Effective Manufacturing Strategy Research Articles

Lean implementation barriers in the apparel industry in Bangladesh

PurposeIn the highly competitive business landscape, manufacturing firms need to adopt an effective manufacturing strategy to attain a successful world-class manufacturing status. Over the past few decades, the lean manufacturing (LM) approach has gained recognition as one of the foremost strategies for enhancing performance. However, the implementation of LM poses significant challenges due to several barriers. The purpose of this paper is to investigate the primary barriers to lean implementation within the apparel industry.Design/methodology/approachThis paper used an exploratory study approach, using a three-part structured questionnaire to assess the level of agreement on different lean barriers. The measurement of these barriers was conducted using a five-point Likert scale. Empirical data were collected from 177 apparel companies located in Bangladesh.FindingsThe findings of the research highlight that the primary obstacles to implementing LI include a lack of understanding of the lean manufacturing system (LMS), the manufacturing process, the company culture and resistance from employees.Research limitations/implicationsThis paper could potentially limit the generalizability of this research, as it exclusively examines a single manufacturing sector – the apparel industry.Practical implicationsThis paper will help practitioners in finding solutions to resolve discrepancies between current manufacturing practices and the LMS.Originality/valueThis paper fulfills an identified need to examine the extent of lean adoption within the apparel industry of Bangladesh.

DEVELOPMENT OF A MANUFACTURING STRATEGY OF SPARE PARTS: A CASE STUDY

Managing supplementary parts for plants and machines plays a major role in accomplishing the needed system availability in a cost-effective manner. Today’s industrial demands require mature technology that is strong in terms of capital and bulk-production oriented. However, the idleness of these machines and equipment due to unavailability of spare parts is a major problem and barrier to effective systems availability. This study aims to develop an effective manufacturing strategy for spare parts. A case study was conducted at a General Water Desalination Establishment in Saudi Arabia to select the right strategy to reduce the total downtime and total maintenance costs of equipment. The results showed the importance of creating a production plan that suits an organization’s ability to manage the supply chain for customers and ensure the company remains competitive within its market. Identification of critical spare parts of equipment for maintenance operations is one of the key decision-making activities to obtain lower downtime for equipment and inventory costs. Therefore, decision-makers should apply the best method and use accurate criteria to analyze and rank the spare parts based on criticality. The strategies proposed in the present study assure that these important parts are available for maintenance and repair of the plant and machinery when required at an optimum cost.

Pristine Multi-walled carbon nanotubes for a rapid and efficient plasmid DNA clarification

Therapeutic approaches based on nucleic acids to modulate cell activity have recently gained attention. These molecules arise from complex biotechnological processes, requiring effective manufacturing strategies, high purity, and precise quality control to be used as biopharmaceuticals. One of the most critical and time-consuming steps for nucleic acids-based biotherapeutics manufacturing is their purification, mainly due to the complexity of the extracts. In this study, a simple, efficient, and reliable method to isolate and clarify plasmid DNA (pDNA) from complex samples is described. The method is based on the selective capture of RNA and other impurities, using pristine carbon nanotubes (CNTs). Multi-walled CNTs (MWCNTs) with different diameters were studied to determine their adsorption capacity and to address their ability to interact and distinguish between nucleic acids. The results revealed that MWCNTs preferentially interact with RNA and that smaller MWCNTs present a higher adsorption capacity, as expected by the higher specific surface area. Overall, this study showed that MWCNTs significantly reduce the levels of impurities, namely RNA, gDNA, and proteins, by approximately 83.6 % compared to their initial level, enabling the recovery of clarified pDNA in solution while maintaining its stability throughout the recovery process. This method facilitates the pre-purification of pDNA for therapeutic applications.

Applying strategic cost management techniques to support the effective manufacturing strategy and its impact on achieving sustainable competitive advantage: an applied study in the General Company for Electrical and Electronic Industries / Al-Waziriyah Br

يهدف البحث الى تطبيق تقنيات إدارة التكلفة الاستراتيجية والمتمثلة بتقنيتي التكلفة على أساس المواصفات والكلفة المستهدفة في معمل السخانات التابع للشركة العامة للصناعات الكهربائية والالكترونية. وذلك من خلال منهج متكامل بين التقنيتين أعلاه لتعزز استراتيجية التصنيع الفعال وتحقيق الميزة التنافسية المستدامة. ومن اجل تحقيق الهدف أعلاه اعتمد الباحث عند تطبيق التقنيين أعلاه على البيانات التي تم الحصول عليها على دراسة السجلات المحاسبية والكشوفات المستخدمة في الاقسام والشعب المختلفة للمعمل عينة البحث، وعن طريق المعايشة الميدانية والمقابلات الشخصية مع المسؤولين في المعمل. وقد توصل البحث الى مجموعة الاستنتاجات لعل ابرزها ان لتقنتي (ABCII)و(TC) القدرة اذا ما تم تطبيقهما في المعمل عينة البحث على تحقيق نجاح تطبيق استراتيجية التصنيع الفعال والتي تسهم في تحقيق ابعادها عن طريق قدرة هذه التقنيتين من الايفاء بمتطلبات التصنيع في الوقت الحالي من خلال استخدام المهارات والكفاءات العالية من ناحية تصميم المنتجات وفق متطلبات الزبون وبطريقة تحقق الاستغلال الامثل للموارد المتاحة وبالشكل الذي ينعكس على تحقيق استدامة الميزة التنافسية .، لذا فان اهم ما جاء في هذا البحث من مقترحات وتوصيات تؤكد على الاهتمام بتطبيق التقنيتين نفة الذكر وذلك لأثرها الملموس في تحقيق الأهداف المنشودة للشركة .

Exploring Key Decisive Factors in Manufacturing Strategies in the Adoption of Industry 4.0 by Using the Fuzzy DEMATEL Method

Globalization has created a highly competitive and diverse market, an uncertain and risky business environment, and changing customer expectations. An effective manufacturing strategy reduces complexity and provides organizations with a well-organized manufacturing structure. However, existing research on manufacturing strategies appears scattered, lacking systematic understanding and finding no causal relationship between manufacturing strategies’ outputs (MSOs) and their importance. Therefore, this study is a pioneer in identifying the influential factors of MSOs in the adoption of Industry 4.0 (I4.0) technologies utilizing the decision-making trial and evaluation laboratory (DEMATEL) approach. This method is considered an effective method for identifying the cause-effect relationship of complex problems. It evaluates interdependent relationships among MSO factors from the perspective of academic and industry experts. Identifying cause and effect factors leads to increasing the market’s competitiveness and prioritizing them. To deal with the vagueness of human beings’ perceptions, this study utilizes fuzzy set theory and the DEMATEL method to form a structural model. Results show that customer satisfaction, cost per unit produced, and the number of advanced features are the main factors influencing MSOs.

Prediction of reversible α/γ phase transformation in multi-pass weld of Fe-Cr-Ni ternary alloy by phase-field method

Duplex stainless steel (DSS) is vulnerable to changes in the α/γ phase fraction due to the dissolution and precipitation of various compounds during multi–pass welding. Thus, prediction of this dissolution and precipitation behavior is key for the development of effective manufacturing strategies. In this study, the kinetics of the dissolution and precipitation phenomena of the γ phase in Fe-Cr-Ni alloy were investigated using the kinetic constants derived by the phase–field method, and the α/γ phase fraction of the multi-pass welds was theoretically investigated. The kinetics of the dissolution and precipitation phenomena were evaluated theoretically and experimentally through optical and scanning electron microscopy. DSSs with different compositions were evaluated to achieve satisfactory correlation. The temperature dependences of the experimental and calculated values were found to be in good agreement, indicating that it is possible to theoretically predict the dissolution and precipitation phenomenon of the γ phase by using the phase-field method presented herein. With regard to the α/γ phase fraction, there was a remarkably high correlation between the results predicted using the kinetic constant of the experimental value and those predicted using the kinetic constant derived from the phase–field method. Therefore, the kinetics-based theoretical results of this study could serve as a resource for predicting the γ phase amount of multi–pass welds in DSSs.

Theoretical phase-field-method-based model of the γ phase dissolution of base metals in duplex stainless steels

Duplex stainless steel (DSS) is vulnerable to changes in the α/γ volume ratio due to the dissolution of various compounds during multi-pass welding. Thus, prediction of this dissolution behavior is key for the development of effective manufacturing strategies. In this study, the γ phase dissolution behavior of different types of DSSs was predicted using the phase-field method. The kinetics of the DSS dissolution phenomena were evaluated theoretically and experimentally through optical and scanning electron microscopy. DSSs with different compositions were evaluated to achieve satisfactory correlation. The results of the theoretical analysis revealed the relationship between the kinetic constant and the temperature and elucidated the kinetics of the α/γ phase transformation. The relationships were adjusted by determining coefficients to improve the correlation with the experimental results. This corrected calculation was then applied to another lean DSS to confirm the generality of the solution. The experimental and kinetics-based theoretical results of this study could serve as a resource for predicting the γ phase dissolution behavior of DSSs.

A new methodology for race-tracking detection and criticality in resin transfer molding process using pressure sensors

In this study, a simplified cost effective simulation-based methodology is proposed to assist manufacturing engineers in the design and development phase of the resin transfer molding process. Race-tracking is unavoidable in the resin transfer molding and can lead to entrapment of air pockets, which results in parts being discarded as scrap. A purely numerical methodology is presented to distinguish between the critical and non-critical race-tracking scenarios, that will guide the design and production engineers plan an efficient and effective manufacturing strategy. The detection methodology is based on computing the pressure evolution with time during the injection process. The novelty relies on the superimposition of the computed pressure gradient maps that reveals unsuspected common features in the numerous race-tracking cases investigated in the various geometries of increasing complexity considered. The pressure sensors are meant to detect and evaluate different race-tracking scenarios and their level of criticality. The minimum number and locations of pressure sensors arise directly from the highest pressure gradient zones for simple geometries. Sensors placement guidelines are introduced for a simple rectangular shape, then this information is used to qualitatively apply the guidelines to parts of more complex shapes. A general rule that all parts, no matter how complex, can be considered as a combination of simpler ones is presented. Furthermore, a new failure criterion is proposed based on the flow patterns that highlights the likely flow patterns to entrap voids.

Manufacturing strategies in different environments: does equifinality or a dominant strategy exist?

This study addresses two essential issues related to equifinality: (1) whether firms can choose different but equally effective manufacturing strategies for different environments (equifinality) and (2) whether there is one strategy adopted by more firms than others (dominant strategy) in each individual environment. With data collected from 434 Chinese manufacturing companies, this study identifies a four-cluster taxonomy of business environments (harsh, labour munificent, stable and low-cost) and a four-cluster taxonomy of manufacturing strategies (mass servers, marketeers, manufacturing emphasisers and low emphasisers). The analyses show that dynamism and munificence exert joint effects on equifinality and the existence of a dominant strategy.

Manufacturing Strategy – A Neglected Success Factor for Improving Competitiveness

In the past decades, the requirements for manufacturing have increased significantly. The major reasons are shorter product and market life cycles, a significantly increased model range but smaller batch sizes and highest technological requirements. In order to distinguish oneself from other companies and to improve the own competiveness in this challenging market, an effective manufacturing strategy is crucial. Therefore, the manufacturing strategy has to be coordinated with other functional strategies and depends on enterprise individual contents. In result, the manufacturing strategy determines the certain use of specific resources and capabilities in manufacturing, which can enable the development and expansion of competitive advantages. However, existing approaches for developing a manufacturing strategy do not allow a sufficient response to the described market situation. In fact, relevant resources and capabilities which lead to a better performance in manufacturing and a higher competitiveness cannot be identified or just with a time lag. To meet the changing market conditions, the manufacturing strategy has to be developed with a new process. Therefore, an approach for developing a manufacturing strategy is presented. This paper points out how manufacturing can enable a decisive differentiation from competitors. In this new process, the development of the manufacturing strategy is seen as an integral part of the enterprise strategy. In summary, the approach allows a unique strategic position that enhances the competitiveness through specific resources and capabilities in manufacturing.

Recent progress in electrospun nanofibers: Reinforcement effect and mechanical performance

ABSTRACTComposite materials are becoming increasingly important as structural materials for aeronautical and space engineering, naval, automotive, and civil engineering, sporting goods, and other consumer products. Fiber‐based reinforcement represents one of the most effective manufacturing strategies for enhancing the mechanical strength and other properties of composite materials. Electrospinning has gained widespread interest in the last two decades because of its ability to fabricate continuous ultrafine nanofibers with unique characteristics. The impact of electrospinning on fiber synthesis and processing, characterization, and applications in drug delivery, nanofiltration, tissue scaffolding, and electronics has been extensively studied in the past. In this article, the authors have focused on a comprehensive review of the mechanical performance and properties of electrospun nanofibers as potential reinforcements as well as their advanced nanocomposites. © 2015 Wiley Periodicals, Inc. J. Polym. Sci., Part B: Polym. Phys. 2015, 53, 1171–1212

Analysis of barriers of total productive maintenance (TPM)

In the highly competitive environment, to be successful and to achieve world-class-manufacturing, organizations must possess both efficient maintenance and effective manufacturing strategies. A strategic approach to improve the performance of maintenance activities is to effectively adapt and implement strategic TPM initiatives in the manufacturing organizations. Total productive maintenance (TPM) is not easy to adopt and implement, due to presence of many barriers. The purpose of this paper is to identify and analyse these barriers. A questionnaire based survey was conducted to rank these barriers. The results of this survey and interpretive structural modelling approach have been used to model and analyse key barriers and drive managerial insights.

Nonvolatile copolymer compositions for fabricating gel element microarrays

By modifying polymer compositions and cross-linking reagents, we have developed a simple yet effective manufacturing strategy for copolymerized three-dimensional gel element arrays. A new gel-forming monomer, 2-(hydroxyethyl) methacrylamide (HEMAA), was used. HEMAA possesses low volatility and improves the stability of copolymerized gel element arrays to on-chip thermal cycling procedures relative to previously used monomers. Probe immobilization efficiency within the new polymer was 55%, equivalent to that obtained with acrylamide (AA) and methacrylamide (MA) monomers. Nonspecific binding of single-stranded targets was equivalent for all monomers. Increasing cross-linker chain length improved hybridization kinetics and end-point signal intensities relative to N,N-methylenebisacrylamide (Bis). The new copolymer formulation was successfully applied to a model orthopox array. Because HEMAA greatly simplifies gel element array manufacture, we expect it (in combination with new cross-linkers described here) to find widespread application in microarray science.

A new optimization approach based on Kriging interpolation and sequential quadratic programming algorithm for end milling refractory titanium alloys

Refractory titanium alloys are often used in aerospace industry for applications requiring high temperature strength and high mechanical resistance. However, the main problems encountered when machining this kind of material are the low material removal rate and the short cutting tool life. Due to their hard nature, an effective manufacturing strategy is required by industrials to optimize cutting parameters and improve machining efficiency. In this work, a new technique of optimization for dry machining refractory titanium alloys has been developed. The optimisation procedure is a new strategy based on both response surface method with “Kriging interpolation” and sequential quadratic programming algorithm. In comparison with previous models taken from the literature, two functions have been formulated in the machining problem to describe the non linear and complex relationship between variables and responses. The first function called “objective function” represents the volume of material removal produced during the cutting tool life and which has to be maximised. The second function called “constraint function” represents the surface roughness and has to be taken below a critical value. Thanks to this new approach, a robust optimization algorithm has been carried out to optimize cutting conditions taking into account productivity and quality.

On some aspects of developing an effective model for the implementation of Six Sigma concept in small and medium sized manufacturing enterprises in India

About four million industrial undertakings in India are under small and medium-size enterprises (SMEs) category and their contribution to the gross domestic product (GDP) of the nation is very much significant. However, the ever-increasing influx of foreign goods and services in Indian market, either imported or manufactured by multi-national companies (MNCs) within India has rendered many SMEs unviable to compete, especially in terms of cost. For survival and growth of SMEs it has become highly imperative for enterprises to adapt cost effective manufacturing strategies by eliminating defects from every one of the company’s products, process, and business transactions. There is a little focus, in the existing literature, on the issue of implementing Six Sigma in SMEs or on developing an implementation model. An implementation model has been proposed in this paper from the viewpoint of human element which is a major asset of most SMEs in India. The model also incorporates the necessary process aspects such as process capability.

Formulation of manufacturing strategies using organizational knowledge created via e-business mechanisms

Eff ective manufacturing strategies have been developed and explored in recent years. Successful manufacturing strategies can result in high manufacturing performance and enable manufacturers to obtain powerful competitive advantages. The question of how to formulate a manufacturing strategy that provides these benefi ts is an important one. This study explores the importance of organizational knowledge creation to the formulation of manufacturing strategy and enhancement of performance and investigates whether organizational knowledge can be created via an e-business mechanism. In this study, we collected 521 observations from a global sample drawn from the International Manufacturing Strategy Survey (IMSS) database and tested the data using structural equation modeling (SEM).

Manufacturing strategy - a potential competitive tool for J&S Botswana (Pty) Ltd [case study

It is quite common a practice for organizations in developing countries with manufacturing functions, particularly small to medium enterprises, to operate without a defined strategy for competitiveness. This has seen many potential businesses failing to survive the competition in the dynamic business environment. In order to thrive in any chosen market, an organization needs to have a well-defined manufacturing strategy that is periodically audited. An effective manufacturing strategy must clarify and define the links between overall competitive strategy and the development of the company’s resources. Strategy formulation provides direction, purpose and coherence; ensures that manufacturing’s interests are taken into account at corporate level; clarifies and emphasizes priorities and potential conflicts; and helps integrate functions. An understanding of the consumer’s needs is critical and a clear awareness of order winning and order qualifying criteria is essential. Thus a manufacturing strategy sets the destination (and course), and implementation of the same defines how to get there. This work therefore outlines a customized methodology for formulating a manufacturing strategy through a strategic audit of a local case study company. The results of the audit carried out indicate that the company is operating without a defined strategy for competitiveness and is performing very badly with respect to the desired levels of competitive performance objectives. Suggestions are made for the effective implementation of a performance improvement programme within the context of the company’s current limitations. Keywords: Competitive strategy, Competitive performance objectives, Manufacturing strategy

A closed loop outsourcing decision model for developing effective manufacturing strategy

The case study deals with aligning production capacity for a US manufacturer of industrial thermal transfer bench-top printer, by exploring various insourcing and outsourcing options based on production, cost and delivery capabilities. A modelling framework is devised which aids in selecting an effective manufacturing strategy that considers key enablers and barriers to successful outsourcing. The proposed model is closed loop, which stresses regular re-evaluation of the existing outsourcing strategy. It models the total product cost for the product currently being manufactured in the US and compares the total costs if it were manufactured offshore in countries such as, Malaysia, China, Slovakia and Mexico. The analysis from the model shows moving manufacturing of the product to Mexico results in the largest business benefit of about $400 savings per unit compared to other countries studied. A closer look at China in the future could be considered as the economic, social and security risks may change enough to warrant re-evaluation of this option. To get a clearer picture of how Mexico rates against Malaysia in the existing state, these risks may be reviewed as an extra data point to finalise the decision to move manufacturing of industrial thermal transfer bench-top printers to Mexico.

Selection of lean manufacturing systems using the PROMETHEE

PurposeIn recent years, many manufacturing companies are attempting to implement lean manufacturing systems (LMS) as an effective manufacturing strategy to survive in a highly competitive market. Such a process of selecting a suitable manufacturing system is highly complex and strategic in nature. The paper aims to how companies make a strategic decision of selecting LMS as part of their manufacturing strategy, and on what basis such strategic decisions are made by the managers.Design/methodology/approachA case study of a small‐ and medium‐sized enterprise is presented, in which the managers are contemplating on implementing either computer integrated manufacturing systems (CIMS) or LMS. To supplement the decision‐making process, a multi‐criteria decision making (MCDM) model, namely, the preference ranking organisation method for enrichment evaluations (PROMETHEE) is used to analyse how it will impact the stakeholders of the organisation, and the benefits gained.FindingsAn extensive analysis of PROMETHEE model revealed that LMS was the best for the given circumstances of the case.Research limitations/implicationsThe same problem can be extended by incorporating the constraints (such as financial, technical, social) of the organisation by utilising an extended version of PROMETHEE called the PROMETHEE V. Since, a single case study approach has been utilised, the findings cannot be generalized for any other industry.Practical limitations/implicationsThe methodology of PROMETHEE and its algorithm has been demonstrated in a detailed way and it is believed that it will be useful for managers to apply such MCDM tools to supplement their decision‐making efforts.Originality/valueAccording to the authors’ knowledge there is no paper in the literature, which discusses the application of PROMETHEE in making a strategic decision of implementing LMS as a part of an organisation's manufacturing strategy.

Auditing system flexibility in the context of manufacturing strategy information

Suggests that there is a need to develop a process to enable manufacturing managers to formulate and implement effective manufacturing strategies. Describes research aimed at identifying those characteristics of manufacturing strategy formulation performance measures which were considered by practitioners to lead to successful creation of strategies. Proposes a viable tool which can help businesses to identify current levels of flexibility, hence enabling them to improve manufacturing flexibility in accordance with strategic objectives.