Lean manufacturing tool in engineer-to-order environment: Project cost deployment

The present paper proposes a modified version of the Manufacturing cost deployment (MCD) method to analyse engineer-to-order (ETO) production systems. The novel approach, named Project cost deployment (PCD), introduces two substantial and innovative modifications. To begin with, the concept of manual assembly macro-activity replaces the traditional concept of station. Then, a brand-new structure for classifying and analysing losses is introduced, that is specifically defined to deal with the inefficiencies of the manual assembly tasks. The validity of the approach is proved by a real-world industrial application. The obtained results demonstrate that the PCD method allows the analyst to identify the hidden losses and to quantify the wastes from an economical point of view. In addition, PCD permits to estimate the impacts of potential (lean) improvement activities and projects in terms of both efficiency and effectiveness.     

Hybrid modelling of MTO/ETO manufacturing environments for performance assessment

Performance assessment is critical in today’s competitive environments, where companies need to establish trade-offs between key competitive dimensions. The complexity of these environments calls for new approaches to performance assessment. Thus, in this work, we propose a novel conceptual framework for performance assessment in manufacturing environments combining different production strategies. Focus is laid on MTO/ETO combined environments and a three-stage problem analysis is considered. Firstly, a hybrid SD-DES-ABS model approach addresses the needs of a system that handles different types of orders, processes and workforce allocation requirements; secondly, the model results for different demand scenarios are assessed using a one-way ANOVA analysis followed by a Tukey – Kramer’s test, with pairwise comparisons for assessment of significant performance variations under different system operating policies. A full factorial Design of Experiments (DOE) analysis follows, for determining the relevant process parameters influencing the system performance. As an example of application of the proposed framework, we consider the case of an advanced manufacturing company, whose manufacturing environment encompasses combined MTO/ETO production strategies.     

Product customisation: an empirical study of competitive advantage and repeat business

Empirical evidence is presented from 24 UK based manufacturing companies, all offering a degree of product customisation, with most having a significant pure customisation engineer-to-order (ETO) element. The evidence addresses the issue of competitive advantage, which has lacked empirical evidence in previous manufacturing strategy literature, and includes a detailed investigation of the strategic importance of repeat business. It contrasts its results with those previously found in the literature and concludes that there are significant differences in the competitive priorities theoretically associated with this sector. In particular, it is argued that cumulative capabilities are needed, with a low cost competence often included. Four different types of repeat business are identified, one relating to repeat business customisers and three relating to versatile manufacturing companies, and the strategic importance of repeat business is discussed. It is indicated that for some ETO companies, repeat business is perceived to be an important method to reduce costs and achieve business stability. However, a number of the other companies studied saw repeat business as infeasible and hence need to find other ways to reduce costs and improve company performance measures. Future research to extend this work into a longitudinal study or a broader survey is proposed.     

Status of engineering change management in the engineer-to-order production environment: insights from a multiple case study

Engineering Changes (ECs) are a fact of life for companies in the Engineer-To-Order (ETO) production environment. Various Engineering Change Management (ECM) strategies, practices and tools exist, but no explicit distinction has been made regarding ECM in different production environments. Using a multiple case study method, this article investigates how ETO companies manage ECs and how ETO characteristics influence ECM. A generic ECM framework was developed and used to map ECM in the cases. The study showed that ETO companies use similar practices for handling ECs, while ECM tools are either not used by the companies or used to a very limited extent. It was found that the use of some ECM practices and tools is complicated by specific ETO company characteristics. However, no reasons were found for the lack of computer-based tools, change propagation and impact assessment tools, change reduction and front-loading tools, and design tools. This suggests, firstly, that there is vast room for improvement in ETO companies when it comes to ECM; and secondly, that the applicability of such tools should be further tested in the ETO environment. Based on the findings, some suggestions as to how ECM can be improved in ETO companies are given to practitioners.     

Improved new product development through enhanced design architecture for engineer-to-order companies

There are many challenges that face companies today in the new product introduction process. These can include reduced design times, fast times to market, improved quality and the need for constant price reductions in order to keep up with the competition. Engineer-to-order firms face even more challenges because of the ‘build to order’ way that they must do business. This study presents new ways for these companies to meet the challenges posed by the market using a business case relating to the product introduction process at a mid-size (～$75 million annual sales) engineer-to-order manufacturer of flexible printed circuits. The company has developed a new product introduction process that seeks to improve quality and delivery times as well as process development for the project at hand. These suggested outcomes of the improved process are generic and widely applicable to contract manufacturers involved in the new product introduction process enabling them to work closely with customers thereby effectively addressing their design concerns. The updated procedures are examined in-depth and the associated forms and record-keeping methods are presented and analysed. The new product introduction process utilises Deming's plan, do, check and act process improvement cycle. Finally, various contributions emanating from the study that enhance our understanding of any engineer-to-order new product development environment are presented.     

基于混合算法的项目型产品装配作业调度研究

针对项目型产品装配作业计划的排序和工人资源的配置问题,以最小项目总工期为优化目标,建立了项目型产品装配作业调度的数学模型,并提出了一种基于离散粒子群和禁忌搜索的混合算法。该算法分为两阶段,离散粒子群进行全局搜索,禁忌搜索用于完善局部搜索能力。将文章提出的算法与文献中已有的粒子群算法、禁忌搜索算法、遗传算法进行了比较,结果表明文中算法得到的解要显著优于文献中已有算法。     

基于VSM/A的单件工程式生产精益分析

为在单件工程式生产企业推行精益生产,应用VSM/A绘制HT汽轮机厂某转子生产的现状价值流图,确定生产中存在的非增值环节。应用拉动式看板、均衡生产、准时化物流等精益生产理论,缩短非增值时间并绘制未来价值流图。通过方案实施,增值时间缩短了71 h,非增值时间缩短了28 d,搬运距离缩短了1 756 m,增值比增加了448%,证明了应用价值流图技术对单件工程式生产企业进行精益分析具有良好的实用价值。