) to share skills, costs and access to one another’s markets. In this emerging business model of virtual enterprise, the decision support functionality, which addresses issues such as partner company selection, is an important domain to be studied. In this paper, we propose an analytic hierarchy process model to contribute in the selection of the partner companies in the virtual enterprises. A case example is also covered to validate the feasibility of the adoption of the model in virtual enterprise situations.     

基于互补性理论的企业信息资源匹配度研究

企业导入信息系统失败或未能实现信息系统应用价值的一个主要原因,是不能与企业的其他资源很好地匹配.基于互补性理论,以某寿险公司客服流程为例,深入探讨了信息技术与其他资源的互补性,建立了一个多层次商业价值模型和变量之间的超模/子模函数.通过引入超模函数,建立了信息技术资源及各类互补资源从投入到业务流程绩效实现多阶段的过程函数,从而对信息技术商业价值实现过程有更深入的理解.     

基于SOA的第三方物流运输管理系统研究与设计

运输管理系统是第三方物流信息系统的重要组成部分。第三方物流企业需要一个灵活的IT系统架构来支撑飞速变化的业务需求。结合某一大型第三方物流企业信息化实施与发展状况,对第三方物流企业的运输业务流程进行细致的分析,并对关键业务流程进行优化。研究了SOA架构的组建模型及其实现的相关技术,提出了一种基于SOA架构的第三方物流运输管理系统的设计方案。新方案能充分支撑企业多变的业务流程,使企业员工将能根据他们的权限拥有相应的跨模块的可视能力,随时了解到运输业务进行的全貌。     

[制造服务]信息共享和信息技术应用对客户服务的影响研究——考虑交互作用影响

构建了企业信息共享和信息技术（IT）应用及其交互作用、配送服务和售后支持服务与企业财务绩效之间关系的概念模型，基于中国制造企业的调查数据，使用结构方程模型方法验证了假设模型。研究发现高水平的信息共享可以显著促进售中配送和售后支持服务；高水平的IT应用只能促进售中配送服务，对售后支持服务的影响不显著；信息共享和IT应用的交互作用能显著促进售中配送服务。在实践中制造企业应重视信息共享和IT应用的交互作用，并合理配置资源以促进信息共享和IT应用的交互作用，从而提高客户服务水平和企业财务绩效。     

Value stream mapping and benefit–cost analysis application for value visibility of a pilot project on RFID investment integrated to a manual production control system—a case study

The importance of responding to customer demand to stay competitive in the global market and to increase market share has been increasing for companies lately. Due to demand fluctuations and difficulties to estimate it, gradually it becomes more difficult to sustain profitability and to fulfill demand. The company’s main problem is how to cut costs while producing small numbers of many types of products. For that reason, cost-conscious companies have focused on monitoring and controlling manufacturing and supplier-related activities by means of manual/electronic control devices in order to enhance the efficiency in the supply chain management and logistics process. This paper presents a case study about deployment of radio frequency identification (RFID) technology-based electronic Kanban system in an automotive industry supplier firm. In this project, by deploying RFID technology in a pilot area within the current manual Kanban system of this company, it has been possible to measure the true value added time in the production process. Value stream mapping is used to exhibit the mandatory requirements of RFID technology deployment in the shop floor. As a part of the study, we generate a current value stream map and a future value stream map, which contain the recommended revisions for the automotive supplier company. To evaluate the return of the investment, performance metrics were established and benefit–cost analysis is made. Obviously, future gains will include better inventory management to reduce the inventory levels within the production system.     

面向需求增溢的客户满意度模型研究

提出一种面向需求增溢现象的产品综合客户满意度计算方法,该方法首先对需求质量特征类型和客户满意度区间进行划分;然后采用分段式指数型函数建立不同类型的客户需求特征满意度模型;最后采用层次分析法确定各个需求特征的相关权重,从而得到不同产品对应的客户综合满意度。以工程自卸车产品客户选择为例,对该客户满意度模型应用的有效性和实用性进行了说明。     

基于三前馈APIOBPCS的供应链弹性与运作成本评估

为兼顾供应链系统的弹性和运作成本,提出三前馈自动渠道的、基于库存和定购的生产控制系统(Triple feed-forward automatic pipeline, inventory and order-based production control system, TFF-APIOBPCS)。在自动渠道的、基于库存和定购的生产控制系统模型中,增加一阶微分前馈环节,以部分抵消需求波动对库存的影响。在零稳态误差情况下针对生产控制系统的不同极点分布,分析一阶微分前馈环节的参数与供应链弹性的关系。综合考虑库存成本及生产调节成本,构造供应链系统的运作成本模型。通过阶跃需求、随机需求下的供应链系统仿真,评估一阶前馈环节参数对供应链弹性及运作成本的影响,验证三前馈自动渠道的、基于库存和定购的生产控制系统的有效性。结果表明,针对不同波动程度的需求,合理设置一阶微分前馈环节的参数,可以获得弹性与运作成本的良好均衡。     

Impact of forecasting methods on variance ratio in order-up-to level policy

This paper considers the impact of forecasting methods on the bullwhip effect for a simple replenishment system in which a first-order autoregressive process describes the customer demand and an order-up-to inventory policy characterizes the replenishment decision. The impact of exponential smoothing and minimum mean squared error forecasting is measured for both the bullwhip effect and inventory variances. Previous similar studies have focused on investigating the impact of forecasting methods on bullwhip effect. However, little research has been carried out to explore the impact of forecasting methods for both bullwhip effect and inventory variances. Through simulation experiments, it has been found that depending on the structure of the demand process, the appropriate selection of forecasting technique can reduce, or even eliminate (i.e., “dewhip”) the bullwhip effect. However, in terms of inventory variances it has been shown that the inventory variances for the exponential smoothing are greater than the minimum mean squared error forecasting method and that gap increases as lead time increases. These findings will help companies to choose the appropriate forecasting technique depending on the nature of demand. These guidelines can help companies to reduce the bullwhip effect and inventory variances across supply chain.     

Analysis: RFID - don't believe the hype

RFID technology offers significant potential benefits to companies and therefore it will come as no surprise that there are a good many RFID trials underway. But the worrying news for those championing the technology is that these trials have delivered fewer benefits than expected, and the majority have not progressed to rollout, raising questions about the value realised. Companies need to look beyond the hype and understand the real value drivers in their business and use those to inform the RFID trials they undertake. RFID trials can also lead to high indirect costs. Civil liberty groups have challenged the degree to which companies can utilise personal data associated with RFID tags, causing customer concern.     

Cutting parameter optimization in NC milling

The continuous demand for higher productivity and product quality asks for better optimizing of the machining process. In this case, numerical controlled (NC) milling is a processing technology massively applied in the metal manufacturing industry; it has received very important interest in this century because it has a very high productivity and high work piece surface quality. The main objective of this work is to evaluate the machining time of different cycles, in 2.5?D NC milling. The prediction of the optimal values of cutting speed was analyzed to minimize both time and cost of die production. Optimum and economical values of cutting speed give, respectively, minimum production time and minimum production cost. An experimental study is carried out to validate machining time calculation models developed in this work. The cutting parameters analyzed in this study are cutting speed, feed per tooth, and the radial cutting depth.     

Pioneering e-supply chain integration in semiconductor industry: a case study

Taiwan Semiconductor Manufacturing Company (TSMC) is the largest semiconductor foundry in the world. Advanced Semiconductor Engineering Inc. (ASE) is the world’s leader in semiconductor assembly and testing. From 1998 to 2004, the two companies completed electronic integration of 11 key business processes through the Internet. The result is a seamless interface between TSMC, ASE and their joint customers. They can now obtain accurate, timely information on their product status and respond appropriately when needed. While the direct economic benefits are estimated to be around US$ 10 million through productivity increase over a total investment of about US$ 2 million, the indirect benefits of this initiative could be on the order of US $100 million if the joint customers’ benefits are considered. In collaboration with the RosettaNet organization, TSMC and ASE leveraged their pioneering experiences to define three data exchange standards which can then be widely adopted in the semiconductor industry. This case study is a demonstration of how two leading companies in their respective fields can join forces to make a difference in creating value for the entire semiconductor industry, which in turn benefits society at large. With the momentum continuing to build and the sphere of influence continuing to expand, it is anticipated that TSMC, ASE and the entire sector will upgrade their competitiveness in terms of cost, quality, responsiveness and customer orientation.     

大规模定制下制造商延迟生产的成本优化模型

为解决大规模定制下延迟生产系统中制造商的生产成本优化问题,建立了大规模定制下制造商实施延迟生产的生产成本优化基本模型和扩展模型,以大规模定制下延迟生产系统的生产成本最小化为目标,综合考虑了固定资产的投资成本、制造成本、在制品持有成本、半成品库存成本,以及客户提前期问题.分析了客户订单分离点最佳位置及其决定因素,并指出了客户需求平均到达率、定制化产品种类数量,以及制造中心平均生产率对客户订单分离点最佳位置的影响.最后,对延迟生产系统的生产成本优化模型进行了仿真.     

A cost model for determining dyeing postponement in garment supply chain

There is a complex, dynamic and highly competitive market for the textile and clothing industries in developed countries. To respond quickly to changes in the market and to insure that the response will be able to satisfy customer fashion requirements, postponement strategy is one of the most important methods. This paper constructs original and postponed garment dyeing cost models and uses practical parameter data to simulate various situations, and then analyzes the differences and relations between the two cost models. The results show that the cost of the postponement model is lower than the cost of the original model when key parameters such as total demand quantity, number of colors, inventory holding cost rate, demand standard deviation, lead-time, and safety stock factor are large. The cost evaluation model provides a strategy and the basis for feasible judgment in evaluating dyeing postponement for the textile and clothing industries in garment supply chain management.     

Capacities-based supply chain network design considering demand uncertainty using two-stage stochastic programming

The design of a supply chain (SC) aims to minimize cost so the product can reach the customer at the cheapest cost with flexible demand. The demand of a product is variable with time and environment. Most of the researchers have considered investment cost, processing cost, and transportation cost as variable costs to minimize the cost while considering a constant demand. In actual practice, the demands are flexible. In this paper, a two-stage stochastic programming model has been proposed for a capacities-based network design of a supply chain for flexible demands while considering inventory carrying cost and missed opportunity cost in addition to the above-mentioned costs. It will enhance the logistic planning and seek the location network optimally. Furthermore, in the first stage, decision variables represent different nodes (facility locations of echelons) of the supply chain, with the assumption that they will be considered at the design stage before uncertain parameters are unveiled. On the other hand, decision variables related to the amount of products to be produced and stored in the nodes of the SC, the flows of materials among the entities of the network, and shortfalls and excess at the customer centers are considered as second-stage variables. The methodology has been illustrated by solving an example. It was found that the proposed model yields more feasible and advantageous results.     

A framework for generating product production information for mass customization

As mass customization companies grow their business, the amount of custom information required to run the business increases. This paper proposes an information technology (IT) framework to solve this problem through automatic generation of information. The framework uses the concept of information templates or models and a rule-based system to generate manufacturing instructions. The templates combine the knowledge of bill-of-materials and resources while applying constraints to ensure the resulting custom product conforms to performance specifications. The feasibility and effectiveness of the framework and concepts are empirically validated by a case study implementation at a company that mass produces customized windows and doors in Calgary, Canada.