Outsourcing in the automotive industry : the elusive goal of tier 0.5

A key aspect of outsourcing is the development of enhanced capabilities by automotive suppliers. An obvious cost benefit is that supplier wage rates are often less than those at the vehicle brand owners (VBO). But time and quality benefits are also expected together with increasingly sophisticated engineering and operational capabilities. This can be seen as a staged development but at each stage, the VBO passes more risk to the supplier. This article addresses the practicalities of becoming a tier 0.5 supplier and some of the pressures that had to be overcome. It focuses on the cockpit module that was developed for the new Micra model that is assembled at the Nissan plant at Washington in the UK.     

An integrated analytic network process with mixed-integer non-linear programming to supplier selection and order allocation

As the global business environment changed, much more commercial and technological competitions evolved in this environment. Consequently, more attention is devoted to the business partners including suppliers. In this paper, supplier selection with order allocation problem is addressed for strategic items with respect to the materials’ characteristics as well as what has been mostly considered in the literature, suppliers’ characteristics. The proposed model comprises an analytic network process (ANP) sub-model to qualify suppliers and filter-suitable candidates among the available ones. Additionally, the ANP sub-model is applied to evaluate suppliers regarding their qualitative attributes which cannot be modeled with mathematical tools properly. Moreover, a mixed-integer non-linear sub-model is presented to simultaneously allocate order quantities to the chosen suppliers. The model is customized to the strategic items by introducing supplier switching cost which is a notable cost component for products. Finally, experimental results and sensitivity analyses are presented to validate the proposed model.     

Analyzing the interaction of critical factors of supplier development using Interpretive Structural Modeling—an empirical study

In order to compete effectively in the global market, a company must have a network of competent suppliers. To create and maintain such a network and to improve various capabilities that are necessary for the buying organization to meet its increasing competitive challenges, the buying firms may engage in supplier development. To improve the supplier capabilities, the buying organizations have to consider various supplier development factors such as supplier base, communication with suppliers, direct involvement of suppliers, etc. Their significance and the role in supplier development process are also to be considered. These factors not only affect the supplier development process but also influence each other. However, the methodologies used in supplier development literature analyze the factors independently. This paper attempts to overcome the above, by analyzing the interrelationship between the supplier development factors. The Interpretive Structural Modeling (ISM) approach has employed to develop the structural relationship among supplier development factors and also tried to define the levels of different factors based on their driver/dependence power and their mutual relationships. Finally, the ISM result is compared with empirical study and a case study.     

Selecting technology for investment in flexible manufacturing

Flexible manufacturing (FM) has progressed to the stage where the concepts and the available technology are well established and proven. Investment in FM can be very profitable, but must be aimed at achieving clearly defined objectives. This article describes the scope of FM and shows that the required technical specification is determined by the nature of the potential benefits.The ability to quantify all the potential benefits of FM in financial terms means that investment should not be made without a financial evaluation, but should be treated as any other investment decision. Advice is given to show companies how to identify the companywide benefits of FM and to relate these to the required technology before selecting potential suppliers.     

Supply coordination based on bonus policy in assembly under uncertain delivery time

The existing research of supply coordination under uncertain delivery time mainly focuses on the collaboration between the supplier and the manufacturer, which aim at minimizing the total cost of each side and finding comparative optimal solutions under decentralized decision. In the supply coordination, the collaboration between suppliers in assembly system is usually not considered. As a result, the manufacturer’s production is often delayed due to mismatching delivery of components between suppliers. Therefore, to ensure supply coordination in assembly system, collaboration between suppliers should be taken into consideration. In this paper, an assembly system with two suppliers and one manufacturer under uncertain delivery time is considered. The model is established and optimal solution is given under decentralized decision. Furthermore, the cost functions of two suppliers are both convex, and a unique Nash equilibrium exists between two suppliers. Then the optimal decision under supply coordination is analyzed, which is regarded as a benchmark for supply coordination. Additionally, the total cost of the assembly system is jointly convex in agreed delivery time. To achieve supply coordination a bonus policy is explored in the assembly system under uncertain delivery time, and the total cost under bonus policy must be lower than under decentralized decision. Finally the numerical and sensitivity analysis shows the cost of assembly system under bonus policy equals that under supply coordination, and the cost of each side in assembly system under bonus policy is lower compared to that under decentralized decision. The proposed research minimizes the total cost of each side with bonus policy in assembly system, ensures the supply coordination between suppliers and the manufacturer, and improves the competiveness of the whole supply chain.     

Contributing to business improvement

Performance measurement systems need to be designed holistically, ensuring they are in line with, and represent, business objectives. The authors challenge some commonly held assumptions about business performance measures. To start one thinking about one's business planning, scheduling and control (PSC) process in a new way, we have provided a PSC process health-check. This is a basic checklist to provide one with pointers to begin to uncover the hidden potential in one's PSC process and to recognise sources for potential improvement. To support this, we also outline a number of modelling tools that will help to visualise and represent the workings of your business PSC process     

Minimizing transportation cost of a joint inventory location model using modified adaptive differential evolution algorithm

Transportation is a key issue in supply chain management and is a major concern for a company. This paper considers a joint-location inventory problem involving a set of suppliers producing different products and a set of retailers where some retailers are treated as distribution centers (DCs). The problem is to determine which retailers to be assigned as DCs, which retailers to receive direct shipments, how much of the retailer’s demand to allocate to the DCs, and how much of the DC’s demand is to be met by different suppliers. The problem is formulated as a mixed integer model and it has been solved through an adaptive differential evolution algorithm known as modified J. Adaptive Differential Evolution. The solutions obtained are compared with that of simple genetic algorithm. This paper also shows that the proposed model is robust in nature and offers near-optimal results for different distributions. The sum of the cost of establishing some retailers as DCs and the total transportation cost incurred in shipping products from the suppliers to the retailers via DCs(for some retailers) or directly (for the other retailers) is also compared with the total transportation cost incurred when all the products are shipped directly from the suppliers to the retailers.     

Intranet/Extranet/Internet-Based Quality Information Management System in Expanded Enterprises

Because of e-commerce and the global economy, industries are challenged by world markets and modern enterprise morphologies, such as agile supply chains, expanded companies and virtual enterprises. Enterprises are thinking more and more about the market, customers and suppliers. Product quality is judged by the global market and the customers in the world village, and not only by the domestic market and customers. Enterprise quality assurance systems not only cover internal functional departments in an enterprise, but are expanding to external parties, such as customers, partners and suppliers, so, an expanded enterprise’s core competencies or leadership capabilities in quality assurance have to be strengthened by the complementary capabilities of partners. The traditional quality assurance technologies have to be innovated. It is reasonable that "customer focus" and "mutually beneficialsupplier relationships" blend into the core concepts of a quality management philosophy. As tools used by enterprises to support quality management, quality information management systems (QIMS) have to capture quality information from both internal and external parties, and to facilitate the communication environment, in order to share quality information among enterprises, customers and suppliers. Because of this, it is impossible for a traditional quality information management system based on the Intranet to meet these needs. In this paper, a model of the expanded enterprise is extended. A concept model and a functional model of the quality information management system based on Internet/Extranet/Intranet (IEI-QIS) are proposed. The system is able to integrate quality information from the enterprise, product customers and suppliers, and serves as a powerful tool to benefit the quality management of modern enterprises. A browser/server-based and the three-layer system architecture of IEI-QIS are also investigated. ID="A1"Correspondance and offprint requests to: Tang Xiaoqing, School of Mechanical Engineering and Automation, Beijing University of Aeronautics and Astronautics, Beijing 100083, PR China. E-mail: tanghuan@public.fhnet.cn.net     

Integrated design and assembly planning

Europe's consumer goods industries are characterized by a high share of assembly cost in the total product costs (up to 40%). Product and assembly costs are mainly determined at the design stage in terms of materials, product structure, geometry, tolerances, and other product and design features. The Integrated Design and Assembly Planning (IDAP) project was generated to help designers and planners create solutions which were right-first-time. Support will be given by methodologies and computer aided tools such as the DFA methodology, but their organizational view may be even more important. This paper outlines the specification work for IDAP, which is based on a market study and a conceptual definition, and includes the Functional, Technical/Methodical Reference, Hardware/Software Reference, and the Organization Reference Models, and the development of a user interface prototype.     

Analysis: offshoring - home sweet home

Offshoring can be defined as relocation of business processes, including high-wage production and manufacturing jobs, to a lower cost location, usually overseas. To be able to adopt this principle, companies must be efficient enough to produce its goods close to the place where they are in demand, even when labour cost are high. They should also look carefully at their economics before they send production overseas. In this paper, this principle is illustrated taking the state of California as an example.     

Modularity Technology in Manufacturing: Taxonomy and Issues

The idea of modularity has gained acceptance because of so-called mass customisation and the need for shorter development time in manufacturing. Modularity is a general concept, and many engineering problems can be generalised under the umbrella of modularity. Numerous studies have been carried out on modularity-relevant issues; however, systematic classification has not been discussed for modularity in terms of its applications and methodologies for developing modularity in systems. This paper presents a taxonomy on modularity applications, research issues, and design methodologies. It provides a general framework for further systematic development of modularity in systems. General solutions to identified problems which should be studied in future are also discussed.       

产品设计质量控制方法研究及系统开发

系统地分析了现代产品设计质量的形成过程，对产品设计质量控制与保证的内容和方法进行了分析与研究。提出了集支持工具、过程方法和质量信息管理于一体的面向产品设计过程的设计质量控制模型，阐述了保证产品设计质量的策略。基于此模型构建了产品设计过程质量控制与保证系统的总体框架模型，并针对框架系统的实现作了介绍。     

风电整机厂商的供应商评估与选择

供应商评估与选择是风电整机制造厂商供应链管理的关键环节,对提高风力发电机组的质量,缩减制造成本起着不容忽视的作用。当今风电行业竞争的焦点正逐步由企业间的竞争转化供应链之间的竞争,为了提高零部件供应商的可靠性,整机制造厂商需要对零部件供应商进行科学、客观地评估,以便做出正确的供应商选择决策。     

面向制造业的第三方物流企业服务能力评价研究

随着全球化进程的加快,很多制造企业都把改善物流看作是企业降低费用和提高服务优势的关键,希望把其物流活动外包给专业的物流服务供应商。如何选择物流服务供应商,对物流服务供应商的服务能力如何进行评价是一个值得研究的课题。面向制造业,就第三方物流企业服务能力的评价体系进行研究,利用层次分析法构建了一种服务能力评价模型,可为制造业合理选择物流服务商提供理论依据,通过评价模型物流服务企业可以发现影响服务能力的关键要素,进而通过对这些要素的调控来改进企业的服务能力。     

Experimental Study of Wear Behaviour of Hot Forging Tool Steels Under Dry Conditions: 40CrMoV13 Against C35E

The dimensions and quality of forged-steel components are significantly affected by the action of friction and wear. The thermal and mechanical operating conditions of hot forging tools provoke serious degradation, such as oxidative wear, thermal fatigue, plastic damage and mechanical cracking. This slowly causes the tools to lose their original geometry and thus they must be either reformed or discarded [1]. The knowledge and control of this damage is essential and must be taken into consideration, both in die design and in the choice of tool material and the type of surface conditioning. The degradation has direct effects on the lifespan of the tools, and consequently on the cost of the components. This paper deals with the sliding wear behaviour of 40CrMoV13 Steel against C35E in the 700 to 850 °C temperature range under ambient conditions. This steel is used frequently as hot forging die material. This study focuses on the effect of the test temperature and the role of the oxide scales. The purpose of these experiments was to obtain tribological data (friction coefficient, wear rate, etc.), in order to include it in numerical simulations of damage to hot forging tools for the purpose of optimizing the tools' lifespan.     

Particle Swarm Optimization Technique Based Design of Pi Controller for a Real-Time Non-Linear Process

Abstract

The increasing complexity of modern control systems has emphasized the idea of applying new approaches in order to solve design problems for different control engineering applications. Proportional-Integral-Derivative (PID) control schemes have been widely used in most of process control systems represented by chemical processes for a long time. However, a very important problem is how to determine or tune the PID parameters, because these parameters have a great influence on the stability and the performance of the control system. Computational intelligence (CI), which has caught the eyes of researchers due to its simplicity, low computational cost, and good performance, makes it a possible choice for tuning of PID controllers, to increase their performance. This paper discusses, in detail, the Particle Swarm Optimization (PSO) algorithm, a CI technique, and its implementation in PID tuning for a controller of a real time process. Compared to other conventional PID tuning methods, the result shows that better performance can be achieved with the proposed method. The ability of the designed controller, in terms of tracking set point, is also compared and simulation results are shown.     

信息不对称的折扣区间研究

为研究不完全合作情况下供需双方的折扣问题,运用运筹学理论,建立基于供应商的非线性规划模型,提出了供需双方都认可的折扣区间并进行了讨论,结果表明:供应商允许折扣上限不受信息对称与否的影响;如果供应商对采购商成本估计偏大,则折扣空间偏小,对供应商制定折扣策略不利;反之,如果供应商对采购商成本估计偏小,则放大了折扣区间范围,容易使谈判进入僵局.结论可以作为信息不对称情况下供应商确定折扣策略的依据.