Design of Lean Manufacturing Support Systems in Make-to-Order Production

2009 ◽  
Vol 410-411 ◽  
pp. 151-158 ◽  
Author(s):  
Dominik T. Matt

Build-to-order was once the only way in which products were made, but limited the market to only the rich buyers. Mass production contributed to a wider access to products, however with losses in individuality. Finally, mass customization aimed at holding out the promise of both, and “lean” concepts helped to (partly) make it a reality. However, the world has changed significantly since the first introduction of “lean” – especially in the most recent years. European companies are facing a growing international competition in volume markets due to the increasing economical and technical emancipation of low labour cost countries. While multinational enterprises are shifting their manufacturing activities to Far East to keep competitive in terms of costs, small and medium sized companies often have to leave their traditional market segments and retreat into niches. However, smaller production lot sizes and the increasing complexity of product programmes require innovative manufacturing strategies. According to several studies and empirical proves, less than 0,5% of a company’s production lead time is value adding, the bigger part of it is dedicated to waiting, handling and internal transport. This paper presents a new approach for the design of lean manufacturing support systems in make-to-order production systems that have to deal with a huge variety of product types and with high variations in demand. A special focus is given to the design of manual material handling and transport (MMHT) solutions. With the help of axiomatic design principles, a tree of design parameters is derived and translated into generally applicable design rules. With the help of a practical example from make-to-order industry, the validity of the methodology is illustrated.

2011 ◽  
Vol 110-116 ◽  
pp. 3997-4003 ◽  
Author(s):  
Jirapat Wanitwattanakosol ◽  
Apichat Sopadang

—In this paper, a conceptual framework to apply many techniques for implementing lean in the high-variety low-volume (HVLV) environment is presented. Lean production has increasingly being implemented as a potential solution for many organizations. Anyway, the lean formula is applicable directly only to the make-to-stock business, but the make-to-order (MTO) product environment has to adapt lean manufacturing principle. The method of this paper has a two-phase quantitative framework to transform small and medium enterprises (SMEs) to be lean. Phase 1 has three interrelated components: (1) re-engineering an organization by using the power of computer simulation combined with business process. (2) Value stream mapping (VSM) is used to create a map of both value and waste in a given process. This tool has also a main drawback for job shop facility because many value streams are composed of hundreds of industrial parts and products. (3) Integrative supplier relationship is one of the most critical factors to maintain an advantage in the increasing levels of competition. Phase 2 performs a just in time production schedule by using ant colony optimization technique combines with a simulation tool. The aims of this paper are to develop a suitable lean manufacturing system for SMEs and to study the performance of the system for improving effectiveness. The result shows how to combine lean concept with simulation optimization, the step of this framework to obtain the optimization solution.


2011 ◽  
Vol 317-319 ◽  
pp. 2302-2305
Author(s):  
Ying Ying Guan ◽  
Bi Xi Zhang ◽  
Jing Song

Based on the structural entropy, this paper establishes a model for analyzing the degree of order of different structure of small or medium sized make-to-order stationery enterprise by using system limitation entropy and quality entropy. This quantificational method to evaluate the process optimization of production system is well validated.


2021 ◽  
pp. 6-20
Author(s):  
П.Я. БАКЛАНОВ ◽  
А.В. МОШКОВ

В статье приводится характеристика основных этапов развития экономико-географических исследований в Тихоокеанском институте географии с момента его организации. Выделено 5 этапов и представлены наиболее важные результаты экономико-географических исследований, полученных в лаборатории территориально-хозяйственных структур за 50 лет. Научные направления исследований определялись общими задачами, решаемыми Тихоокеанским институтом географии, в первую очередь это комплексные прогнозно-географические исследования разномасштабных геосистем Дальнего Востока России в контактной зоне «суша–океан». В основу выделения этапов исследований положены изменения тем научно-исследовательской работы лаборатории. Основным направлением в течение большого периода времени было изучение разноранговых территориально-хозяйственных структур Дальнего Востока, географических, в т.ч. природно-ресурсных, и геополитических факторов их развития. Изложены основные результаты, полученные сотрудниками лаборатории на разных этапах, в т.ч. теоретических и методологических исследований географического пространства и разноранговых пространственных систем, географических и геополитических факторов формирования разноранговых территориально-хозяйственных структур, в том числе трансграничных и аква-территориальных, разработки предложений для Программ устойчивого развития регионов, методов исследования производственно-природных отношений в локальных и районных территориально-производственных системах, оценки территориальных сочетаний природных ресурсов, изучения особенностей трансформации территориально-отраслевых структур, районирования территории и прибрежной акватории Дальнего Востока и т.д. Отдельные экономико-географические исследования имеют и большое практическое значение. В первую очередь, это разработанные в лаборатории предложения для Стратегий и Программ социально-экономического развития Дальнего Востока, Приморского края, агломерации Владивостока и других территорий. The article describes the main stages in the development of economic - geographical research at the Pacific Institute of Geography (now Pacific Geographical Institute) since its organization. The authors identified five such stages and presented the most important results of economic and geographical research accomplished in their laboratory of spatial-economic structures for 50 years. Scientific directions of these researches were determined by the general tasks solved by the Pacific Geographical Institute, in first turn, comprehensive forecasting and geographical research of different-scale geosystems of the Far East of Russia in the ‘land-ocean’ contact zone. The selection of the research stages was based on changes in the topics of the laboratory’s research work. For a long time its main topic was in the studies of multi-ranked territorial and economic structures of the Far East, and geographical factors of their development including natural resource and geopolitical ones. The main research activities of the laboratory staff at different stages included theoretical and methodological studies of geographic space and different-ranked spatial systems; geographical and geopolitical factors in the formation of multi-ranked territorial and economic structures, including transboundary and aqua-territorial ones; working out of proposals to the state programs of the sustainable development of regions; methods of researching the productive-natural relations in local and regional territorial-production systems; assessing the territorial combinations of natural resources; studying the features of the transformation of territorial and sectoral structures; zoning the territory and coastal waters of the Far East, etc. Separate economic and geographical studies are also of great practical importance. In first turn, there are proposals developed in the laboratory for strategies and programs of the socio-economic development of the Far East, Primorsky Kray, Vladivostok agglomeration and other territories.


2013 ◽  
Vol 2 (4) ◽  
pp. 19
Author(s):  
Jenny Calabrese ◽  
Cesare Pacini ◽  
Concetta Vazzana ◽  
Mariana Nikolla

Dependence of conventional agricultural systems on chemical fertilizers and pesticidesmakes agricultural systems less stable and important drift polluters influencing to theregional and global sustainability. This problem made human being think about thealternative systems: agricultural systems that mimic natural systems and are friendly to theenvironment; those have higher economical efficiency concerning production level andcosts. The objective of the present study was sustainability assessment and comparison oforganic and conventional system with special focus environmental and economicalperformance. The case study consisted of two organic and conventional olive producingfarms in the South of Italy. The method used for sustainability assessment wasEnvironmental Accounting Information System (EAIS) that integrates togetherenvironmental (soil organic matter, soil erosion, genetic and landscape biodiversity,EPRIP, etc ) and economical indicators (gross margin). Data used for assessment ofEAIS indicators values were mainly collected from: farm economic-accounting systems,interviews, farm maps, area public organizations, bibliographical sources, farm nutrientaccounting systems, observations and field assessments and chemical soil analyses. Theindicator values measured into two farms were compared to theoretical or referenceindicator values. Based on indicator assessment it was concluded that organic olivegrowing farm had better performance than conventional farm.


2020 ◽  
Vol 11 (1) ◽  
pp. 054
Author(s):  
José Antonio De Miranda Lammoglia ◽  
Nilson Brandalise ◽  
Cecilia Toledo Hernandez

The scenario of global competitiveness demands more and more of the organizations the search for continuous improvement. For survival, in the face of adverse market conditions, modern production management strategies are essential to make production processes increasingly efficient, lean and sustainable, minimizing losses in their production systems. In this sense, when thinking about changes in production lines, in search of improvements in their process, criteria that provide Benefits, Opportunities, Costs and Risks (BOCR) should be considered. In this way, managers and executives should rely on tools and methods that allow them to guide their decisions in a clear way. The objective of this work is to apply a method of Decision Making with Multiple Criteria to the alternatives of investment projects in production lines in Lean Manufacturing concept. As a general result, it was possible to observe the applicability of the AHP BOCR method for the decision-making case involving several criteria and subcriteria for choosing the Lean investment project in the steel environment, the preferred alternative being the discontinuity of the production line 1 and the absorption of their respective production volume by production lines 2 and 3 through investments in them.


Author(s):  
C. D. Mote ◽  
Eric Mockensturm

Abstract Our webs are wide, very thin, two-dimensional, continua arising commonly as a material in transport in machine systems. Though they are thin, webs often require modeling as plates or shells, albeit very thin and flexible ones, because even small bending stiffness distinguishes their behaviors from membranes in critical ways. Technological applications generating interest in web mechanics include the manufacture and handling of paper where wide sheets are transported by rollers at the highest possible speed, thereby maximizing productivity. Material handling problems of a similar type also arise with tissues, films, magnetic media, textiles, fabrics, polymer sheets, and the like. In a technical world pressing for ever higher speeds of stable transport, the web instabilities of wrinkling and flutter commonly bound the productivity of a technological process. These instabilities can result in permanent damage or rupture of the material and disruption of the manufacturing process. Consequently, the presentation today addresses some findings on webs that relate to their modeling, the prediction and causes of wrinkling, and the effect of roller misalignment on web behavior during transport. To allow us to maintain this focus, the rich collection of works on membrane structures, including modeling of inflated membranes, space structures and fiber reinforced membranes will not be part of our discussion. For attention to interesting membrane developments readers might examine Reissner (1938), Steigmann and Pipkin (1989), Jenkins and Leonard (1991), Li and Steigmann (1993), and Haseganu and Steigmann (1994). The most important topic of web flutter caused by air flows over the web surfaces will not be addressed, though recent experimental findings can be found in Chang and Moretti (1992) and Nguyen (1993). Theories modeling the flow and web in these coupled problems tend to underestimate the flutter speeds. This problem area is one of great importance.


2021 ◽  
Vol ahead-of-print (ahead-of-print) ◽  
Author(s):  
Hemant Sharma ◽  
Nagendra Sohani ◽  
Ashish Yadav

PurposeIn the recent scenario, there has been an increasing trend toward lean practices and implementation in production systems for the improvement of an organization’s performance as its basic nature is to eliminate the wastes. The increasing interest of customers in customized products and the fulfillment of customers’ demand with good productivity and efficiency within time are the challenges for the manufacturing organization; that is why adopting lean manufacturing concept is very crucial in the current scenario.Design/methodology/approachIn this paper, the authors considered three different methodologies for fulfilling the objective of our research. The analytical hierarchy process, best–worst method and fuzzy step-wise weight assessment ratio analysis are the three methods employed for weighting all the enablers and finding the priority among them and their final rankings.FindingsFurther, the best results among these methodologies could be used to analyze their interrelationships for successful lean supply chain management implementation in an organization. In this paper, 35 key enablers were identified after the rigorous analysis of literature review and the opinion of a group of experts consisting of academicians, practitioners and consultants. Thereafter, the brainstorming sessions were conducted to finalize 28 lean supply chain enablers (LSCEs).Practical implicationsFor lean manufacturing practitioners, the result of this study can be beneficial where the manufacturer is required to increase efficiency and reduce cost and wastage of resources in the lean manufacturing process.Originality/valueThis paper is the first of the research papers that considered deep literature review of identified LSCEs as the initial step, followed by finding the best priority weightage and developing the ranking of various lean enablers of supply chain with the help of various methodologies.


2011 ◽  
pp. 727-748
Author(s):  
Susumu Uchida ◽  
Kiyotada Hayashi ◽  
Masaei Sato ◽  
Shingo Hokazono

Increased public focus on agri-environmental issues and recent policies on agricultural sustainability have necessitated the construction of a life cycle inventory (LCI) database for agricultural production systems. However, the current progress of LCI database construction is far from being complete in both developed and developing countries. In this chapter, an integrated view for a data-construction methodology for agri-environmental assessment is proposed. The applications of computational methods to the construction processes are also proposed, with a special focus on Japanese case studies. After discussing the methods for construction, the implications of LCI construction are presented, which includes the following issues: how to make a transition to sustainability, and how to achieve informed and science-based policy decisions by increasing the applicability of life cycle assessment and the level of preparedness. The Japanese case studies should support assessment and decisions in developed and developing countries.


Author(s):  
Emre Bilgin Sarı ◽  
Sabri Erdem

Seru production system is a flexible, cost-effective, workforce competence-oriented manufacturing management system that provides the opportunity to respond quickly to customer demand. As in parallel to technology and physical improvements, customer demands are also effective for development of production systems. The impact of change in demand has been seen on changeover from job shop to mass production, flexible, and lean manufacturing systems. Seru production system is more appropriate for targeting work both cost-effectively like mass production and maximum diversification like job shop production. This chapter clarifies the Seru production system and explain its use and benefits in the clothing industry. In the application, a shirt production is illustrated according to the principles of mass production, lean production, and Seru production. Thus, different types of production systems have been benchmarked. There will be potential study areas for proving the efficiency of Seru soon.


2011 ◽  
Vol 201-203 ◽  
pp. 1066-1069 ◽  
Author(s):  
Hua Li Gao ◽  
Bin Dan ◽  
You Guo Jing

This paper proposes a decision-making model of the planning quantity put into production for Make-To-Order (MTO) companies with capacity constraint. The low repeatability and the uncertain products eligibility-rate of the MTO production systems are fully taken into account, and an optimal solution is presented. Finally, a numerical example is given to illustrate the validity of the model.


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