《卓越绩效评价准则》之“过程管理”的变化与实施

本文简要介绍了新版GB/T 19580《卓越绩效评价准则》之过程管理条款的主要变化,分析了这些变化的主要依据,详细探讨了关键过程识别、过程要求的确定、过程设计、过程实施和改进等评价要求,以帮助读者深入理解过程管理的条款要求。     

Standardised product development for technology integration of additive manufacturing

ABSTRACT

The implementation of additive manufacturing (AM) as an industrial production process poses extraordinary challenges to companies due to the far-reaching differences to conventional processes. In addition, there are hardly any standards and guidelines or methodical process models for the relatively new technologies that enable the reproducible and target-oriented use of AM. In order to solve this problem, five industrial companies together with the Paderborn University are researching as part of the ‘OptiAMix’ research project funded by the Federal Ministry of Education and Research (BMBF). This paper focuses on the development of an ideal process chain. Reference processes of the OptiAMix partners were analysed, norms and standards from conventional production were adapted and implemented and procedure models developed OptiAMix were integrated. The resulting AM Product Development Process was then applied and validated with the aid of a previously developed integration methodology using an example component from the automotive industry.     

Requirements for forming an ‘e-supply chain’

In today's digital economy, web-based integration of the enterprises to form an e-supply chain is a critical weapon for orchestrating the whole supply chain towards competitiveness. This paper intends to discuss the requirements for forming an e-supply chain from different perspectives, such as integration with the legacy systems, timing and prior presence of ERP (enterprise resources planning) systems, BPR (business process re-engineering) needs of internal and external business processes and business intelligence/decision support needs. A look at technical knowledge and structure to construct an e-supply chain is provided. Challenges involved in forming an e-supply chain are also briefly mentioned as a separate section in this paper. During the study, requirements are gathered by making a review of recent literature.     

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.     

Exploring the Use of Design of Experiments in Industrial Processes Operating Under Closed‐Loop Control

Industrial manufacturing processes often operate under closed‐loop control, where automation aims to keep important process variables at their set‐points. In process industries such as pulp, paper, chemical and steel plants, it is often hard to find production processes operating in open loop. Instead, closed‐loop control systems will actively attempt to minimize the impact of process disturbances. However, we argue that an implicit assumption in most experimental investigations is that the studied system is open loop, allowing the experimental factors to freely affect the important system responses. This scenario is typically not found in process industries. The purpose of this article is therefore to explore issues of experimental design and analysis in processes operating under closed‐loop control and to illustrate how Design of Experiments can help in improving and optimizing such processes. The Tennessee Eastman challenge process simulator is used as a test‐bed to highlight two experimental scenarios. The first scenario explores the impact of experimental factors that may be considered as disturbances in the closed‐loop system. The second scenario exemplifies a screening design using the set‐points of controllers as experimental factors. We provide examples of how to analyze the two scenarios. © 2017 The Authors Quality and Reliability Engineering International Published by John Wiley & Sons Ltd     

Multivariate process incapability vector

Process capability indices evaluate the capability of the processes in satisfying customer's requirements. This paper introduces a superstructure multivariate process incapability vector for multivariate normal processes and then, compares it with four recently proposed multivariate process capability indices to show its better performance. In addition, the effects of two modification factors are investigated. Also, bootstrap confidence intervals for the first component of the proposed vector are obtained. Furthermore, real manufacturing data sets are presented to demonstrate the applicability of the proposed vector.     

The integration of the standards systems of quality management,environmental management and occupational health and safety management

This paper considers the systems of Quality, Environmental and Occupational Health and Safety management. It prospectively analyses the advantages and disadvantages of integrating these systems, as opposed to the systems having independent management in a manufacturing company. Quality Management standards' (ISO 9000) evolution towards Total Quality Management is the starting point. Recent revisions embodied some of the requirements portrayed in the Environmental Management standards (ISO 14000), as well as issues pertaining to Occupational Health and Safety (OHSAS 18001). This tendency towards inclusion of material from different standards systems is expected to be even more evident in the forthcoming revision of the ISO 9000 standards. There is still a notorious absence of an integrated document; ISO has not yet adopted the OHSAS 18001 standard and there are hardships inherent in such an integrative approach. Commonalities between the three systems are emphasized. Foreseen advantages for companies pertain to economies of scale in the certification processes and a joint approach to the provision of quality, environmental responsibility and workforce protection. As a conclusion, the need to pursue standards integration is emphasized. The paper also exposes some predictive gains to be encountered in further integrating the standards system with the inclusion of ergonomics certification.     

Developments of traditional value stream mapping to enhance personal and organisational system and methods competencies

This paper presents developments of traditional value stream mapping (VSM) related to enhancing system and method competencies of both individuals and organisations. Since systematic immersions in traditional VSM – a highly accepted technique for improving production systems – are necessary, this paper describes from a production research point of view approaches for systematic productivity increases, reduction of lead time and an approach to improve sustainability indicators of value streams. The introduced developments of VSM focus on the entire flow and on details, thus creating synergies for designing and improving value streams, processes and work systems both economically and ecologically. On the one hand, this paper shows how practical approaches respectively rationalisation concepts (Lean principles, VSM, Process Management, short-cyclic improvement routine, Methods-Time Measurement) are used in industry in order to manage and improve processes and value streams. On the other hand, sustainability management can be supported on shop floor with utilisation of VSM. It aims to extend the view on value streams of both researchers and practitioners in sense of system and methods competencies.     

企业过程再造的一个实例研究

企业过程再造（BPR）是为了实现企业经营业绩上的突破而对企业经营过程进行的彻底的再思考和根本的再设计。它通过应用现代信息技术对企业经营过程、人力资源和组织结构进行重新设置,彻底消除企业原有劳动和部门分工对企业实现根本经营目标所形成的障碍。作业集成和组织扁平化是成功实施BPR的两个重要因素,也是BPR的难点。本文结合一个电话障碍维修业务再造的成功案例,分析了如何在BPR实施过程中将作业集成与组织扁平化二者有效地结合起来,共同实现经营过程的变革。提出的几点成功经验可供其它企业实施BPR时参考。     

社区复合型托老所的空间适老性服务系统构建研究

目的 为完善现代社区托老所中服务要素分配不均衡、服务质量差异性显著、服务流程不完备的实际问题，建构复合型社区托老所服务系统，信息互联和协同支持。方法 通过实地调研与用户访谈，明确主体用户与其他用户交互关系；根据空间功能服务需求的整合结果构建服务情境，系统分析服务情境中的具体流程信息绘制用户行为旅程图；挖掘并提取用户行为流程中的服务触点，通过因子分析提炼触点的主要影响因素，总结社区复合型托老所空间具体服务项目。结论 完成社区复合型托老所空间服务系统原型构建，明确服务系统与实体空间的对应关系。为后期构建社区复合型托老所服务蓝图、空间设计要素的适老性评价和托老所空间模型设计提供依据。     

Plant-level maintenance decision support system for throughput improvement

In the current global scenario of extreme competition, factors such as productivity, availability, quality and cost of operations play a vital role in the success of a company. A critical component relating to all of the above is maintenance. The conventional maintenance decision support systems have primarily focused on maximising the gains of a single machine system. However, a real life application usually consists of multiple machines, and the operational level decisions are more complex. In this paper, an on line plant-level maintenance decision support system (PMDSS) is developed by combining the short term and long term decision making process to improve the overall system performance while continuously attempting to maximise immediate profits in the short term. The PMDSS works towards two basic aims: (1) unplanned downtime reduction by predicting the remaining useful life of the machines, and (2) efficient utilisation of the finite maintenance and production resources through identifying the throughput-critical machines. The benefits of this approach are presented by considering an industrial case study of an automotive assembly line. The results obtained using this PMDSS approach shows a big throughput improvement as compared to the conventional maintenance policies.     

Supervisory control and data acquisition for virtual enterprise

The new manufacturing paradigms, such as agile manufacture and lean production, are leading industrial countries towards the new generation of concurrent enterprises involving virtual enterprise architecture and concurrent engineering extended methodology. Continuing adaptation to the market can only be achieved efficiently if the planning and control processes are both optimized horizontally (Automatic Control Systems) and vertically (Management Control Systems). The desired improvement in performance and the realization of global enterprise objectives require a tight integration of the units of the enterprise. The close monitoring of the operational performance of various plants, manufacturing shop-floors/cells/machines, as well as their associated instrumentation and control is of increasing strategic importance. Failures can lead to increased costs and reduced product quality, consistency and production, and to plant shutdowns and increased environmental impact. There is a real need for advanced monitoring technologies to be applied, and their potential demonstrated, on complex industrial plants. The planning and scheduling of manufacturing systems integrated into virtual enterprise architectures requires the implementation of new General Master Production Planning and Scheduling techniques and Supervisory Control and Data Acquisition (SCADA) functions. This paper discusses some key issues on the SCADA-oriented open system for virtual enterprise architecture.     

流程的角色观及其管理

认识流程是变化管理的基础。传统的流程基本上是用活动描述的,流程的变化也是从活动及其之间的关系入手,忽略了流程是目标驱动的多角色协同的过程。基于流程的角色观,讨论了角色的分形和流程的角色契合等问题,最后分析基于角色的流程变化管理,指出流程的管理实质上是对角色能力及其协调关系的管理,是对其能力和关系的契合。     

Optimal process targeting for multi-inputs,multi-stages and multi-characteristics production systems

In this paper, a process targeting model is developed for multi-stages, multi-inputs and multi-characteristics production systems. The model extends a previous single stage, multi-inputs and multi-characteristics production system to an n-stage flow line. Recursion and augmented matrix approaches were used to formulate the n-stage model. The optimal process targeting solution is based on minimising a Taguchi-type quadratic loss function across all production stages. A constrained version of the problem is considered in order to cover a wider class of real life industrial applications. The model is very useful especially for mixing-based processes, batch processes, and other multi-stage and multi-characteristic production processes. Finally, an illustrative example is provided.     

Modelling process platforms based on an object-oriented visual diagrammatic modelling language

Process platforms have been recognised as a promising means of dealing with product variety while achieving a near mass production efficiency. To assist practitioners to better understand, implement and use process platforms, this study addresses the underlying logic for coping with the challenges in high variety production by adopting process platforms. Accordingly, this paper proposes to model process platforms with focus on the application processes. In view of the significance of dynamic modelling and visualisation in shedding light on the logic of any processes, this study introduces a visual diagrammatic modelling language based on object-oriented (OO) techniques, named as OOVDML. With the graphical notations, uniquely shaped symbols, syntax and semantics, control mechanisms and arrangement rules, the OOVDML not only captures the logic of process platform's application but also provides a visualisation of their behaviours in a holistic view. Moreover, incorporating OO modelling allows readers to focus on their own interests. This study approaches to modelling process platform's application with respect to activities pertaining to customer order processing, engineering change control and production job planning. An industrial example of electronics products is also reported. The results of the case study not only show the suitability of the OOVDML but also shed light on the dynamic behaviours of process platforms.     

Industry 4.0 integration with socio-technical systems theory: A systematic review and proposed theoretical model

Industry 4.0 promises the fourth industrial revolution by integration of cyber and physical worlds through technology. Industry 4.0 implementation will result in human interaction with technical system in a specialised manner. Therefore, Industry 4.0 will also be a socio (human related) and technical (nonhuman related) system in pursuit of a common goal. The purpose of this study is to suggest a mechanism to include Socio-Technical Systems Theory perspective while designing architecture for integration while implementing Industry 4.0. Building on the previous literatures on Socio-Technical Systems Theory and Industry 4.0, the article proposes bringing the two approaches together and presents a framework for integration mechanism. Successful implementation of Industry 4.0 warrants vertical, horizontal and end-to-end integration. This study suggests a design mechanism for three types of integration mechanism in Industry 4.0 by considering the socio-technical systems impact on people, infrastructure, technology, processes, culture and goals. Further, the integration is also suggested for analysis on the impact of stakeholders, economic situation and regulatory frameworks around which the operating organizations are operating. This is the first paper to propose the consideration of Socio-Technical Systems theory while designing the horizontal, vertical and end-to-end integration for sustainable implementation of Industry 4.0.     

The impact of technology development on the future of the labour market in the Slovak Republic

One of the current open labour market issues is to analyze how the technology progress in production processes will affect the labour market, especially in the context of the replacement of human workers with machines. This paper aims to identify potential threats faced by the labour market in Slovakia, which based on the analysis, employs a significant number of workers in areas susceptible to automation. According to the results, industrial production in Slovakia is divided into several areas, where almost 41% of all industrial workers are employed in the manufacture of metal constructions, machinery and equipment, motor vehicles, semitrailers and trailers and the number of people employed in this sector is increasing linearly over the reference period from 2008 to 2016. The paper focuses on potential scenarios that may arise in the labour market in the near future, using Cobb-Douglas production function. In the original model, the production function of the company is based on production factors in which labour plays an important role. However, with the growth of automation, the original model of companies is changing, transforming, and workforce who has played the key role in the production process of goods or services are becoming redundant due to the growing autonomy of machines. The analyzed scenarios show situations that may arise in the labour market if a company changes the scale of the use of production factors in its production process. In other words, given the current situation as labour costs increase, the power and capabilities of machines are growing and a company wants to stay competitive on the global market.     

A human task-oriented simulation study in autonomous production cells

Simulation on human tasks has become increasingly important in manufacturing systems’ design, assessment and improvement. In order to evaluate working processes and human factors in autonomous production cells (APCs), a collective analyzis of human-centred simulation approaches in advanced manufacturing systems is carried out, and a human task-oriented simulation methodology is proposed in this paper. Based on the methodology, a comparative simulation study is carried out in a 3D laser welding production cell from the aspects of human task spectrum, human error and occupational requirements. Human task network models of both conventional working process and APC working process are constructed using timed coloured Petri Nets. The evaluation criteria architecture for the simulation is formulated and the respective algorithms and parameters for the criteria are discussed in detail. A simulation program using C++ is developed based on Poses++ Petri Net simulator. The simulation results show some important transitions of system performance and human factors from the conventional production cell to the APC, which can support the decision-making when redesigning the conventional production cells to fit the requirements of APCs.     

过程链管理--用于制定和管理转型组织的工具

在当今企业环境日益复杂而活跃的背景条件下，企业需要不断进行重组和迅速转型。这要求企业要具备更强的适应性和更高的灵活性。为了确保实现这些动态的要求，企业必须制定和实施新型的组织形式。本文介绍过程链管理——一种面向过程进行转型的工具。本文首先简要说明了过程链管理应用的工具、过程链管理的任务和构造。它的出发点是由行动、结构、资源、和指挥所组成的过程链管理。在第二步骤中，重点阐述了客户取向这个过程链管理中最重要的取向量。总体来说，整个价值创造链及与此相关的内部交换关系都具有重要意义。在对过程链管理的方法进行了说明以后，提出了一个应用实例，该实例不仅描述了垂直重构，也对水平重构进行了描述。