Agile Manufacturing Research Articles

Environmental sustainability from a decoupling point perspective

Combatting climate change is of global importance. The fact that all UN member nations have agreed on the sustainable development goals (SDGs) is testament to this. The manufacturing industry plays a crucial part in meeting these goals. However, if manufacturing firms are to improve in terms of sustainability, such efforts must be reconcilable with their ability to make profit. Hence, sustainability efforts must be adapted to firms’ individual context and competitive priorities.Focusing on environmental sustainability, this paper is the first to empirically investigate and compare the commitment to environmental sustainability practices (ESPs), and the outcomes of such practices, across make-to-order (MTO) and make-to-stock (MTS) manufacturing plants. Furthermore, the paper investigates whether the customer order decoupling point moderates the relationship between characteristics of lean and agile manufacturing and ESPs. Hypotheses are developed based on extant literature and tested. The results indicate that MTO plants experience more benefits related to manufacturing and financial performance from their ESPs than MTS plants. The data also show that the association between ESPs and the outcomes of such practices are more robust for MTO plants than they are for MTS plants. Plausible explanations for these results are discussed and the findings of the paper are connected to the contemporary topic of smart manufacturing, as well as potential policy implications. Suggestions for future research are also provided.

Stakeholders’ perspectives and performance outcomes of sustainable market-focused manufacturing system in Indian manufacturing organizations

Sustainability and the ever-changing customer demands are the key drivers for innovation across product, process, system, and supply chain management. Sustainability innovations aim to improve organizational environmental, social, and economic performance. Given the complexity of sustainability and ever-changing business and stakeholders’ requirements, organizations must focus their innovation in the direction of meeting the requirements of their stakeholders and business. Integrated sustainable green lean six sigma agile manufacturing system (ISGLSAMS) is a sustainable market-focused manufacturing system. It provides a sustainability and market-oriented business model and meets the perspectives of the various stakeholders. This study aims to identify and rank the various performance outcomes of ISGLSAMS. The study also explores the correlations among the various performance outcomes of ISGLSAMS. The study helps the practitioners to better understand the ISGLSAMS and stakeholders’ perspectives of ISGLSAMS. This research provides a foundation for practitioners, policymakers, organizations, and value chain partners (i) to formulate policies and roadmaps for the successful adoption of ISGLSAMS and (ii) for fostering a more sustainable development of manufacturing organizations in India.

Evaluation of the effect of forming strategy in newly introduced flexible roll forming process

In recent years, with the emergence of Industry 4.0 trends and the impact of the COVID-19 pandemic, the agile manufacturing paradigm has gained increasing significance. Substantial efforts have been directed towards introducing new methods, driven by the dual objectives of flexibility and agility. This paper presents an innovative machine that employs two rollers to apply localized deformation to sheet metal through repetitive movement along the length of the sheet. As with all incremental forming processes, the forming strategy is a critical parameter influencing both the forming force and the dimensional accuracy of the manufactured workpiece. In this research, two different forming strategies, internal and external, were implemented for manufacturing elongated 90 deg bends on 1 mm and 3 mm thick AISI 304 sheets. Both numerical and experimental analyses were performed to assess the effects of these different strategies. The results confirm that the forming force with the external strategy is 50 % and 47 % less for the 1 mm and 3 mm sheets, respectively. Moreover, the external forming strategy allows for better control of the obtained angle, but limits the minimum obtainable bending radius.

Impact of Total Quality Management and Agile Manufacturing on Performance in the Apparel Industry: A Moderating Role of Higher Management Commitment

This study investigates the impact of Total Quality Management (TQM) and Agile Manufacturing (AM) on the performance of apparel mills, while also exploring the moderating role of Higher Management Commitment (HMC). The goal is to assess whether TQM and AM enhance mill performance and whether HMC amplifies these effects. The research adopts a quantitative approach using data from 104 respondents across various apparel mills in Karachi, Pakistan. A structured questionnaire was employed, measuring TQM, AM, Operational Safety (OS), Training, and HMC using a 5-point Likert scale. Regression and correlation analyses were conducted to evaluate relationships between the variables. The results indicate that both TQM and AM have significant positive effects on apparel mill performance, with training also showing a strong correlation. However, OS did not demonstrate a significant impact. Furthermore, HMC significantly moderates the relationship between TQM and training on mill performance but does not moderate the relationship between AM and OS. The findings suggest that managers in the apparel industry should focus on implementing TQM and AM to enhance performance, while also fostering strong managerial commitment to maximize these benefits. This study contributes to the existing literature by integrating TQM, AM, and HMC, providing a comprehensive understanding of their effects on apparel mill performance

ORPP—An Ontology for Skill-Based Robotic Process Planning in Agile Manufacturing

Ontology plays a significant role in AI (Artificial Intelligence) and robotics by providing structured data, reasoning, action understanding, context awareness, knowledge transfer, and semantic learning. The structured framework created by the ontology for knowledge representation is crucial for enabling intelligent behavior in robots. This paper provides a state-of-the-art analysis on the existing ontology approaches and at the same time consolidates the terms in the robotic task planning domain. The major gap identified in the literature is the need to bridge higher-level robotic process management and lower-level robotic control. This gap makes it difficult for operators/non-robotic experts to integrate robots into their production processes as well as evaluate key performance indicators (KPI) of the processes. To fill the gap, the authors propose an ontology for skill-based robotics process planning (ORPP). ORPP not only provides a standardization in the robotic process planning in the agile manufacturing domain but also enables non-robotic experts to design and plan their production processes using an intuitive Process-Task-Skill-Primitive structure to control low-level robotic actions. On the performance level, this structure provides traceability of the KPIs down to the robot control level.

Evaluating the performance of Bi58Sn42 mold produced by material extrusion additive manufacturing system for agile manufacturing

PurposeThe purpose of this study is to produce a low-cost sheet metal forming mold made from the low melting point Bi58Sn42 (bismuth) alloy by using an open-source desktop-type material extrusion additive manufacturing system and to evaluate the performance of the additively manufactured mold for low volume sheet metal forming. Thus, it was aimed to develop a fast and inexpensive die tooling methodology for low-volume batch production.Design/methodology/approachInitially, the three-dimensional printing experiments were performed to produce the sheet metal forming mold. The encountered problems during the performed three-dimensional printing experiments were analyzed. Accordingly, both tunings in process parameters (extrusion temperature, extrusion multiplier, printing speed, infill percentage, etc.) and customizations on the extruder head of the available material extrusion additive manufacturing system were made to print the Bi58Sn42 alloy properly. Subsequently, the performance of the additively manufactured mold was evaluated according to the dimensional change that occurred on it during the performed pressing operations.FindingsResults showed that the additively manufactured mold was rigid enough and proved to have sufficient strength in sheet metal forming operations for low-volume production.Originality/valueAlternative mold production was carried out using open-source material extrusion system for low volume sheet metal part production. Thus, cost effective solution was presented for agile manufacturing.

Value chain management practices and value creation in sub-Saharan African apparel firms

Purpose: This study explores value chain management (VCM) practices in the sub-Saharan African apparel industry, developing a strategic framework to enhance value creation.Design/methodology/approach: A quantitative research design was adopted, surveying 430 managers across the apparel value chain. Data were analysed using factor, correlation, and regression analyses to ascertain the impact of VCM practices on value creation. However, it is essential to notice that the study’s findings are limited to the sub-Saharan African context and may not directly apply to other regions.Findings/results: The analysis revealed a strong correlation between specific VCM practices, such as information sharing, incentive realignment, agile manufacturing, and value creation. These practices help firms to navigate the industry’s complexities and leverage regional opportunities.Practical implications: The study provides a valuable framework for managers, highlighting customer-centricity and strategic sourcing strategies. These strategies are crucial for enhancing operational efficiency and competitive positioning in the global market.Originality/value: The study offers original insights by empirically validating VCM practices and their contribution to value creation within the sub-Saharan apparel sector. The strategic framework fills a gap in the literature and aids the sector’s integration into the global value chain.

Ambidextrous supply chain strategy: roles and consequences with agile manufacturing and resilience

PurposeThe purpose of this study is to investigate the influence of ambidextrous strategy on supply chain resilience and its impact on firm performance, employing the Dynamic Capabilities View.Design/methodology/approachThrough a survey of 215 supply chain professionals, the research employs a structural equation modeling analysis to examine the relationships between ambidexterity, agile operations, resilience, and performance.FindingsThe findings demonstrate that the ambidextrous strategy significantly enhances both agile operations and supply chain resilience. In turn, agile operations and resilience positively impact firm performance. The study also reveals that agile operations and supply chain resilience partially mediate the relationship between ambidextrous strategy and firm performance.Originality/valueThis research contributes to the supply chain management literature by highlighting the importance of an ambidextrous approach in fostering agile operations and resilience, thereby improving firm performance. It extends the dynamic capabilities view framework by elucidating how ambidexterity acts as a pivotal mechanism for adapting to disruptions and securing competitive advantage in volatile markets. Finally, measurements of ambidextrous strategy and resilience are provided to further enhance practitioners’ understanding of building these important components in networks.

Production Floor Digitalization

The digitalization of production floors is becoming increasingly important in the context of e-commerce manufacturers' interactions with customers. This paper investigates the nuances of production floor digitalization in the context of e-commerce manufacturing, examining the implications for both manufactures and buyers. E-commerce manufacturers, faced with the unique challenges of online retail, are leveraging digital technologies to optimize production processes and improve customer experiences. Data-driven demand forecasting, agile manufacturing practices, and seamless integration with e-commerce platforms are all important aspects of production floor digitalization in this context.Digitalization of the production floor provides opportunities for manufacturers to improve efficiency, reduce costs, and respond more quickly to market demand. Manufacturers can improve customer satisfaction and loyalty by implementing real-time data analytics and automation to streamline production workflows, reduce lead times, and ensure timely order fulfillment.On the other hand, production floor digitalization provides significant benefits to e-commerce buyers. Buyers can make more informed purchasing decisions and enjoy greater convenience and reliability in their online transactions thanks to improved product visibility, accurate delivery estimates, and customized purchasing procedures.

Driving sustainability in industry 5.0 through sociotechnical approach of quality management

Industry 4.0 is primarily driven by technology, while Industry 5.0 (I5.0) places more emphasis on the interaction between human (socio) and technology (technical) aspects in shaping sustainability. Although I5.0 represents a burgeoning area of research, however, there remains a paucity of research on the sociotechnical perspective of quality management (QM) and sustainability in I5.0. This study intends to investigate the direct and indirect effects of socio-technical components of QM on sustainable performance through agile manufacturing, as well as the moderating role of firm size on these relationships. Data is gathered from 298 small and medium enterprises (SMEs) through a survey approach employing proportionate stratified sampling techniques. The findings support the socio-technical view of QM in Industry 5.0. Unexpectedly, employee education and training has no significant role in enhancing technical QM practices. Furthermore, QM and agile manufacturing are crucial to achieving sustainable performance in manufacturing SMEs. Finally, firm size has played a significant role as a moderating variable, particularly in I5.0. Based on the findings, the study offers novel theoretical contributions and practical implications by shedding light on the nuanced role of QM and agile manufacturing on sustainability within Malaysian manufacturing SMEs.

Research Methods – is Agile different ?

: The fourth industrial revolution was a radically new round in the evolution of many processes in society, including management processes. The digital revolution has provoked the development of new management models and concepts. Agile manufacturing is one of such managerial production concepts that meets modern challenges and requirements of the business environment. Literature review as a research method plays an important role in the studies. This paper presents a systematic literature review of the papers published in SCOPUS and Web of Science database about agile manufacturing since 2000. Specifically, we aim at analysing the research methods on this very popular topic on the economy and management. We believe that by defining the methods used in the agile field we may understand the nature of the research. It is well known that agile manufacturing methods are meant to be upfront in terms of efficiency, but in this paper we want to make a review on research methods to check how research has been made. Therefore, we believe this research is useful for scientists and practitioners

Fast and sustainable production of smart nanofiber mats by solution blow spinning for food quality monitoring: Potential of polycaprolactone and agri-food residue-derived anthocyanins

The shelf life of perishable foods is estimated through expensive and imprecise analyses that do not account for improper storage. Smart packaging, obtained by agile manufacturing of nanofibers functionalized with natural pigments from agri-food residues, presents promising potential for real-time food quality monitoring. This study employed the solution blow spinning (SBS) technique for the rapid production of smart nanofiber mats based on polycaprolactone (PCL), incorporating extracts of agricultural residues rich in anthocyanins from eggplant (EE) or purple cabbage (CE) for monitoring food quality. The addition of EE or CE to the PCL matrix increased the viscosity of the solution and the diameter of the nanofibers from 156 nm to 261–370 nm. The addition of extracts also improved the mechanical and water-related properties of the nanofibers, although it reduced the thermal stability. Attenuated total reflectance Fourier-transform infrared spectroscopy confirmed the incorporation of anthocyanins into PCL nanofibers. Nanofiber mats incorporated with EE or CE exhibited visible color changes (ΔE ≥ 3) in response to buffer solutions (pH between 3 and 10), and ammonia vapor. Smart nanofibers have demonstrated the ability to monitor fish fillet spoilage through visible color changes (ΔE ≥ 3) during storage. Consequently, smart nanofibers produced by the SBS technique, using PCL and anthocyanins from agro-industrial waste, reveal potential as smart packaging materials for food.

Rise of Intelligent Machines: Influence of Artificial Intelligence on Mechanical Engineering Innovation

The integration of artificial intelligence (AI) into mechanical engineering has precipitated a profound transformation in the way engineers conceive, design, and execute projects. This paper explores the multifaceted impact of AI on mechanical engineering innovation, elucidating the myriad ways in which intelligent machines are revolutionizing traditional practices and catalyzing unprecedented advancements. In the realm of design, AI algorithms are revolutionizing the conceptualization and optimization processes. By leveraging machine learning and optimization techniques, engineers can explore vast design spaces with unparalleled efficiency, uncovering innovative solutions that might otherwise remain elusive. These AI-driven design tools not only expedite the development cycle but also enable the creation of products and systems with enhanced performance characteristics, such as improved energy efficiency, structural integrity, and functional versatility. Moreover, AI's influence extends beyond the design phase and permeates the entire manufacturing ecosystem. AI-driven automation is reshaping production lines, enabling agile and adaptive manufacturing processes that respond dynamically to changing demands and conditions. Through the integration of sensors, actuators, and AI-powered control systems, factories are becoming increasingly intelligent and autonomous, optimizing resource utilization, minimizing waste, and maximizing throughput.

Implementation of Small-Scale Industries and Medium-Scale Industries using Agile Manufacturing in Different Methods

The overall market for current power gadgets and get-together structures with related organizations has a gigantic number of individuals with numerous things in different applications like social occasion parts, exhausting and material clearing. Clients are found in adventures like the auto business, off-turnpike vehicles, the equipment business, aeronautics, devices, the energy region, and general present-day get-togethers. In particular, the business area has been powerful in making advanced electric present-day contraptions and systems that assist clients with achieving getting according to their subtleties and cutoff missteps and breaks in progress. With a rising interest in electric vehicles, battery creation, and creating use of lighter materials, the auto business centres around imaginative party plans. The market demands new assembling developments, for example, controlling paste and sealants and self-infiltrating riveting. The market for machine vision ends up being continuously huge, driven by creating revenue in computerization, quality and proficiency in current creation. Machine vision courses of action are used in discrete creation, similar to the vehicle business, and conflicting cycle creation, similar to metal and paper creation, significant level material collecting, and sun-fueled chargers. Nimble Assembling and Nimble Gathering is a technique for making and Creating things in a manner that is more versatile and Flexible than Standard Systems. This implies Changing or Adjusting the Creation Communication Quickly and Actually to satisfy the Client's endless needs better. The Gathering System is working and has changed to a 21st-century technique. Expected to be Very Responsive. They license makers to rapidly answer changes, whether those changes are in client interest, advancement, or even the business place itself. Keywords—Agile Manufacturing. Organizations' names are PSR, ABC, and SRR veiled are be the Tainted level, and can't be revived since organizations are Coercion Objects are Situated in Mysore City (India).

Predictive Three-Dimensional Printing of Spare Parts with Internet of Things

Industry 4.0 integrates digital and physical technologies to transform work management, where two core enablers are the internet of things (IoT) and three-dimensional printing (3DP). IoT monitors complex systems in real time, whereas 3DP enables agile manufacturing that can respond to real-time information. However, the details of how these two can be integrated are not yet clear. To gain insights, we consider a scenario where a three-dimensional (3D) printer supplies a critical part to multiple machines that are embedded with sensors and connected through IoT. Although the public perception indicates that this integration would enable on-demand printing, our research suggests that this is not necessarily the case. Instead, the true benefit is the ability to print predictively. In particular, it is typically more effective for the 3D printer to predictively print to stock based on a threshold that depends on the system’s status. We also identify a printing mode called predictive print on demand that allows for minimal inventory, and we find the speed of 3DP to be the primary factor that influences its optimality. Furthermore, we assess the value of IoT in cost reductions by separately analyzing the impact of advance information from embedded sensors and the real-time information fusion through IoT. We find that IoT provides significant value in general. However, the conventional wisdom that IoT’s value scales up for larger systems is suitable only when the expansion is paired with appropriate 3DP capacity. Our framework can help inform investment decisions regarding IoT/embedded sensors and support the development of scheduling tools for predictive 3DP. This paper was accepted by David Simchi-Levi, operations management. Supplemental Material: The online appendix and data files are available at https://doi.org/10.1287/mnsc.2023.00978 .

Optimization of 3D printing supply chain in the era of live streaming e-commerce.

This study examines the effects of the rising live streaming e-commerce on the 3DP supply chain, employing system dynamics to develop separate models for pure polymer and polymer-metal mixed printing. The analysis focuses on optimizing the 3DP supply chain configuration. Results indicate that, based solely on printing time, cost, and quality metrics, Corporate-live-3DP services are optimal for live commerce scenarios. However, despite this, Private-live-3DP maintains a substantial consumer base in practice, as evidenced by literature data and case studies. Both models pose significant challenges to conventional supply chains, necessitating adaptation. For Corporate-live-3DP, optimization strategies may include technology advancements, digital transformation, agile manufacturing, global network optimization, innovative management, collaborative R&D, fine-tuned inventory control, quality system upgrades, talent development, and organizational restructuring. Conversely, Private-live-3DP can be optimized through consolidation of private 3D printing resources, demand prediction and order optimization, supply chain collaboration platforms, quality management extensions, inventory strategy adjustments, increased transparency, regulatory compliance, and risk mitigation measures.

Intelligent design of reconfigurable flexible assembly fixture for aircraft panels based on smart composite jig model and knowledge graph

The current demand for aircraft panel assembly fixtures necessitates agile manufacturing solutions. Traditional welding fixtures struggle to meet diverse panel types, high quantities, and short manufacturing cycles. Conversely, reconfigurable flexible assembly fixtures offer universality, efficiency and ease of maintenance but heavily rely on designers' experience, hindering knowledge reuse. Existing research on computer-aided fixture design (CAFD) primarily addresses specialized fixtures, neglecting reconfigurable flexible ones, lacking fixture design knowledge systems. Aiming at the above problems, the study proposes an intelligent design method for the reconfigurable flexible assembly fixture for aircraft panels based on the smart composite jig model (SCJM) and knowledge graph (KG). Firstly, based on the SCJM of the aircraft panel type assembly fixture (PSCJM), a configuration design method is proposed to carry out the multi-level design of reconfigurable assembly fixture to instantiate PSCJM containing fixture configuration rules and a module library based on model definition (MBD). Then, a knowledge retrieval method is proposed to search the suitable fixture design knowledge based on KG, assisting designers in achieving the flexible design of aircraft panel reconfigurable assembly fixtures. Finally, practical engineering design validation confirms the method's feasibility and effectiveness in obtaining the reconfigurable flexible assembly fixture design scheme for aircraft panels.

Critical Role of Manufacturing Execution Systems in Digital Transformation of Manufacturing Industry

The manufacturing industry is undergoing a significant digital transformation, propelled by advancements in technology. Central to this evolution is the implementation of Manufacturing Execution Systems (MES), which act as a vital link between the shop floor and enterprise-level systems. This paper explores the critical role of MES in the digital transformation of the manufacturing industry, focusing on how it enhances operational efficiency, improves product quality, and enables real-time decision-making. Manufacturing Execution Systems are software platforms designed to monitor, control, and optimize production processes from the initiation of orders to the delivery of finished goods. MES provides real-time data on production activities, enabling manufacturers to make informed decisions, reduce production costs, and increase overall productivity. The integration of MES with advanced technologies such as the Internet of Things (IoT), Big Data analytics, and cloud computing has further amplified its impact, leading to smarter and more agile manufacturing processes. One of the key benefits of MES is its ability to improve operational efficiency. MES offers real-time visibility into the production process, allowing manufacturers to identify and resolve bottlenecks, minimize downtime, and optimize resource utilization. Predictive maintenance capabilities, enabled by IoT integration, prevent unexpected equipment failures and reduce maintenance costs. MES also plays a crucial role in enhancing product quality. By monitoring each stage of production, MES ensures adherence to quality standards and facilitates traceability. In the event of a quality issue, MES allows for quick identification of the root cause and implementation of corrective actions. Real-time quality checks at critical points in the production process help detect and address defects promptly. Moreover, MES supports real-time decision-making by providing up-to-date data that allows production managers to respond swiftly to changes in demand or production conditions. This agility is essential in today's fast-paced manufacturing environment. In conclusion, Manufacturing Execution Systems are indispensable in the digital transformation of the manufacturing industry. By improving efficiency, product quality, and decision-making capabilities, MES equips manufacturers to succeed in the era of Industry 4.0. This paper highlights the benefits and challenges of MES implementation, offering valuable insights for manufacturers aiming to leverage MES in their digital transformation efforts

Evaluating the Impact of 3D Printing Technology Innovations on Industrial Production Efficiency and Economic Growth in the Automotive Sector in China

This paper evaluates the impact of 3D printing technology innovations on industrial production efficiency and economic growth in the automotive sector in China. The study explores the historical development and current market trends of 3D printing in China, highlighting its adoption and integration into automotive manufacturing. The applications of 3D printing, including the production of complex geometric parts, rapid prototyping, and customization, are examined for their economic benefits and production efficiency gains. The paper also addresses the technological and market challenges, such as material limitations, printing speed, quality control, regulatory compliance, and market readiness. Emerging technologies and future research directions, including advancements in materials, multi-material printing, large-scale 3D printing, and the integration with IoT and AI, are discussed. Strategic recommendations are provided to maximize the potential of 3D printing in the automotive industry, focusing on investments in R&D, partnerships, workforce training, agile manufacturing practices, sustainability, IP protection, and supply chain optimization. The findings suggest that while 3D printing technology offers significant advantages, addressing existing challenges and leveraging future innovations are crucial for its successful adoption and impact on economic growth in the Chinese automotive sector.

Impact of Motivational Factors on Productivity and Efficiency of Workers in a Motor Industry using Agile Manufacturing Techniques

The mechanism that starts, directs, and sustains goal-oriented behaviour is known as motivation. It is what motivates you to take action, whether it's drinking a drink of water to quench your thirst or reading a book to learn something new. The motor industry competes fiercely in a market where businesses are always looking for ways to perform better and gain an advantage. The ability of an organization to meet consumer requests, deliver goods on time, and retain profitability are all directly impacted by productivity and efficiency. Organizations can discover solutions to improve performance and achieve a competitive edge by understanding the impact of motivating factors on productivity and efficiency. Individual motivation is a key aspect in the success of an organization, so it is necessary to research the different factors that motivate employees and how they can be improved for the benefit of both the individual and the business. In this project, the elements that influence employee motivation are identified, and the relationship between organizational effectiveness and employee motivation is inferred by rationally analyzing each motivational factor. It is of utmost importance and significance to research how motivational variables affect productivity and efficiency in the automotive sector. The motor industry competes fiercely in a market where businesses are always looking for ways to perform better and gain an advantage. Organizations may develop ways to improve performance, raise employee engagement, and promote job satisfaction by studying the impact of motivating factors on productivity and efficiency.