Abstract

Process reengineering (PR) in manufacturing organizations is a big challenge, as shown by the high rate of failure. This research investigated different approaches to process reengineering to identify limitations and propose a new strategy to increase the success rate. The proposed methodology integrates data as a procedure for process identification (PI) and mapping and incorporates process verification to analyze the changes made in a specific process. The study identifies interdependency within the manufacturing process (MP) and proposes a generic process reengineering approach that uses simulation and analysis of production line data as a method for understanding the changes required to optimize the process. The paper discusses the methodology implementation technique as well as process identification and the process mapping technique using simulation tools. It provides an improved data-driven process reengineering framework that incorporates process verification. Based on the proposed model, the study investigates a production line process using the WITNESS Horizon 21 simulation package and analyse the efficiency of data-driven process reengineering and process verification in terms of implementing changes.

Highlights

  • Today’s global market is unstable and intensively competitive, perhaps due to economic globalization and the liberalization of the trade market [1]

  • There are different aspects that have created some debate about the modelling and analysis of the current business processes, as some researchers believe and describe it as a modelling strategy, which is time consuming and hinders the implementation of innovative ideas, while others recognize it as a fundamental issue of a successful Business process reengineering (BPR) effort [18,21]

  • The initial BPR methodologies were quite simple and at times proved to be ineffective when dealing with complex situations

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Summary

Introduction

Today’s global market is unstable and intensively competitive, perhaps due to economic globalization and the liberalization of the trade market [1]. The term “process reengineering” in organizations, especially in the manufacturing industries, refers to bringing in changes in the business environment, and may include the reform of the business strategy from having a technological focus to a cultural one [3]. Business process reengineering (BPR) is a strategy to increase efficiency in an organization in a precise and calculating manner. Several strategies have been developed since organizations started adopting process reengineering (PR) for major changes in management and operations. Most of these approaches are traditional initiatives carried out by the conventional linear life cycle system of PR. Integrating data into process reengineering is possibly the solution to eliminating the uncertainty of success of implementing process reengineering to bring about changes to an organization [11]

Literature Review
Hammer and Champy’s BPR Methodology
Methodology
Object-Oriented
Object-Oriented BPR Methodology
Jacobson’s
Analysis of the Literature Review
Limitations of the Existing
Implementation Comparison of the BPR Methodologies
Learning Process Phase
Modelling and Analyzing or Mapping Current Processes
Modelling and Analyzing Processes or Re-engineering the Process
Data in Manufacturing Industries
Proposed Data-Driven Process Reengineering
Overview of the Proposed Approach
Process Mapping and Identification
Gathering Quantifiable and Quality Data
Process Reengineering
Process Validation
Analysis of the Proposed Methodology Implementation Technique
Project and Knowledge Management Contingency Plan
Setting BPR Objective Based on the Business Vision
Continuous Improvement Plan to Compare the Outcomes with the Business Vision
Case Study
Mapping
Mapping the Process
Process Verification
Process Analysis
12. Machine
Reengineering
15. Buffer
Conclusions
Full Text
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