Abstract
Process re-engineering and optimization in manufacturing industries is a big challenge because of process interdependencies characterized by a high failure rate. Research has shown that over 70% of approaches fail because of complexity as a result of process interdependencies during the implementation phase. This paper investigates data from a manufacturing operation and designs a filtration algorithm to analyze process interdependencies as a new approach for process optimization. The algorithm examines the data from a manufacturing process to identify limitations through cause and effect relationships and implements changes to achieve an optimized result. The proposed cause and effect approach of re-engineering is termed the Khan-Hassan-Butt (KHB) methodology, and it can filter the process interdependencies and use those as key decision-making tools. It provides an improved process optimization framework that incorporates data analysis along with a cause and effect algorithm to filter out the process interdependencies as an approach to increase output and reduce failure factors simultaneously. It also provides a framework for filtering the manufacturing data into smart structured data. Based on the proposed KHB methodology, the study investigated a production line process using the WITNESS Horizon 22 simulation package and analyzed the efficiency of the proposed approach for production optimization. A case study is provided that integrated the KHB methodology with data-driven process re-engineering to analyze the process interdependencies to use them as decision-making tools for production optimization.
Highlights
Process re-engineering in manufacturing industries refers to changes in the manufacturing process and could be a significant change in business environments, from technology to culture [1]
The exploding amount of data produced by industries is a big challenge and requires a filtration process to transform data into smart data to understand the characteristics of manufacturing processes
The process re-engineering technique has long been used for the optimization of manufacturing processes
Summary
Process re-engineering in manufacturing industries refers to changes in the manufacturing process and could be a significant change in business environments, from technology to culture [1]. There is always a set objective of process re-engineering within a manufacturing organization, which is increased productivity, flexibility and cost efficiency by changing core business procedures and adapting by eliminating unproductive layers and activities in the organization [2]. Designs 2019, 3, 44 solutions to improve their manufacturing quality while reducing support costs by improving defect tracking and improving forecasting abilities to optimize supply chains, leading to overall operational efficiency improvements. These manufacturing and operational improvements, combined with achieving a favorable customer experience, remain crucial to driving success. External data from social media outlets and supplier network channels provide a huge influx to augment existing data that combine sensors and machine data coming from the production line
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