Quality Control 4.0: a way to improve the quality performance and engage shop floor operators

2021 ◽  
Vol ahead-of-print (ahead-of-print) ◽  
Author(s):  
Cláudia Sousa Silva ◽  
António Fernando Borges ◽  
José Magano
Keyword(s):  
Quality Control ◽  
Continuous Improvement ◽  
Information Technologies ◽  
Human Factor ◽  
Shop Floor ◽  
Multidisciplinary Teams ◽  
Singular Case ◽  
Content Type ◽  
User Friendly

PurposeOrganizations must focus on increasingly complex and customized products and production processes integrated into technological and digital evolution. Thus, shop floor operators have a more significant number of complex tasks with responsibility for their quality control, looking for high productivity levels. However, there are human limitations to deal with the increased amount of information/data resulting from the integration of new technologies. As such, the main research objective is to answer the following research question “How can the combination of recent smart technologies with the human factor contribute to employees' involvement at the shop floor level and thus improve quality control?”Design/methodology/approachThis study follows a qualitative research approach by developing a singular case study in CPMG PSA Group – Peugeot Citroën, where two innovative information technology (IT) projects were implemented following the continuous improvement methodology PDCA cycle (Deming, 1986).FindingsThis work contributed to highlighting the human-centered approach in the discussion of Quality 4.0 development. The main theoretical contribution of this research is the identification of a set of key elements that should be present in the integration of the information technologies in quality control, namely: Prioritizing the quality problems supported by the fundamentals knowledge and tools of traditional quality management (QM); building multidisciplinary teams at different organization levels; following approaches that promote continuous improvement; developing the human-centered and user-friendly perspective; implementing solutions as directly as possible in the workstation; finally, enabling an effective communication and motivation strategies.Research limitations/implicationsThe research addresses a singular case study and solely explores the vertical integration process of Quality 4.0.Practical implicationsThe projects presented may inspire other organizations to integrate information technologies solutions in quality control, following the implementation process and the essential elements described in these examples. Thus, this research stresses that one should customize these projects with the involvement of shop floor operators in a human-centered and user-friendly perspective, both at the preliminary and succeeding stages.Originality/valueThis research presents two original and customized projects, bridging the technological perspective with the human factor in the digital transformation era, supporting the worker, not replacing it.

Doctors’ functional leadership in psychiatric healthcare teams – a reversible leadership logic

2015 ◽  
Vol 21 (3/4) ◽  
pp. 159-180 ◽  
Author(s):  
Johan M. Berlin
Keyword(s):  
Leadership Style ◽  
University Hospital ◽  
Multidisciplinary Teams ◽  
Leadership And Management ◽  
Content Type ◽  
Team Members ◽  
Healthcare Teams ◽  
Medical Teams ◽  
Difficult Situations

Purpose – The purpose of this paper was to study how psychiatric doctors practise leadership in multidisciplinary healthcare teams. The paper seeks to answer the question: How do psychiatric doctors lead multidisciplinary teams during treatment conferences? Design/methodology/approach – Six psychiatric teams were studied at a university hospital. Each team was observed over a period of 18 months, and data were collected during four years (2008-2011). Data were collected through interviews with doctors (n = 19) and observations (n = 30) of doctors’ work in multidisciplinary psychiatric teams. Findings – Doctors in a multidisciplinary team use either self-imposed or involuntary leadership style. Oscillating between these two extremes was a strategy for handling the internal tensions of the team. Research limitations/implications – The study was a case study, performed during treatment conferences at psychiatric wards in a university hospital. This limitation means that there is cause for some caution in generalising the results. Practical implications – The results are useful for understanding leadership in multidisciplinary medical teams. By understanding the reversible logic of leadership, cooperation and knowledge sharing can be gained, which means that a situation of mere peaceful coexistence can be avoided. Understanding the importance of the informal contract makes it possible to switch leadership among team members. A reversible leadership with an informal contract makes the team less vulnerable. The team’s professionals can thus easily handle difficult situations and internal tensions, facilitating leadership and management of multidisciplinary teams. Originality/value – Doctors in multidisciplinary psychiatric teams use reversible leadership logic.

Business survival and market performance through Lean Six Sigma in the chemical manufacturing industry

2019 ◽  
Vol 10 (2) ◽  
pp. 566-600 ◽  
Author(s):  
Peter Muganyi ◽  
Ignatio Madanhire ◽  
Charles Mbohwa
Keyword(s):  
Continuous Improvement ◽  
Six Sigma ◽  
Market Performance ◽  
Lean Six Sigma ◽  
Chemical Product ◽  
Business Survival ◽  
Content Type ◽  
Chemical Manufacturing ◽  
Product Manufacturing

Purpose The research paper aims to unveil the practical use of Lean Six Sigma and its effectiveness as a business survival strategic tool by a chemical product realization concern, as well as to establish the market and business performance impacts on the manufacturing entity. Design/methodology/approach A case study approach was pursued with a multi-national chemical manufacturing entity in South Africa. A comprehensive literature research was undertaken to establish the contemporary tools used for implementing Lean Six Sigma, and the classification and flow of tools and steps undertaken to ensure the successful and effective application of Lean Six Sigma in a manufacturing organization and the benefits derived. The critical success factors and reasons of ineffective use of tools are reviewed. To ensure that a comprehensive research was conducted which is relevant to the body of knowledge in engineering, recent articles on the application of Lean Six Sigma were selected and reviewed during the progress of the study to add impetus to the relevance of the findings. Findings The research findings were mainly based on the inferences obtained from a chemical product manufacturing concern in South Africa, to distinguish the efficacy and relevance of Lean Six Sigma as strategic business survival tool and imputing strategic resonance to corporate strategy. Research limitations/implications This research was limited to distinguishing Lean Six Sigma as a business survival strategic tool and an ultimate enhancer of market performance for a chemical product manufacturing entity. The implementation and evaluation of the Lean Six Sigma methodology as a business survival strategic and market performance enhancement option for the case study organization was entailed as the corollary of deductive resemblance to similar entities. Practical implications This study enables continuous improvement practitioners to evaluate the Lean and Six Sigma practices. The advantages posed by the simultaneous and optimized application of the two approaches versus individual application were assessed and verified to produce enhanced continuous improvement. This poses further challenges to scholars and academics to pursue further researches on the practicality of applying Lean Six Sigma as a strategic option. Originality/value The paper prompts the efficacy of well publicized methodologies and evaluates their implementation for strategic performance for manufacturing organizations. The practical application, constraints and resultant effects of deploying Lean Six Sigma were reviewed to give impetus to the methodology.

Improving effectiveness of mitigation measures in EIA follow-up

2015 ◽  
Vol 26 (4) ◽  
pp. 518-537 ◽  
Author(s):  
Amarilis Lucia Casteli Figueiredo Gallardo ◽  
Caio Pompeu Cavalhieri ◽  
Sofia Julia Alves Macedo Campos ◽  
Omar Yazbek Bitar
Keyword(s):  
Water Quality ◽  
Quality Control ◽  
Quality Parameters ◽  
Mitigation Measures ◽  
Water Quality Control ◽  
Content Type ◽  
Study Approach ◽  
Phase Water

Purpose – The purpose of this paper is to investigate the effectiveness of mitigation measures adopted in a scheme of EIA follow-up by examining their performance in reducing geo-environmental impacts in earthwork activities during the Rodoanel southern section construction in São Paulo, Brazil. This environment is fragile in terms of affected watersheds because the highway crosses two important reservoirs that supply most of the metropolitan water demand. Therefore, this research also aims at promoting water quality control. Design/methodology/approach – This study combines complementary sources as evidences in the literature and field checks, tests and monitoring. The methodology was supported by criteria for evaluating the effectiveness of mitigation measures in the case study approach. Findings – The EIA follow-up activities contributed to the maintenance of environmental conditions in the majority of the control points at the end of the construction phase. Water quality parameters were not statistically different before and during the construction of the highway. The choice and arrangement of mitigation measures were successful in ensuring water quality control by avoiding siltation. Practical implications – A robust scheme for designing and evaluating mitigation measures contributes to the improvement of their effectiveness and is pivotal to the success of the EIA follow-up. Originality/value – This case study serves as an example for extending EIA follow-up practice in special to the improvement of the design and evaluation of mitigation measures in similar contexts.

Assessing an academic library performance before and during the COVID-19 pandemic: a case study in UAE

2021 ◽  
Vol ahead-of-print (ahead-of-print) ◽  
Author(s):  
Abdoulaye Kaba
Keyword(s):  
Quality Control ◽  
United Arab Emirates ◽  
Information Literacy ◽  
Academic Library ◽  
Collection Development ◽  
Digital Resources ◽  
Content Type ◽  
Reference Services ◽  
Significant Difference

PurposeThe purpose of this case study is to assess and compare the performance of an academic library, in the United Arab Emirates (UAE), before and during the coronavirus disease 2019 (COVID-19) pandemic.Design/methodology/approachThe study is based on data collected from the library management system, usage reports of online databases, and monthly reports and archives to evaluate and assess library performance in managerial activities, collection development, collection treatment, collection circulation, usage of digital resources, quality control, reference services and information literacy activities. Frequency distributions and non-parametric tests were used in identifying differences and testing hypotheses.FindingsThe study found that library performance before the COVID-19 pandemic outperformed library performance during the pandemic in collection development, collection treatment, collection circulation, access and use of digital resources, quality control and information literacy. On the other hand, the library demonstrated higher performance in managerial activities and reference services during the COVID-19 pandemic than that of before the pandemic period. Interestingly, the analysis of the Wilcoxon signed-ranks test revealed statistically no significant difference in the library performance before and during the COVID-19 pandemic. The results supported all the eight hypotheses stated in this study.Research limitations/implicationsThis is a case study based on data collected from an academic library in the UAE before and during the COVID-19 pandemic. The findings may not be generalized and may differ if more data are analyzed from many academic libraries.Practical implicationsCOVID-19 pandemic is a turning point for library managers to increase the number of digital resources and services, to ensure that library staff are equipped with essential and up-to-date information and communication technology (ICT) skills and knowledge, to ensure that library users are equipped with essential and up-to-date information literacy skills and knowledge. These will enable them to satisfy users' information needs and ensure library operation in disasters and crisis periods.Originality/valueThis is one of the few studies conducted in the Gulf Cooperation Council (GCC) countries to evaluate library performance before and during COVID-19 pandemic. The findings of the study could be an important reference in understanding how libraries responded to COVID-19 pandemic in the Middle East. The results of the study may contribute to the provision of digital resources and services during the pandemic and disasters in the UAE and the Arab world.

Shop floor management system in the context of smart manufacturing: a case study

2019 ◽  
Vol 11 (5) ◽  
pp. 837-862 ◽  
Author(s):  
Diamantino Torres ◽  
Carina Pimentel ◽  
Susana Duarte
Keyword(s):  
Cyber Security ◽  
Performance Indicator ◽  
Theoretical Background ◽  
Smart Manufacturing ◽  
Shop Floor ◽  
Security Technology ◽  
Content Type ◽  
Smart Technologies ◽  
Manufacturing Technologies

Purpose The purpose of this study intends to make a characterization of a shop floor management (SFM) system in the context of smart manufacturing, through smart technologies and digital shop floor (DSF) features. Design/methodology/approach To attain the paper objective, a mixed method methodology was used. In the first stage, a theoretical background was carried out, to provide a comprehensive understanding on SFM system in a smart manufacturing perspective. Next, a case study within a survey was developed. The case study was introduced to characterize a SFM system, while the survey was made to understand the level of influence of smart manufacturing technologies and of DSF features on SFM. In total, 17 experts responded to the survey. Findings Data analytics is the smart manufacturing technology that influences more the SFM system and its components and the cyber security technology does not influence it at all. The problem solving (PS) is the SFM component more influenced by the smart manufacturing technologies. Also, the use of real-time digital visualization tools is considered the most influential DSF feature for the SFM components and the data security protocols is the least influential one. The four SFM components more influenced by the DSF features are key performance indicator tracking, PS, work standardization and continuous improvement. Research limitations/implications The study was applied in one multinational company from the automotive sector. Originality/value To the best of the authors’ knowledge, this work is one of the first to try to characterize the SFM system on smart manufacturing considering smart technologies and DSF features.

The managerial issues related to transferring shop floor knowledge in manufacturing relocation

2014 ◽  
Vol 34 (11) ◽  
pp. 1389-1416 ◽  
Author(s):  
Mette Praest Knudsen ◽  
Erik Skov Madsen
Keyword(s):  
Shop Floor ◽  
Content Type ◽  
Manufacturing Facility ◽  
Managerial Practices ◽  
Study Approach ◽  
International Production ◽  
Time Gap ◽  
Manufacturing Facilities ◽  
Practical Implications

Purpose – The purpose of this paper is to explore the specific practices of management in the dispatching unit and to identify mechanisms for supporting transfer of shop floor knowledge embedded in operating manufacturing equipment. Design/methodology/approach – The paper applies an inductive and a case study approach for exploring three empirical cases that represent different manufacturing facility relocation processes and differences in the applied managerial practices. Findings – The paper identifies two important gaps in international production literature when firms relocate equipment to other sites; a time gap (from dismantling to re-assembly of production facilities) and a space gap (from the current to the new site abroad). These gaps are important for understanding why relocation processes are difficult and what management can do to facilitate such processes. Practical implications – The paper identifies four issues that management faces in the dispatching context when relocating manufacturing facilities. Originality/value – The paper gives new insights to a limited literature of shop floor knowledge transfer when relocating manufacturing facilities.

A practical integrated solution into enterprise application: a large-scale quality control system development case study

2020 ◽  
Vol ahead-of-print (ahead-of-print) ◽  
Author(s):  
Vahid Hajipour ◽  
Hamidreza Amouzegar ◽  
Sajjad Jalali
Keyword(s):  
Quality Control ◽  
Enterprise Resource Planning ◽  
Large Scale ◽  
Resource Planning ◽  
Qualitative Assessment ◽  
Primary Concern ◽  
Content Type ◽  
Business Units ◽  
Functional Units

PurposeEnterprise resource planning (ERP) offers a streamlined system architecture to feed businesses with beneficial information in the current intense global competition. The primary concern of ERP is how to integrate different functional units to facilitate a unified flow of information. This paper aims at providing a non-trivial practice of integrating the quality control (QC) system into the core ERP processes of a real large-scaled case study.Design/methodology/approachTo satisfy the purpose of the current study, a large-scale steel making holding, inclusive of 27 business units being dispersed over a wide area, has been targeted. In our research methodology, a sample of four business units is selected as the pilot cases to be investigated at first. The output results of such investigations are further extended to the other units. In light of the investigation, the existing QC working conditions of the pilot cases are assessed through the As-Is model. The To-Be models are derived based on the best practices and the integration scope is then bordered.FindingsThe findings show that the integrated QC solution has enabled the following features: the smooth interconnection between QC and other functional units like purchase and manufacturing, the ease of generating real-time performance report of QC unit, the sack of tracing the quality of any available item in the system and the root-cause of defects, and the straightforwardness of the qualitative assessment of the suppliers.Research limitations/implicationsThere is almost no similar practice for designing a large-sized integrated system from scratch in the target region associated with our case study while the off-the-shelf products are prohibitively expensive.Practical implicationsThis paper includes implications for providing a standard practice on integrating a substantial module of ERP down to the smallest detail.Originality/valueThe value of the current paper is associated with fulfilling a critical research gap in the context of studying the QC integration into an enterprise solution. In fact, despite the importance of the QC module and its plethora of interconnection with other functional units, the literature review shows a centric lack of considering such integration in a real case study, particularly the large-scale one. Further, this paper works as a valuable study in the literature owing to not only focusing on the design and development of an integrated QC solution but also considering the deployment facet of such a practice.

An application of 5S concept to organize the workplace at a scientific instruments manufacturing company

2015 ◽  
Vol 6 (1) ◽  
pp. 73-88 ◽  
Author(s):  
Shaman Gupta ◽  
Sanjiv Kumar Jain
Keyword(s):  
Design Methodology ◽  
Shop Floor ◽  
Small Scale ◽  
Content Type ◽  
Audit Score ◽  
Manufacturing Organization ◽  
Practical Implications ◽  
Cause And Effect Diagram ◽  
Collection Methods

Purpose – The purpose of this paper is to use the 5S tool to assist a small-scale manufacturing organization to become more productive and more efficient. Design/methodology/approach – A simple approach has been adopted to create the teams for implementing 5S. Cause-and-effect diagram has been studied for shop floor analysis. Later, four data collection methods have been used to ensure right implementation of the 5S. Findings – In the frames of this case study, it has been analyzed that implementation of “5S” resulted in overall improvement of the organization. With the implementation of “5S”, major benefits in the form of tool searching time have been achieved. Tool searching time from shop floor has been reduced from 30 minutes to 5 minutes. “5S” audit has been conducted in the organization. “5S” audit score has been increased from 7 (Week 1) to 55 (Week 20). Practical implications – 5S is a powerful tool and can be implemented in various industries whether micro, small, medium or large. Implementation of 5S has large horizontal development and can be implemented in all the workstations of an organization. Originality/value – The publications and case study presented in this paper will be useful to researchers, professionals and others concerned with this subject to understand the significance of 5S.

Classification and relationships between risks that affect lean production implementation

2015 ◽  
Vol 26 (1) ◽  
pp. 57-79 ◽  
Author(s):  
Giuliano Almeida Marodin ◽  
Tarcísio Abreu Saurin
Keyword(s):  
Factor Analysis ◽  
Lean Production ◽  
Shop Floor ◽  
Management Support ◽  
The South ◽  
Multiple Sources ◽  
Content Type ◽  
Confirmatory Factor ◽  
South Of Brazil

Purpose – The purpose of this paper is twofold: to classify the risks that affect the lean production implementation (LPI) process, and to demonstrate how that classification can help to identify the relationships between the risks. Design/methodology/approach – Initially, a survey was conducted to identify the probability and impact of 14 risks in LPI, which had been identified based on a literature review. The sample comprised 57 respondents, from companies in the south of Brazil. An exploratory factor analysis was carried out to analyze the results of the survey, allowing the identification of three groups of risks in LPI. Then, a case study was conducted in one of the companies represented in the survey, in order to identify examples of relationships between the risks. Multiple sources of evidence were used in the case study, such as interviews, observations and documents analysis. Findings – The risks that affect LPI were grouped into three categories: management of the process of LPI, top and middle management support and shop floor involvement. A number of examples of relationships between the risks were identified. Research limitations/implications – The survey was limited to companies from the south of Brazil and therefore its results cannot be completelly generalized to other companies. Moreover, the results of the survey were not subjected to a confirmatory factor analysis. Originality/value – This study helps to improve the understanding of LPI, as: it re-interprets the factors, barriers and difficulties for LPI from the perspective of risk management, which had not been used for that purpose so far; it presents a classification of the risks that affect LPI, which can support the understanding of the relationships between the risks and, as a result, it can support the development of more effective methods for LPI.

scholarly journals Kaizen Selection for Continuous Improvement through VSM-Fuzzy-TOPSIS in Small-Scale Enterprises: An Indian Case Study

2018 ◽  
Vol 2018 ◽  
pp. 1-10 ◽  
Author(s):  
Sunil Kumar ◽  
Ashwani Kumar Dhingra ◽  
Bhim Singh
Keyword(s):  
Continuous Improvement ◽  
Cycle Time ◽  
Fuzzy Topsis ◽  
Shop Floor ◽  
Small Scale ◽  
Market Demand ◽  
Current State ◽  
Future State ◽  
Indian Industries

In the era of cut throat competitive market, Indian industries are under tremendous pressure to continuously reduce the cost and improve product quality. The main objective of this research paper is to provide a road map for investigating the opportunities to reduce cost and improve productivity and quality in the existing production system through the application of Lean-Kaizen concept using value stream mapping (VSM) tool at shop floor of an Indian Small-Scale Enterprise (SSE). On the basis of collected data from the selected industry, a current state map was made. After analysis, the current state map was modified to develop a future state map. By comparing current and future state map, the gap areas were identified and takt time (TT) was calculated considering actual market demand. To overcome the gap between current state map and future state map and to synchronize cycle time of each station with talk time, Kaizen event (KE) was proposed. Fuzzy technology for order preference by similarity to ideal solution (TOPSIS) was applied to prioritize and select the appropriate KE for optimized performance level. After analysis of data obtained after application of the Lean-Kaizen concept, the final improvements in terms of improved productivity (57.15%) and reduced lead time (69.47%), reduced cost (65.61%), and station cycle time (75.25%) were recorded. Through the case study drawn from realistic situations of the industry, the authors highlight that implementation of Lean-Kaizen using VSM and fuzzy TOPSIS provides improvement opportunities across the organization. The findings can inspire the SSEs to adopt the Lean-Kaizen concept for optimizing continuous improvement opportunities in their production industry. This study offers the researchers and practitioners a good example for understanding, selecting, and performing KE program. They can even attain more improvement in various areas by establishing or improving these KE programs.

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