Developing a reconfigurability index using multi-attribute utility theory

Reconfigurable manufacturing systems (RMSs) have been acknowledged as a promising means of providing manufacturing companies with the required production capacities and capabilities. This is accomplished through reconfiguring the system elements over the time for a diverse set of individualised products often required in small quantities and with short delivery lead time. This necessitates the requirement of mapping the manufacturing system capabilities and other characteristics by developing a suitable index. In this paper an index has been developed to measure the reconfigurability of RMSs keeping in mind their various core characteristics such as modularity, scalability, convertibility and diagnosability. These characteristics have been mapped together using multi-attribute utility theory. One could easily use this index to find the reconfigurability of a system possessing different characteristics. An illustrative example is provided to reveal the application of the proposed methodology on a given system. Insight gained would be of much interest to the decision makers managing the complexity of a manufacturing system for diversified products.     

灵捷生产系统

我国企业面临变化和不确定的市场环境，要求建立具有快速性、多品种适应性和可重组性三层特性的灵捷生产系统，以抓住市场机遇。本文针对某小型企业的具体情况，设计了一种基于自治单元的混合生产系统。这个方案交少的层次，统一管理生产部门和生产后勤部门；综合动用拉式与推式方法进行生产计划与控制。论文讨论了单元内部的组织机制和可重组性的实现要素。本文对我国中小企业生产重构有一定参考价值。     

Design of smart connected manufacturing resources to enable changeability,reconfigurability and total-cost-of-ownership models in the factory-of-the-future

The fourth industrial revolution requires higher capabilities of changeability and reconfigurability (C–R) of the future factories (FoF), as well as a higher focus on business models that are based on total-cost-of-ownership (TCO) paradigm. Up to date, there are little scientific contributions to deploy C–R into TCO models, as well as to systematic plan and design manufacturing resources such as to facilitate FoF ecosystem. In order to address this issue, this paper introduces research results that show how to deploy C–R, connectivity, smartness and TCO requirements into the technical solutions of manufacturing resources of FoF. Contributions emerging from this research include an index to measure C–R capability of manufacturing resources, a model to assess economic feasibility of a FoF over its lifecycle, as well as a methodology and related tools to design smart connected manufacturing resources with embedded features to facilitate changeability and reconfigurability in a FoF. Theoretical contributions are explained through a case study of a fast reconfigurable robotic manufacturing cell. Preliminary results demonstrate that it is possible to rapid design smart connected manufacturing resources and integrate them into FoF architectures that support convertibility, integrability, modifiability, adaptability, serviceability, scalability, integration of resources from various producers, service clustering and cloud-based services.     

3D Pixel Mechanical Metamaterials

Metamaterials have unprecedented properties that facilitate the development of advanced devices and machines. However, their interconnected building structures limit their applications, especially in the fields that require large deformation, rich programmability and efficient shape‐reconfigurability. To break this limit and exploit more potentialities of metamaterials, an innovative material design strategy is proposed, named mechanical pixel (MP) array design. Similar to a screen that displays images by adjusting the colors of pixels, the metamaterials can form and reconfigure 3D morphologies by tuning the heights (lengths) of the MPs in the array. The strategy is demonstrated in a multistable metamaterial by experimental tests, theoretical analysis, and numerical simulations. Using this strategy, a large macroscopic shear deformation is obtained, and remarkable enhancements in the mechanical programmability, shape‐reconfigurability and adaptability, and reusable shock‐resistance are exhibited. Moreover, mechanical design and property prediction for the metamaterials are both greatly simplified due to the pixelated design. For a piece of the 3D pixel metamaterial with m n‐unit MPs, the number of programmable displacement–force curves increases from n+1 to 2^m?n+1, and the number of stable morphologies grows from n+1 to at least (n+1)^m. This strategy can be used to enhance the merits and further excavate the potential of versatile metamaterials.     

Large-scale systems resilience: A survey and unifying framework

A unifying framework in defining and measuring resilience has been an intense research topic. In this paper, resilience is measured as a function of intrinsic capacities of a system, the effectiveness of recovery, and the extrinsic random shock process. Some existing resilience measures are analyzed as special cases of the proposed unifying measure. Then, we develop a framework in which the key constituents in achieving resilience are identified. Resilience is represented by four key dimensions: reliability, robustness, recovery, and reconfigurability. Finally, some practical and specific strategies are proposed to enhance the resilience of critical infrastructure systems under the proposed framework.     

A new method for guiding process flexibility investment: flexibility fit index

Flexibility enables manufacturing firms to respond efficiently to changes in the environment. Many firms make great efforts to increase their manufacturing flexibility to remain competitive in today's turbulent market. However, it is not true to say that the more flexible the better, because the cost of flexibility investment is high, and the capital for flexibility investment is limited. In this paper, we present a new method to guide process flexibility investment by developing a flexibility fit index. Taking demand changes into account, our method first defines a measure to quantify the requirement level of process flexibility. Then, a flexibility fit index is defined, which specifically identifies where flexibility is insufficient and where flexibility is surplus for a manufacturing system operating in a changing environment. The proposed fit index is objective and dimensionless, and so can be used more universally than previous subjective or non-dimensionless measures proposed in the literature. A set of simulation experiments shows that the proposed method can better guide flexibility investment by indicating the system structure which fits best with a given business situation, and other measures that ignore demand information may lead to over-investment or adding links that bring little benefit.     

Manufacturing strategy,the business environment,and operations performance in small low-tech firms

This paper reports on a ten-year study of ten manufacturing companies in New Zealand. Over the period the firms endured a turbulent environment where they were subject to large changes in exchange rate, and some faced forced changes in products, and markets as a result of changes in ownership and government policy. The paper examines the stability of manufacturing strategies in such an environment, the emphasis placed on improvement initiatives and what impact these decisions had on manufacturing performance. The study uses a multi-case, longitudinal approach. It found the strategy configurations were not stable and many firms moved towards a price-based configuration, contrary to other literature. The more successful firms put greater investments into infrastructural categories of their operations strategy in accordance with the resource-based view. Operations performance indicators showed some improvement on manufacturing costs but other indicators showed no real pattern.     

Cumulative manufacturing capabilities: an extended model and new empirical evidence

There has been intense debate in the manufacturing strategy literature on the way in which firms work on different manufacturing capabilities, with two opposing approaches considered – the trade-off model and the sand cone model. Analysis of these models has essentially been based on study of the links amongst four classic manufacturing capabilities (quality, delivery, flexibility, and cost efficiency) and has obviated the need to consider environmental protection as an important manufacturing capability. This study analyses the theoretical arguments and the prior empirical evidence on the two models, and proposes and tests an extended sand cone model which includes the environmental protection objective alongside the four traditional ones. The research uses structural equation modelling and data from a sample of 274 manufacturers to contribute additional empirical evidence on the existence of cumulative effects amongst manufacturing capabilities. It is observed that the predominant strategic model in these firms is one of multiple, non-incompatible capabilities with cumulative effects according to the following sequence: quality, delivery, flexibility, environmental protection, and cost efficiency.     

A participatory systems design methodology for changeable manufacturing systems

The ability to adapt to changes in products, processes and technologies is a key competitive factor. Changeable manufacturing paradigms have emerged to address this need, but the industrial implementation remains challenging. In this paper, a participatory design methodology for changeable manufacturing systems is proposed, including requirements specification, selection of appropriate manufacturing paradigm and suitable physical and logical enablers. The methodology supports companies in determining the potential for and mechanisms of transitioning towards changeable manufacturing systems, based on knowledge of products, production, technologies and facilities. The developed methodology is applicable to both new and existing manufacturing systems. It is demonstrated in two industrial cases which highlight its applicability and differences in the appropriate recommended manufacturing systems transition towards changeability as a result of differences in manufacturing characteristics, change requirements and enablers.     

Innovation Strategies: Are Knowledge-Intensive Business Services Just Another Source of Information?

The objective of this paper is to contribute to the empirical literature on innovation strategies and services, by analysing the use of knowledge-intensive services, and their impact on innovation, in manufacturing firms. The analysis is carried out at the firm level, on the basis of a survey covering 804 manufacturing establishments in the Province of Quebec (Canada). We investigate the extent to which existing internal capabilities and their interaction with external sources of knowledge, in particular the use of knowledge-intensive business services (KIBS), affect the level of innovativeness of manufacturing firms. Then we examine the extent to which different innovation strategies, and the way KIBS are integrated into these, are associated with innovation. We show that manufacturing firms adopt a variety of innovation strategies, none of which preclude innovation, even introverted strategies whereby firms interact little with outside agents. However, those strategies that incorporate KIBS have a considerably greater chance of leading to innovation.     

Transaction attributes and buyer-supplier relationships in AMT acquisition and implementation: the case of Malaysia

This paper explores how transaction attributes of technology affect differences in the relationship between technology buyers and suppliers. It also examines the impact on performance of different patterns of relationship between technology buyers and suppliers. Data obtained from 147 manufacturing firms in Malaysia are used to test several hypotheses, which were derived from a review of the literature on technology, transaction cost theory and buyer–supplier relationships (BSR). The research results indicate that the higher the level of technological complexity, specificity and uncertainty, the more firms are likely to engage in a closer relationship with technology suppliers. Even though the majority of firms reported improvements in their performance, results indicate that firms demonstrating a closer relationship with technology suppliers are more likely to achieve higher levels of performance than those that do not. It is also shown that with high levels of transaction attribute, implementation performance suffers more when firms have weak relationships with technology suppliers than with moderate and low levels of transaction attribute.     

Flexibility trade-offs in a random flexible manufacturing system: A simulation study

Flexible manufacturing systems (FMSs) are allowing firms to take advantage of diversified, low volume production of products with short life-cycles. The flexibility provided by an FMS improves the ability of a system to respond to change. Several types of manufacturing flexibility (M F) have been identified in the literature. Ideally, it is desirable to provide an FMS with all types of flexibility. However, there is a general consensus on the discordant nature of some of the flexibilities. This makes it imperative for management to recognize which flexibilities it deems critical to the manufacturing strategy of the firm. This allows the management to trade-off some of the less important flexibilities for the more important ones, as the need arises.

This study is an attempt toward an empirical examination of the flexibility trade-offs in an FMS. By using computer simulation, we study the flexibility tradeoffs in the stochastic environment of a random FMS. Various configurations of the FMS are simulated under the influence of a variety of loading and dispatching strategies. The results show that there is a trade-off among the various flexibility types under most circumstances. However, some scenarios illustrate that an appropriate combination of the variables like scheduling environment, product variety, and system configuration, can be effective in containing these trade-offs. In other cases, it is seen that the FMS can accommodate more than one flexibility type simultaneously.     

Optimal supply contract selection

Selection of supply contracts is a critical decision faced by manufacturing firms in a variety of industries. Manufacturing firms often have the option of selecting from several types of supply contracts that include long-term, medium-term, and short-term contracts. While extant literature has stressed the importance of such contracts, few methodologies have been proposed for optimally selecting contracts under various business conditions. To this end, this paper proposes a methodology for optimal contract selection based on a mixed-integer programming approach. We present specific insights to manufacturing managers on choosing the right contracts in the presence of market price uncertainty, supplier discounts, investment costs, and supplier capacity restrictions.     

Dynamic restructuring process for self-reconfiguration in the fractal manufacturing system

To meet the rapidly changing customer needs in the manufacturing environment, future manufacturing systems must be dynamically and flexibly reconfigured. The fractal manufacturing system (FrMS) is one of the new manufacturing paradigms that can meet such requirements. The basic component of the FrMS is referred to as a fractal. Consisting of self-similar agents, each fractal autonomously cooperates and negotiates with others to coordinate its tasks. Dynamic restructuring process (DRP) supports reorganization of the system configurations so that the FrMS can be adapted to dynamically changing environments. Although traditional approaches have endeavoured to demonstrate reconfigurability of a manufacturing system, they are not accurate enough to meet the requirements of circumstances such as high-level autonomy in reconfiguring the system architecture. In this paper, therefore, the DRP, which embodies self-reconfigurability of a system, is proposed focusing on the FrMS. To check the effectiveness of the DRP, we have developed the FrMS test bed and conducted the experimentation on the DRP. A simulation study has been conducted to show the effectiveness of the DRP under an illustrative situation.     

Relative importance of contingency variables for advanced manufacturing technology

The academic literature on manufacturing technology was reviewed to identify key contingency variables that can moderate the influence of advanced manufacturing technologies on manufacturing performance. Using this literature as a basis, this research proposes an ordering of relative importance of individual contingency variables among a set of contingency variables that influence the advanced manufacturing technologies–manufacturing performance relationship. Plant level data from a large multi-industry sample of firms are analysed, using regression and Chow tests, to confirm the hypothesized ordering among the contingency variables. The findings indicate that lean manufacturing and work organization practices are the primary contingency variables that affect the advanced manufacturing technologies–manufacturing performance relationship. The implications of the results are discussed in the light of past findings and their impact on practice.     

Intangible investments and innovation propensity: Evidence from the Innobarometer 2013

This paper investigates the innovation impact of intangible investments. Drawing on the resource-based view of the firm, we argue that through intangible investments, companies acquire knowledge assets that increase their innovativeness. However, a greater innovation impact is expected from investing more in technological intangibles rather than in intangibles overall, and a greater one from using internal versus external resources. Through a new survey on a large sample of firms in 36 countries, accounting for different intangibles and addressing their endogeneity through proper instruments, these hypotheses are partially confirmed. Developing intangibles internally is actually the most innovation-impacting aspect, but not in manufacturing. Instead, by controlling for this choice and for that of investing in technological intangibles, the intensity of intangible resources is significant for innovation in manufacturing only. Policy/strategic implications about the need of readdressing the boost to intangible investments for the sake of innovation in Europe are drawn accordingly.     

Determinants of mobile supply chain management system diffusion: a structural equation analysis of manufacturing firms

Mobile supply chain management (SCM) is gaining recognition as a major source of cost reduction and supply chain performance improvement. The current literature related to mobile SCM needs to be extended further in order to provide insights into how manufacturing firms can implement mobile SCM successfully. Specifically, there is a need to provide empirical and systematic analysis of the variables that can explain the various stages of mobile SCM diffusion. A review of recent literature suggests that existing e-supply chain technology adoption literature is not strongly grounded in theory. A theoretical model with six hypotheses was proposed based on the technology–organisation–environment (TOE) framework and innovation diffusion theory (IDT). This study draws its survey responses from a group of manufacturing firms in order to investigate the factors that affect the diffusion of mobile SCM. The results show that the variables derived from TOE and IDT can explain mobile SCM diffusion well. However, interorganisational relationships (IORs) play a crucial role in determining the success of mobile SCM routinisation. This is one of the first known empirical studies on the factors influencing the diffusion of mobile SCM. The results of this study will help decision makers better understand the implementation process of mobile SCM and formulate strategies for successful diffusion of mobile SCM.     

Improving the implementation effectiveness of cellular manufacturing: a comprehensive framework for practitioners

In today's competitive environment cellular manufacturing (CM) is a well-known strategy in improving manufacturing performance. To obtain the full benefits that CM has to offer successful implementation is a critical factor. Evidence indicates that firms converting to CM often struggle with implementation and achieve results that are less than anticipated. A comprehensive review of implementation literature was undertaken and a multi-phase model developed and evaluated through a case study. The framework recognizes the importance of both technical and human aspects of CM and provides practitioners with a better understanding of the various phases in the implementation process, including the many activities and issues which need to be considered for each step. In the case study company, implementation of CM not only provided many of the benefits associated with this form of manufacturing but also allowed operators to become a value-adding link in respect to process and product improvement and new product development.     

Developing due dates in an engineer-to-order engineering environment

Engineer-to-order (ETO) firms comprise approximately one-fourth of all North American manufacturing, and the number is growing. These firms produce complex one-of-a-kind products and, like most firms, desire shorter lead times as a key component to cost competitiveness. In ETO firms, the engineering process is the largest controllable consumer of lead time using one-half of the total. Hence, one critical process is to accurately determine the engineering due date. However, unlike other manufacturing models such as Make to Stock or Make to Order, the design for an ETO product is not realised until after the engineering process has been completed; therefore, the only information available does not include data normally required by most due date-setting algorithms. The question then becomes how does one accurately determine the engineering due date in a complex transactional process when the job has not even been designed yet? This paper investigates this issue in the context of the engineering process within the ETO model. Analytical research is conducted in conjunction with multiple ETO firms. Several common factors are identified which drive complexity in the ETO engineering environment. A new framework and algorithm are then presented for using these factors to predict ETO engineering flow times in the absence of normally assumed information. Comparison of the performance of this new algorithm with that reported in the literature shows it to be a statistically significant improvement.     

The interaction mode and geographic scope of firms’ technology alliances: implications of balancing exploration and exploitation in R&D

This paper proposes that the interaction mode, i.e. interactive and iterative, and geographic scope, i.e. domestic and international, of technology alliances generate sources of exploration and exploitation for firms. An implication of this idea is that firms can use these sources for balancing its internal focus on exploratory and exploitative research and development activities (R&D). Then, the paper suggests that the use of this balancing strategy has positive effects on a firm’s innovative performance. Using panel data based on Spanish manufacturing companies for the period 2004–2012, the empirical results confirm that firms balancing their internal exploration or exploitation in R&D with sources of external exploitation or exploration in their technology alliances are the firms with better prospects to produce innovation streams. Implications for the literature on complementarities in innovation, ambidexterity and R&D alliance formation are derived from the analysis.