Empirical models of the effect of integrated manufacturing on manufacturing performance and return on investment

The effect of integrated manufacturing on non-financial manufacturing performance and return on investment is studied. Technology-use data from over 1000 manufacturing plants in the USA were used to test empirically the relationships between variables integrated manufacturing, non-financial manufacturing performance and return on investment. Notable findings were (1) integrated manufacturing shows a strong effect on non-financial manufacturing performance and (2) non-financial manufacturing performance has a statistically significant direct effect on return on investment. It is recommended that the justification of investments in manufacturing technologies that contribute to integrated manufacturing must be based on non-financial manufacturing criteria as well as on return on investment. Using two different models, it is shown that the causal model developed in the study is robust.     

Toward New-Generation Intelligent Manufacturing

Intelligent manufacturing is a general concept that is under continuous development. It can be categorized into three basic paradigms: digital manufacturing, digital-networked manufacturing, and new-generation intelligent manufacturing. New-generation intelligent manufacturing represents an in-depth integration of new-generation artificial intelligence (AI) technology and advanced manufacturing technology. It runs through every link in the full life-cycle of design, production, product, and service. The concept also relates to the optimization and integration of corresponding systems; the continuous improvement of enterprises’ product quality, performance, and service levels; and reduction in resources consumption. New-generation intelligent manufacturing acts as the core driving force of the new industrial revolution and will continue to be the main pathway for the transformation and upgrading of the manufacturing industry in the decades to come. Human-cyber-physical systems (HCPSs) reveal the technological mechanisms of new-generation intelligent manufacturing and can effectively guide related theoretical research and engineering practice. Given the sequential development, cross interaction, and iterative upgrading characteristics of the three basic paradigms of intelligent manufacturing, a technology roadmap for “parallel promotion and integrated development” should be developed in order to drive forward the intelligent transformation of the manufacturing industry in China.     

Effectiveness of planning and control systems: An empirical study of US and Japanese firms

Both researchers and practitioners have investigated the effectiveness of manufacturing planning and control systems (MPCS) in an attempt to justify the investment in MPCS. This study uses the Wight's (1981) detailed questionnaire to measure the degree of planning and control implementation in a manufacturing system, which is referred to as MPCS rating. The MPCS rating is then used to study the relationship between the self-assessed manufacturing competitiveness (cost, quality, delivery and flexibility) and the objective performance measures of manufacturing performance such as production cost, productivity change, customer reject percent, manufacturing lead time, etc. The results show that there is a strong relationship between MPCS ratings and objective performance measures as well as self-assessed competitiveness in both Japanese and US firms. The results are important since they indicate that fundamental manufacturing planning and control procedures improve a firm's performance on both its internal operations as well as external competitiveness goals.     

A quantitative investigation of the technological innovation in large construction companies

The construction industry is considered as backwards and lack of innovation. The main driving power of technological innovation in the construction industry is large construction companies. However, the driving process of technological innovation in them has not been fully investigated in previous studies. This study constructs a quantitative model to explore the technological innovation driving process of large construction companies considering the key influencing factors for technological innovation. The sample data are the 57 large construction companies selected from the world's largest construction market – China. The results show significant positive correlation between innovation input and innovation output, and between innovation output and performance. The operational capacity of the companies is positively correlated with innovation input, whilst the capital structure is negatively correlated with innovation input. The technical employees have a positive impact on the performance. The underlying reasons are discussed and suggestions are given for the construction industry to improve the technological innovation capacity of construction companies. This research contributes to the literature of construction innovation and benefits practitioners by providing a quantitative approach to demonstrate the driving power of large construction companies for technological innovation.     

Green Remanufacturing Engineering and Its Development Strategy in China

Made in China 2025 proposes that “develop the remanufacturing industry vigorously, implement high-end remanufacturing, smart remanufacturing, and in-service remanufacturing, advance the identification of remanufacturing products, and promote sustainable and healthy development of the manufacturing industry”. Remanufacturing is an extension of the manufacturing industry chain, and it is an important part of advanced manufacturing and green manufacturing. The product function, technical performance, greenness and economy of the remanufacturing products are no worse than those of the new products. The cost of remanufacturing products is only about 50% of new products. Remanufacturing can save energy 60%, and material 70%, so the adverse impact on the environment is significantly reduced. At present, China’s remanufacturing industry is developing rapidly, and the manufacturing pilot has been in full swing. Meanwhile, the policies and regulations, basic theory, key technology, and industry standards of remanufacturing have been continuously innovated and completed.     

The effects and time lags of R&D spillovers in Brazil

Government's innovation investments for science intensive sectors, such as the capital goods industry for developing countries play an important role in technology dissemination; however, few studies have addressed this issue. This study is conducted in the framework of a developing economy (Brazil), and aims to estimate the spillover effects throughout the industry resulting from public investment in innovation, as well as the spillovers of R&D and management investment performed by the capital goods industry through the rest of the industrial sector, and also the time lapse between the occurrence of innovative investment and output growth due to such expenditures. The results of the estimated econometric model exhibit significant and positive spillover effects by the government R&D expenditures for the capital goods industry with a three-year lapse, as well as a one-year lag for the occurrence of output effects on the other companies of the manufacturing sector, resulting from innovative investments by the capital goods industry.     

Evaluating the performance of US manufacturing and service operations in the presence of IT: a Bayesian stochastic production frontier approach

In this paper, we evaluate the performance of US manufacturing and service operations in the presence of information technology (IT) as measured by technical efficiency, using firm-level data from 133 companies over the period from 1999 to 2009. To gain insight into the phenomenon of the ‘IT productivity paradox’, or the history of inconsistent findings in the existing literature, we employ a Bayesian stochastic production frontier approach to model the relationship between performance and technical efficiency at the firm, industry and sector levels. Some results are indicative of a slight advantage of the manufacturing sector over the service sector in terms of technical efficiency and a significant positive contribution of IT-investment to firm output. However, other results do suggest the productivity paradox, because of a lack of any definitive association of high IT investment levels with either high- or low-technical efficiency. Indeed, the findings of this study suggest that the origin of some portion of the IT productivity paradox may exist at the industry level, in that the relationship between extreme levels of IT-investment and extreme levels of technical efficiency appear to work differently in sufficiently different industries.     

Performance measurements in the implementation of CIM in small and medium enterprises: An empirical analysis

If a company has a strategic goal of achieving better productivity and quality, it is not only necessary to have action programmes that support productivity and quality, but also score-keeping system in manufacturing must integrate both the strategy and the actions. Performance measurements must appraise, reinforce and reward improvements in terms of action programmes being used to pursue productivity and quality. Performance improvement in small- and medium-sized enterprises (SMEs) can be achieved through the implementation of computer-integrated manufacturing (CIM). Many SMEs do not consider the implications of long-term benefits of CIM, but only consider short-term financial benefits when they decide about the implementation of CIM. They simply ignore the strategic benefits and intangibles. However, performance measurements considering financial, non-financial, tangible and intangible costs, and benefits have not received significant attention from SMEs while deciding on CIM. Nevertheless, CIM plays an increasingly important role in all aspects of competitiveness both in terms of product development and production techniques in SMEs. Therefore, considering the importance of investment in CIM by SMEs, an attempt has been made in this paper to study the implications of performance measurements on the implementation decisions. A framework has been developed to study the investment justification on CIM in SMEs with the help of an empirical study conducted in British SMEs. Finally, the conclusions are presented.     

Optimizing OEE,productivity and production cost for improving sales volume in an automobile industry through TPM: a case study

The aim of this paper is to investigate how increase in sales volume has evolved by improving overall equipment effectiveness (OEE) of machines, plant productivity and production cost through total productive maintenance (TPM) initiatives in a reputed tractors manufacturing industry in India. In the present scenario of global competitive market, the manufacturing industry needs to improve their operational performance for surviving and prospering. TPM is practised by industry as a business tool for rapid and continuous improvement in its manufacturing capabilities. OEE offers a powerful control tool to overcome production deficiencies and operational performance constrains. Productivity and manufacturing cost are also crucial operational measures to analyse the manufacturing performance. In this study, evaluation and analysis of the methodology adopted for improving sales volume through TPM initiatives was carried out using an interactive research approach. The industrial example on the application of OEE tool demonstrates that it has a remarkable potential to enhance the equipment effectiveness. The empirical findings of the study reveal that augmented OEE and productivity, and reduced production cost resulted to double the sales revenue and triple the profit within a period of three years. The industry also achieved notably tangible and intangible benefits with the TPM implementation.     

IT investments and business performance improvement: the mediating role of lean manufacturing implementation

The main purpose of this study is to examine whether the application of current information technology (IT) and different principles of lean manufacturing (LM) are interdependent and complimentary or they are mutually exclusive. This study draws on the so-called IT-enabled organisational capabilities perspective to study the relationships between IT, LM and business performance improvement. Using a questionnaire-based survey, the data come from 231 leading Iranian and Malaysian auto-part manufacturers. The findings suggest that LM and IT are mutually interdependent and value of IT investments can be effectively transformed into business performance improvement for auto-part manufacturers through the higher levels of lean manufacturing system (LMS) implementation. Advanced manufacturing technology (AMT) competency is a valuable intermediate capability which links IT investments into LMS implementation. It was found that IT investment is one of the minimum requirements of LMS implementation for surveyed business, and the value of IT investment is truly transformed to LMS implementation when IT investments offer competent administrative AMTs to effectively manage all production processes. Findings also recommend that managers should avoid isolating the performance metrics only on areas such as net financial measures, while assessing the business value of IT and LM.     

维修管理模式对制造企业质量控制影响的实证研究

可靠的设备预防维修水平和卓越的产品质量保证能力是保障产品过程质量的关键,现有多数研究集中在质量管理模式与企业绩效的关系分析。在对过程质量控制、设备维修管理评述的基础上,探讨了设备维修管理模式与维修绩效及过程质量控制绩效间的关系。以国内制造企业的连续生产方式为研究对象,运用结构方程模型剖析了RCM、TPM、设备采购管理与和设备维修绩效、过程质量控制绩效的路径关系,发现基础维修管理活动对维修绩效有间接影响,RCM、TPM对设备维修绩效有显著影响,路径系数分别为0.346、0.717,设备维修绩效对过程质量控制绩效的影响显著,路径系数为0922。证明制造企业为提升产品质量,需要完善其设备预防维修系统。     

核电用316L不锈钢粉末增材制造研究现状

增材制造技术是一种无须模具、近净成形的先进制造工艺。不锈钢是一种在核电行业广泛应用的结构材料。实现不锈钢结构件的增材制造将进一步推动增材制造技术的发展,也可为核行业带来革命性改变。以核电用316L不锈钢为例,系统阐述了不锈钢粉末增材制造研究现状,包括粉末制备工艺现状、增材制造成形工艺现状以及成形件的组织性能研究现状。目前,增材制造用316L不锈钢粉末的制备工艺主要为雾化法,粉末的物化性能受制粉工艺参数的影响。在激光粉末床熔融增材制造技术、电子束选区熔化技术和等离子增材制造技术中,尤以激光粉末床熔融增材制造不锈钢的应用最为广泛。增材制造316L不锈钢的组织与性能存在各向异性,但各向异性可通过增材制造的后处理技术消除。目前增材制造最为常用的后处理技术为热处理。与锻造316L不锈钢相比,经热等静压处理的增材制造316L不锈钢的力学性能与辐照性能更优。目前,核用不锈钢的增材制造技术还处于起始阶段,后续应重点关注增材制造的成形机理及成形材料中子辐照性能等内容。     

Manufacturing strategy,performance indicators and improvement programmes

This article reports on a survey conducted in Belgian industry. The purpose was to get insight into manufacturing objectives, performance measurement systems and improvement programmes. It turns out that quality is dealt with very consistently. But in many cases time-based objectives are not yet supported by consistent time-based performance criteria and/or time-based improvement actions.     

中国制造业产品质量:基于技术含量视角的实证分析

利用WIOD数据库2000-2014年世界投入产出表,结合生产工序方法测算中国制造业的整体技术含量、国内技术含量和国内技术贡献率,基于技术含量视角分析中国制造业出口产品质量的动态变迁及其影响因素。研究发现:(1)中国制造业及其细分行业技术含量增速较快,但绝对量低于世界其他主要国家(地区),国内生产环节的技术含量有待进一步提升。(2)引进国外技术对制造业产品质量的影响具有“U”形特征,成本效应占优时,表现为负向作用;技术溢出效应占优时,表现为促进作用。随着国内技术含量的增加,国外技术引进的抑制作用开始显现,在技术密集型行业中,技术引进总体表现为抑制作用。(3)行业自主研发是出口产品质量升级的重要推动力,分别与国内技术以及行业开放具有互补效应,即自主研发可以增加行业对技术的消化吸收能力,提高技术溢出效应,且互补效应在资本密集型行业和技术密集型行业中更为显著。     

A review on strategic capacity planning for the semiconductor manufacturing industry

Due to the high capital investment cost in the semiconductor manufacturing industry, strategic capacity planning plays an important role in improving business performance. The reasons that make these problems especially difficult are: the complex fabrication process, rapid changes in technology and products, the long lead time and the high cost of capacity increment, and the high uncertain demand and capacity. Hence, a review of the existing solutions to capacity planning to cope with these difficulties is important for developing new methodologies and practices. In this paper, we provide a review of the current research and fundamental methods in strategic capacity planning, identify emerging methods for capacity planning, and take an in-depth look at future research interests.     

Organic fibre modified ceramic shell moulding for investment casting

Abstract

Investment casting research is being carried out by the University of Birmingham sponsored by the EPSRC and a consortium of industrial companies. The programme is aimed at developing a fundamental understanding of the process, with a view to routinely producing sound, net shape castings. The casting of liquid metals to produce solid objects is a manufacturing process, which has been practised for over five thousand years, with investment casting being one of the oldest known metal shaping methods. The technique itself has tremendous advantages in the production of quality components and key benefits of accuracy, versatility and integrity. As a result the process is one of the most economic methods of forming a wide range of metal components. Environmental and economic pressures have, however, resulted in a need for the industry to improve current casting quality, reduce manufacturing costs and explore new markets for the process. Optimisation of the mechanical and physical properties of the ceramic shell will be fundamental to achieving these aims. This paper reports on the work carried out to determine the applicability of the use of fibres as reinforcement media for investment shells and to explore methods by which the use of organic fibres can improve ceramic shell performance.     

我国制造业实施ERP的策略研究

针对ERP在我国制造业“水土不服”的观点，对ERP面向制造业管理架构、我国制造业现状进行了深入分析和比较，并据此找出“水土不服”的根本原因，提出使ERP融入我国制造业的具体解决方案和步骤。     

Towards a holistic sustainability index for measuring sustainability of manufacturing companies

Competition from low wage countries and the adoption of free market strategies have forced manufacturing firms to recognise and implement productivity enhancement strategies. This research defines a holistic sustainability index embedding several performance indices. The aim of this study was to establish a relevant framework that would assess the current situation of an industry through aggregation of environmental, social, economical as well as manufacturing variables. The proposition has its roots in trends and gaps in the sustainability literature of manufacturing industries and is based on the analytic hierarchy process (AHP) method. A list of indicators measuring the industry performance based on an AHP scoring methodology is proposed. The next stages include grouping industries according to common deficiencies across the four dimensions and establishing a cooperation framework. The food manufacturing industry is the main target in this study and will benefit from adopting sustainable long-term policies. By recognising the importance of social–environmental sustainability and taking the initiative to pursue it, profits will grow as a positive effect of such policies. The added value is twofold: (1) coupling all sustainability dimensions, often addressed in silos and (2) integrating manufacturing indicators which enable the analysis of interrelationships with sustainability.     

New cost model for feasibility analysis of utilising special purpose machine tools

Special purpose machine tools (SPMs) have been widely used to perform drilling-related operations in high volume production including within automotive component industries. The first step in designing and manufacturing a SPM is a feasibility analysis. Since SPMs have relatively higher investment cost than other machine tools, this task must be performed before any investment on the preparation of detailed design. The present paper explores an economic feasibility analysis strategy which aims to make logical decision by assessing the strengths and limitations of an SPM in comparison with other machine tools. The mathematical product cost model for SPMs is proposed for estimating important economic factors and then financial indicators are calculated to evaluate the SPM’s economic performance. A case study is used to examine the proposed model and results are compared with other machine tools. The proposed model provides a decision support approach for selecting an SPM for manufacturing a given part from an economic perspective.     

Synergy between evolutionary optimization and induction graphs learning for simulated manufacturing systems

The performance of manufacturing systems is strongly dependent on a set of numerical and non-numerical decision variables, such as transport lot sizes and priority rules, for example. Configuring such systems requires determining a value for each decision variable to optimize a performance criterion. Recent works have shown that simulation optimization of manufacturing systems can be efficiently addressed using evolutionary algorithms. Nevertheless, these algorithms do not provide any understanding on the system's behaviour, which could be crucial regarding the investment amounts. Existing methods based on learning strategies try to provide knowledge on the system, but relevant information could be scattered. To optimize the system, characterize good solutions and highlight critical decision variables, an ‘intelligent optimization’ method is proposed based on the synergy between evolutionary optimization and induction graphs learning. These approaches work together to find good solutions with associated knowledge. The method is illustrated by the configuration of an assembly kanban system constituted of five machines that process three types of product.