Application of interpretive structural modelling and structural equation modelling for analysis of sustainable manufacturing factors in Indian automotive component sector

Sustainable manufacturing practices are essential for automotive component manufacturing organisations to ensure competitive advantage. The interrelation between sustainability enablers' namely economic prosperity, environment well-being, social well-being, performance management and research and development need to be analysed for deriving practical insights. Theoretical model development of enablers using interpretive structural modelling (ISM) has been statistically verified using measurement models and structural model of partial least square, structural equation modelling (SEM). In this context, this article presents a combined ISM and SEM approach for building the models with the help of experts for automotive component manufacturing organisation. The measurement and structural model are constructed based on survey among 70 practitioners from automotive component manufacturing organisations in Southern India. The research hypotheses have been formulated to verify the relationship and are analysed. The results of the study indicated that the usage of ISM is very powerful to establish structural relationship between sustainable manufacturing enablers and there exist structural relationship between the enablers.     

Reasons for change propagation: a case study in an automotive OEM

This paper focuses on identifying the reasons for change propagation during the production phase of the product life cycle. Unlike the traditional change propagation study where the focus is within the product, this study is focused to understand the propagation effects of change on other functional silos in the manufacturing firm. First, the reasons for the changes are identified using archival analysis through which it is found that 77.0?% of changes are due to internal reasons while 23.0?% are external. Second, these changes are distinguished into genesis, and propagated changes using a matrix-based modeling approach from which the reasons for propagation are identified. It is inferred that 32.4?% of the total changes are due to propagated changes such as inventory issues, manufacturing issues, and design error rectification. The majority of reasons for these propagated changes include document error rectification such as BOM error, drawing error, incorrect introduction date in engineering change note, and design error rectification such as design limitations. The findings indicate nearly one-third of time spent by the engineers can be reduced by developing appropriate controls during the change release process.     

Application of analytical network process for the evaluation of sustainable business practices in an Indian relays manufacturing organization

Sustainable business strategies or technologies determine the market dynamism so as to withstand competitiveness. The evaluation of such strategies is a multi-criteria decision making (MCDM) problem. To deal with such problems, analytical hierarchy process (AHP) and analytical network process (ANP) could be deployed. AHP considers the distribution of goal amongst the elements being compared and judges the element which has the greater influence on the goal. In order to overcome the drawbacks with AHP, ANP could be used which is a holistic approach in which all attributes and alternatives involved are connected in a network system that accepts dependencies. Priorities which are established in ANP are the same way as they are in the AHP using pair wise comparisons and judgments. ANP is the most comprehensive framework for the analysis of societal, governmental and corporate decisions that are available today to the decision-maker. It is a process that allows one to include all the factors and criteria, tangible and intangible that has an effect on making a best decision. The paper reports a research study that is focused on the selection of the best alternative from the perspective of sustainability for an Indian relays manufacturing organization.     

Web-services-based supply-chain-control logic: an automotive case study

This paper discusses the design and implementation of a decision-support software system based on web services, capable of modelling the supply chain and querying the supply-chain partners to provide information, regarding the availability of parts, required for the production of a highly customisable product. Furthermore, it describes the details of a software system for the evaluation of time and financial feasibility of acquiring the necessary parts in order for the customised product to be built. The feasibility of implementing this approach is demonstrated in a typical automotive case study. The system is capable of simulating the customer's orders impact on the supply-chain operation, while it utilises the Web services technology for facilitating the supply-chain control logic.     

Analysis of manufacturing effects on fatigue failure of an automotive component using finite element methods

In this study, the fatigue life of an automotive suspension component was analysed using finite element methods with regard to stamping and welding effects. Because automotive suspension components are produced by forming and welding sheet metal, there are various effects on the final product, such as uneven thickness distribution, residual stresses and weld notches. Manufacturing effects may change the mechanical performance of the automotive components; therefore, it is desirable to consider these effects in the early design stage. Residual stresses due to work hardening and thermal deformation were investigated through process simulation. The redistribution and relaxation of residual stresses in a component were investigated in fatigue life analysis under a cyclic loading condition. Various equivalent relaxation curves were investigated and one was selected after comparisons with test results. The fatigue simulation results were compared to the test results; a good correlation between the two was achieved for the residual stress effects in terms of life cycles and failure locations. The simulation results also show that welding produces more detrimental effects than stamping with regard to the fatigue life of a component.     

r-FrMS: a relation-driven fractal organisation for distributed manufacturing systems

Up-to-date market dynamics and decentralisation have brought about the need of flexible and robust organisational structures for manufacturing resources. To meet the need of such an environment, the manufacturing system should be equipped with an open, reconfigurable and scalable organisational structure. This paper proposes a novel organisational model, referred to as a relation-driven fractal organisation, to meet the requirements. The proposed model applies the concept of a fractal to its organisational structure and adopts a relational pattern between composing entities as a basic building block for organising. In this paper, the existing fractal-like systems involved in manufacturing systems are investigated, and the fractal organisation is derived as their super-ordinate concept. Then, r-FrMS, a relation-driven fractal organisation applied into distributed manufacturing systems, is proposed along with its organising mechanism which adopts employment relations between manufacturing resources as its organising principle.     

Kaizen costing for lean manufacturing: a case study

In the past decade due to increasing global competition US firms have radically changed their manufacturing practices to improve their competitiveness. In pursuing this goal they have adopted a number of advanced techniques, such as just-in-time, total quality management, lean manufacturing, flexible manufacturing systems, process improvement, and design for manufacturability, to name a few. The objectives of all these programmes have been to reduce cost, improve quality, reduce cycle time, and increase flexibility on the factory floor. Support systems such as finance and cost management, however, have generally not kept pace with the level of corresponding operational changes being implemented. This paper presents a case study of kaizen costing as practised by Boeing Commercial Airplane Company, IRC Division. The purpose of this study is to describe a method used to set kaizen costs which will provide relevant cost data to support lean production decisions that would be useful to practitioners.     

Human performance modelling as an aid in the process of manufacturing system design: A pilot study

Manufacturing system design is an ongoing activity within industry. Modelling tools based on Discrete Event Simulation are often used by practitioners during this design cycle. However, such tools do not adequately model the behaviour of 'direct' workers in manufacturing environments. There is an important need to expand the capability of modelling to include the relationships between human centred factors (demography, attitudes, beliefs, etc), their working environment (physical and organizational), and their subsequent performance in terms of productive routines. Therefore, this paper describes research that has formed a pilot modelling methodology that is an important first step in providing such a capability.     

Object-oriented modelling of manufacturing information system for collaborative design

Object-oriented technology has been widely acclaimed as offering a revolution in computing that is resolving a myriad of problems inherent in developing and managing organisational information processing capabilities. Although its foundations arose in computer programming languages, object-oriented technology has implications for a wide range of business computing activities including: programming, analysis and design, information management, and information sharing. The problematic issues in the development of manufacturing software systems are related to the various characteristics of manufacturing systems, which are wide, dynamic and complex. Design for manufacturing (DFM) is the integrated practice of designing components while considering their manufacturability, and its benefits are widely acknowledged in the industry. A model has been developed using object oriented technology, after analysing the fundamental elements necessary for modelling manufacturing and process planning framework used in collaborative design and manufacturing in machine tool manufacturing. The main components of this model are: process planning model (PPM), manufacturing activity model (MAM), manufacturing resource model (MRM) and manufacturing cost and time model. We are using ontologies in conjunction with specific conceptual models, which can contribute to improve the interoperability between these models. The performance of this model is shown by means of one real world case. The developed manufacturing information based design tool integrated with an intelligence design system can be used for collaborative design and manufacturing, which will support machine tool designers’ to achieve cost effective and timely design.     

Application of interpretive structural modelling for analysing the factors influencing integrated lean sustainable system

The modern manufacturing systems recognize the importance of adopting lean and sustainable manufacturing principles. Especially, Indian automotive component manufacturing organizations are interested in adopting the integrated lean sustainable manufacturing system. An appropriate methodology is required for enabling the organizations to identify the dominant factors. In this context, this article presents the interpretive structural modelling approach for identifying the mutual relationship among factors influencing the integrated lean sustainable manufacturing system. From the literature study and survey conducted among Indian automotive component manufacturing organizations, 25 influencing factors have been identified. Based on the study, top-management commitment in adopting integrated lean sustainable manufacturing and environmental knowledge occupy the bottom level of model which shows that it has more driving power. Efforts are being taken to implement the factors in the surveyed organizations.     

Production planning in automotive powertrain plants: a case study

Based on a real case study from the automotive industry, this paper deals with production planning in powertrain plants. We present an overview of the production planning process and propose a mixed integer linear programme to determine the production quantities of each product over a planning horizon of several days. Then, using real data of an engine assembly line, we simulate the performance obtained through the proposed model within a rolling horizon planning process. We perform multiple tests in order to evaluate the impact of two parameters involved in this process: planning frequency and frozen horizon length. Furthermore, in order to illustrate the value of improving coordination between engine plants and their customers, we evaluate the impact of the quality of demand information (orders and forecasts). We analyse the simulation results and provide insights and recommendations in order to achieve a good trade-off between service level, inventory, and planning stability.     

Application of fuzzy quality function deployment for sustainable design of consumer electronics products: a case study

With a steep increase in the demand for consumer electronics products, the contemporary manufacturers are committed toward sustainable development of such products. There exists a scope for developing a methodology for enabling sustainable development of consumer electronics products. In this context, fuzzy quality function deployment (QFD) approach has been presented in this article in order to prioritize relevant customer requirements, sustainability parameters and sustainability initiatives. Key influential parameters for sustainable development of consumer electronics products have been identified from the literature. In the first phase of fuzzy QFD, parameters influencing sustainable development have been prioritized in accordance with customer requirements. In the second phase, environmental design initiatives have been prioritized based on critical sustainability parameters. From phase I of fuzzy QFD, ‘reduction in environmental release’ has been found as the most significant sustainability parameter with a crisp value of 22.83, and from phase II, environmental impact assessment is proved to be the significant design method with a crisp value of 20.40. The methodology would provide a comprehensive understanding to practitioners on the interrelationships among customer requirements, sustainability parameters and environmentally benign initiatives for development of consumer electronic products. The generic model developed can be applied to most of the consumer electronics product     

Making a case for sustainable building materials to promote carbon neutrality in Indian scenario

Clean Technologies and Environmental Policy - Construction industry adds more than 35 percent of global emissions through the entire lifecycle procedure of the structure. Every stage of...     

Implications of form postponement to manufacturing: a case study

Postponement is an approach that helps to deliver more responsive supply chains. Form postponement involves the delay of final manufacturing until a customer order is received and is commonly regarded as an approach to mass customization. However, while much is written in the literature about the benefits and strategic impact of form postponement, little is still known about its application. This paper addresses how form postponement was applied in terms of its operational implications within a manufacturing facility through a retrospective study that tracked implementation of form postponement in a manufacturer of specialist high-voltage cabling equipment, called here ‘ElectriCo’. The operational measures for products selected for form postponement were compared with those for products that continued to be made under make-to-order and make-to-stock regimes. Propositions were tested that addressed the operational implications of form postponement within the manufacturing facility, the impact of form postponement on selected performance metrics, and the demand profile for which form postponement was the preferred regime. Multiple data collection methods were used whereby documentary, archival and database evidence were used to measure operational characteristics across a broad front. The findings show that form postponement improved responsiveness but did not necessarily improve delivery reliability. The extent to which the order lead time can be reduced is dependent not only on the responsiveness of the postponed process, but also crucially on the responsiveness of the planning system. It was found that the problem of adapting the manufacturing planning and production scheduling systems at ElectriCo had been underestimated. This and other problems subsequently undermined the form postponement application and led to its eventual abandonment. The authors are undertaking further research of form postponement applications in different production contexts to provide further evidence for its operational implications.     

Applying Value Stream Mapping to eliminate waste: a case study of an original equipment manufacturer for the automotive industry

Since its beginning, lean manufacturing has built a worldwide reputation based on results related to production improvement and cost reduction in several companies. This management philosophy focuses on customer value creation through the elimination of production wastes. Lean methods and techniques have spread their scope from the automotive industry to a wide range of industries and services. This article presents a case study that describes the use of the lean tool value stream mapping in the production process of automotive parts for a major automotive company. At the beginning of the project, relevant data from the process were collected and analysed. Subsequently, the initial process was mapped, the related wastes were identified, and then future processes were mapped and financial results were estimated. The proposals were presented on kaizen meetings, the action plan was discussed and the decision regarding which option to choose was taken. Consequently, the Cycle Time and the level of the workforce were reduced, the process was improved and savings were obtained.     

Operation allocation and materials-handling system selection in a flexible manufacturing system: A sequential modelling approach

Materials-handling systems are an integrating component of manufacturing operations and as such must be considered within a common framework in manufacturing systems design. This work proposes a first approach to the simultaneous consideration of the operation allocation and the materials-handling system selection problems in a flexible manufacturing system. The objective of the operation allocation model is to select a group of machines where the operations of the part types will be performed and then to assign those operations to the selected machines. The operation allocation model interfaces with the materials-handling system selection model by providing input data in the form of the manufacturing operations to be performed at each machining centre. The selection of the materials-handling system is centred on the matching of the parts visiting a machining centre to perform a manufacturing operation and the abilities of the handling equipment to perform the required materials handling functions of those part types. The objective is to select an optimal group of materials-handling equipment to be assigned to a cell.     

A material allocation scheme for optical fibre cable manufacturing: a case study

Optical fibre cable manufacturing is a multistep process that combines individual fibres into colour-coded buffer tubes. These tubes are grouped together to make cables in which individual fibres are protected from external loads and environmental factors. This assembly process has a tree structure in which components are progressively combined into a finished cable. The main component, optical fibre, is held in inventory on spools in varying lengths and in both pre-coloured and natural states. Orders are received for lengths of finished cable. Since the glass fibre is the highest cost component of the cable, the allocation of fibre inventory to orders should be accomplished so that fibre scrap is minimized. In this paper a heuristic procedure for minimizing glass fibre scrap is presented. Computational results are given.     

Application of a systematic design methodology: an engineering case study

The basic steps of a design process have been reviewed and applied to seek an optimum solution for an industrial design problem. The problem was about a mechanical swivel-joint in a sea-current-metering system for underwater marine use. It was expensive ($200) and not functioning properly because of rattling and high friction between parts. The objective was to design another joint of better performance and lower cost, if possible. Ten steps were defined and carefully followed to solve the problem. This led to the design and production of a good quality swivel-joint as far as performance, appearance and other aspects were concerned and the cost reduced by 40%. This design method, in addition to yielding good results, is suitable for the organization of the activities of new designers and design students.     

Indicators for the dynamics of research organizations: a biomedical case study

This paper reports results on a bibliometric case study of the long-term development of research organizations, using an internationally leading biomedical institute as example. Using scientometric concepts, small group theory, organizational ecology, and process-based organizational theory, we developed a life cycle based theoretical model for analyzing long-term development of research groups and institutes. Three bibliometric indicators are proposed for growth, activity profile stability, and focus. With these, the research dynamics of the case institute are described. First, overall output growth matches developments internationally in developmental biology and stem cell research, and, in line with this, journal article output increasingly dominates the institute’s activity profile. Second, superposed on the overall growth curve, a stepwise development is observed, consisting of long phases of growth and stabilisation. These steps reflect local conditions and events. Historical sources from the Institutes’ archive and interviews with the current staff of the institute suggest that the pattern of life cycles reflects a strong influence of pioneering individuals. But once settled, pioneering directors who remain in function for many years delay adaptation of the institutes’ mission to field developments. Furthermore, national science policies on PhD training, and on priority areas have influenced the life cycles, as did merging with other institutes. As in a social science case, also in this case study stabilized local conditions lead to adaptation to research field dynamics in a delayed fashion. In the present case stable output periods lasted at most 15 years, when local impulses led to new growth of research output and thus prevented onset of a lifecycle decline. The continued growth in the larger field both promoted and legitimized these local impulses.