The triple value model: a systems approach to sustainable solutions

The unintended environmental impacts of economic development threaten the continued availability of ecosystem services that are critical to human well-being. An integrated systems approach is needed to characterize sustainability problems and evaluate potential solutions. The Triple Value Model is an innovative framework that depicts the dynamic linkages and resource flows among industrial, societal, and environmental systems. The U.S. EPA has begun using this model to support transdisciplinary research projects that focus upon water resources, communities, and other broad sustainability themes. One recent application addresses opportunities for mitigation of nutrient impairment in the Narragansett Bay watershed, and has produced a policy simulation tool that enables evaluation of alternative sustainable solutions.     

Methodology for integrated management system improvement: combining costs deployment and value stream mapping

Integrated Management System – Quality, Environment, Safety (IMS-QES) combines all related components of a business into one system for easier management and operations Quality (QMS/ISO 9001), Environmental (EMS/ISO 14001), and Health & Safety (OHSAS 18001). IMS-QES has been generally used to increase operational performance in manufacturing systems. However, the economic impact of standard approach of IMS-QES remains difficult due to the lack of alignment between IMS-QES objectives and strategic management of the company (policy of IMS-QES) and also the inadequacy between the improvement processes and the cost of losses.

Therefore, the main objective of this work is to overcome this limitation. The Framework proposed approach called IM-VCF integrates concepts from IMS-QES, Value Stream Mapping and Cost Deployment tool. It is structured in ten steps. It allows a company to assure proper alignment between IMS-QES policy and business operations and identify the categories of losses. IM-VCF allows analysing critical issues and estimating the potential savings, in terms of cost. A case study taken from the application of the IM-VSF within certified QSE chemical fertiliser port is presented.     

PSS modularisation: a customer-driven integrated approach

The shift from product ownership to integrated solutions (Product-Service Systems (PSSs)) is expected to lead to a higher customer satisfaction in many cases compared to providing products and services separately. PSS providers are required to add more value to the products they offer, as well as to augment and diversify the services related to these products. To deal with this complex task, this paper proposes a practical methodology to support manufacturers in designing services related to the proper functioning of their products fulfilling customers’ needs and expectations. This approach is based on the synergic use of Quality Function Deployment for PSS (QFDforPSS), Axiomatic Design (AD) and the service blueprint tools, providing a correlation between the customers’ expectations, the PSS components and the PSS modules. The methodology was verified by means of a service modularisation for PSS at a company operating in the biomedical sector. While the proposed approach needs to be validated through further studies in different contexts, its positive results in reducing both the risk of overdesigning and the possibility of creating design conflicts can contribute practically to the scientific knowledge on the development of integrated solutions.     

Scrap value stream mapping (S-VSM): a new approach to improve the supply scrap management process

In this work, an innovative methodology to improve the Supply Scrap Management Process (SSMP), based on Value Stream Mapping (VSM), is presented. VSM is one of the best tools to map a process and eliminate its critical issues, that produces good results if applied to production processes, but can be ineffective for management processes as the SSMP. Therefore, the main objective of this work is to overcome this limitation. The proposed approach taking the name Scrap Value Stream Mapping (S-VSM) and integrates concepts from VSM and other Lean Production (LP) and World Class Manufacturing tools. It is structured in five steps. The definition of the process borders and the identification of categories of loss through the first four steps of Cost Deployment is the first step. Then, the SSMP is subdivided in its Accounting and Physical Streams and the current state is drawn. Next, wastes and critical issues are analysed and their root causes are determined using some of LP tools. In step four, improvements are proposed and the future state is drawn. Furthermore, potential savings, in terms of €, are estimated. In the last step, a methodology to monitor the effects of implemented improvements is defined. A case study taken from the application of the S-VSM within automotive company is presented.     

A simulation-enhanced value stream mapping approach for optimisation of complex production environments

Value stream mapping (VSM) is a widely adopted method for transformation of production environments into a lean operational state. The straightforwardness as well as the completeness, with which processes are analysed and optimised, are key to the success of the method originating from the automotive industry. However, these attributes of the ‘paper and pencil’ approach result in limitations when applying VSM in complex production environments. This research paper targets to overcome these limitations, specifically in production environments involving significant demand variability, complex routing and cost factors which potentially increase with lean implementation. For this purpose, an enhanced VSM method is developed, which utilises discrete event simulation (DES). The method features a feasibility and trade-off analysis which is incorporated into the VSM procedure. A case study covering a process of exhaust gas purification catalyst production is then conducted to test the newly developed method. The VSM project yields a shop floor lead time reduction from 11.4 to 1.4?d. The additional DES feasibility and trade-off analysis determines customer demand fulfilment and quantifies the monetary benefit of the future state. In that way, potential iterative implementation which is inherently oppositional to the lean philosophy is avoided.     

Deflection of a jet injected into a stream

A solution is given for the deflection of the axis of two-dimensional and circular jets by an entraining stream. Design formulas are obtained and compared with experiment.     

Investigating the value of integrated operations planning: A case-based approach from automotive industry

During the last decade, many researchers have focused on joint consideration of various operations planning aspects like production scheduling, maintenance scheduling, inventory control, etc. Such joint considerations are becoming increasingly important from the point of view of current advancement in intelligent manufacturing, also known as Industry 4.0. Under the concept of Industry 4.0, advanced data analytics aim to remove human intervention in decision-making. Thus, the managerial level coordination of decisions taken independently by various departments will be out of trend. Therefore, developing an approach that optimises various operations planning decisions simultaneously is essential. Available literature on such joint considerations is more of the exploratory in nature and is limited to simplistic production environments. This necessitates the investigations of value of integrated operations planning for wide range of manufacturing scenarios. Present paper adopts a case-oriented approach to investigate the value of integrated operations planning. First, an integrated approach for simultaneously determining job sequencing, batch-sizing, inventory levels and preventive maintenance schedule is developed. The approach is tested in a complex production environment of an automotive plant and substantial economic improvement was realised. Second, a comprehensive evaluation is performed to study the robustness and implications of proposed approach for various production scenarios. Results of such pervasive performance investigations confirm the value of proposed approach over conventional approaches.     

Extending value stream mapping: the synchro-MRP case

Nowadays, value stream mapping (VSM) is recognised as the main tool for implementing lean manufacturing. Unfortunately, it always leads to pure pull systems and discourages the adoption of hybrid push/pull ones, although their superiority has been proven in several industrial settings. Due to these issues, this paper presents an enhancement of the standard VSM, which supports the user in designing the future state map of a synchro-MRP system. This new tool includes new mapping icons, simple mathematical formulas and operating guidelines that make it possible to assess the benefits of a synchro-MRP system, with respect to the usual kanban or CONWIP ones. In order to demonstrate the quality and the practical utility of the proposed approach, an industrial application of relevance is finally presented.     

The systematic integration of human factors into safety analyses: An integrated engineering approach

The performance of the human reliability analysis (HRA) and integration of its outcomes into quantitative risk assessment schemes remains quite a difficult and complex task to perform. Even worse is the assessment of organisational reliability assessment. The reasons of this difficulty mainly lay on the absence of a generically accepted paradigm that enables engineers to include systematically human and organisational factors (H&OF) into the analysis. Broadly speaking, engineering approaches very often account for error of omission forgetting the errors of commission (EOC), and, on top of that, they do not make any macro distinction between pre- and post-initiating human failures. This paper offers a paradigm on how to integrate H&OF into safety analysis by means of the recursive operability analysis (ROA), which has been adapted to accommodate H&OF, and renamed integrated recursive operability analysis (IROA). By means of a practical example, the method will illustrate how to account for H&OF in a systematic and consistent manner using an engineering approach. The paper will even provide a paradigm for the construction of integrated fault trees consistent with the IROA framework.     

Lateral emitter as a base element of integrated emission electronics

A field emitter is the principal element of emission electronics determining the performance of devices. We propose a lateral emitter based on carbon nanotubes for use in integrated emission electronics. The dependences of the emission current on the pulling and control fields have been studied. It is shown that the proposed lateral emitter can be used in all microelectronic analogues of vacuum tubes, from microwave devices to flat displays, the device technology being substantially integrated.     

Dynamic control in automated manufacturing: a knowledge integrated approach†

Flexibly automated facilities permit a wider variety of products as well as objectives for making those products—thus requiring manufacturing control strategies to face an environment of ever present change. To operate in this environment, a system composed of hard automation, flexible automation and humans, which can be responsive to product and process requirements, machine breakdowns and delays, engineering changes and improvement opportunities, is needed. Such a system does not fall into the realm of any current manufacturing solution techniques. Something more than exact optimization, heuristic algorithms or stochastic estimates must be utilized. The research discussed herein describes a dynamic solution strategy to operate in this changing environment with adaptive self-improving characteristics. The proposed methodology for optimizing the control of an automated manufacturing facility is an integrated approach utilizing real-time feedback from the operating facility, direct feedback from a simulation of the facility and guidance from a historical knowledge base. This system is being implemented in a knowledge based environment called CAYENE. CAYENE is a hybrid artificial intelligence system, written in Lisp, based on the idea of using object oriented programming as a unifying principle for functional, frame and rule-based programming.     

On-line particle-image velocimeter: an integrated approach

We describe an on-line particle-image velocimeter (PIV) and its implementation for the measurement of the velocity field in steady and unsteady flows. The instrument uses up-to-date solid-state sensors, dedicated electronic boards, and digital microcomputers to combine the image-acquisition and processing steps into a single, fully integrated unit. A calibration experiment evaluates the accuracy of the velocity measurement instrument. The experiment consists of the measurement of the velocity distribution of a laminar wall jet and shows that the velocity, as well as the vorticity profiles, obtained by using the on-line PIV compare well with those obtained by means of a conventional photographic PIV and a numerical prediction.     

Multi-site integrated production-distribution planning with trans-shipment: a fuzzy goal programming approach

In multi-site (parallel) manufacturing systems, each selling region (SR) is usually allocated to a specific manufacturing site (MS) in order to minimise the transportation costs, simplify the planning process, etc. However, such manufacturing systems usually encounter great drawbacks in terms of over-achievement or under-achievement of the forecasted demand due to isolation of the MSs. To cope with this drawback, this paper proposes a novel framework for preparing an optimal aggregate production plan by interconnecting the MSs through lateral trans-shipment. In the presence of fluctuating and dynamic demands, we apply some classic strategies including the inventory holding, back-ordering, and additional capacity options (i.e. overtime and changing workforce level) as well as lateral trans-shipment of products among MSs as the feasible strategies undertaken. Maximising the total profit and minimising the manufacturing lead time are considered as two managerial goals. Due to ambiguousness of some critical parameters as well as vagueness of objectives’ target values, a fuzzy goal programming (FGP) approach with imprecise goal hierarchy is developed for modelling the aggregate production-distribution planning (APDP) problem with trans-shipment. The proposed FGP model is then converted to an equivalent crisp one by combining the two recently developed fuzzy programming approaches. An illustrative example inspired by a real case study is provided to show the usefulness and applicability of the proposed model.     

An integrated approach to environmental education and research: a case study

Industrial processes have different levels of impact on the environment and there is a need to foster knowledge of the environmental consequences of industrial activities. One way of achieving this is the application of the concepts of industrial ecology (multidisciplinary research approach) to industry’s day-to-day activities. Another possible way of pursuing this goal is to use environmental education as a tool towards increasing awareness with regard to the social, political and economic relevance, as well as to the need for environmentally sound industrial activities. This paper outlines the common features of both subjects and provides an example from Kaunas University of Technology (Lithuania), where such approaches have been integrated in an M.Sc. programme.     

AgeWa: an integrated approach for antisense experiment design

One of the major fallouts of the human genome project relates to the investigation of the molecular mechanisms of diseases. Identification of genes which are involved in a specific pathological process and characterization of their interactions is of fundamental importance for supporting the drug design processes. Discovery of targets and the related experimental validation is a critical step in the development of new drugs. The new experimental methods for gene expression analysis, such as microarray technology, allows for the concurrent evaluation of the expression of multiple genes. The outcome of these new experimental methods requires a subsequent validation of the gene function by using in vitro or in vivo models. In the last decade, one of the most promising methodologies for the investigation of gene function relies upon antisense oligonucleotides (ASO). The crucial step in antisense experiment design is the characterization of the nucleotide domains that can efficiently be targeted by this kind of synthetic molecule. At present, no standardized procedures for target selection are available. In this paper, we propose an integrative approach to ASO target selection: the proposed tool Automatic Gene Walk (AgeWa) combines a neural filter with database mining for the prediction of the optimal target for antisense action.     

RealityGrid: an integrated approach to middleware through ICENI

The advancement of modelling and simulation within complex scientific applications is currently constrained by the rate at which knowledge can be extracted from the data produced. As Grid computing evolves, new means of increasing the efficiency of data analysis are being explored. RealityGrid aims to enable more efficient use of scientific computing resources within the condensed matter, materials and biological science communities. The Imperial College e-Science Networked Infrastructure (ICENI) Grid middleware provides an end-to-end pipeline that simplifies the stages of computation, simulation and collaboration. The intention of this work is to allow all scientists to have access to these features without the need for heroic efforts that have been associated with this sort of work in the past. Scientists can utilise advanced scheduling mechanisms to ensure efficient planning of computations, visualize and interactively steer simulations and securely collaborate with colleagues via the Access Grid through a single integrated middleware application.     

Analysing the effects of Lean manufacturing using a value stream mapping-based simulation generator

Value stream mapping (VSM) has become a popular implementation method for Lean manufacturing in recent years. However, its limitations such as being time-consuming, its inability to detail dynamic behaviour of production processes and to encompass their complexity, have spurred us to turn to simulation. This paper introduces two new elements to the value stream mapping method. First, it describes how the value stream mapping paradigm (VSMP) can be adapted for use in simulation, introducing specially designed VSM objects. Secondly, based on the VSMP and these objects, it presents a formal modelling method and its related database structure, that drives a generator which automatically yields a simulation model of the value stream map. In this way, a model generator, using the set of objects and the model database, can generate simulation models of Current and Future VSM scenarios quickly and automatically. Additionally, algorithms for converting raw ERP data and information from a VSM drawing into tables of the structured database are developed. Finally, the formal modelling method is applied to a real company case. A Current State model of the manufacturing system and three scenarios of Future States are generated to see the effects of Lean when transforming part of the system from push to pull.     

From value stream mapping toward a lean/sigma continuous improvement process: an industrial case study

Though lean manufacturing has been widely recognised for its effectiveness in continuously improving productivity, product quality, and on-time delivery to customers, the cost for hiring a full-time lean manufacturing engineer has kept many small businesses from implementing lean in their facilities. This paper presents a case study of lean implementation at a small manufacturer in the United States. Starting with collecting process information, a current value-stream map was created that reflected the current operation status. A future value stream map was then proposed to serve as a guide for future lean activities. Next, hurdles that kept the company from moving towards future state were identified. The ‘5 whys’ method was employed to reveal the root cause for each hurdle, followed by kaizen events proposed as solutions. In this case study, two kaizen events were proposed. For the first kaizen event, Taguchi experiment design was used to find the optimal machining parameters that reduced variation in a plasma cutting process. It consequently eliminated rework time and improved productivity. In the second kaizen event, implementation of rabbit chasing increased the system flexibility and consequently reduced inventory levels between work stations.     

Wave structure of a supersonic jet discharging into an opposing supersonic stream

A similarity parameter is suggested for the longitudinal dimensions of the wave structure of a supersonic underexpanded jet discharging into an opposing supersonic stream, and empirical equations are obtained for the calculation of these dimensions.Translated from Inzhenerno-Fizicheskii Zhurnal, Vol. 35, No. 4, pp. 672–676, October, 1978.