Large Manufacturing Industries Research Articles

Key observations from a survey about Six Sigma implementation in Brazil

Purpose – The purpose of this paper is to present a survey on Six Sigma and key observations on which variables/management practices are the most important for a successful Six Sigma implementation, as well as the strengths and weaknesses of the practices observed in companies in Brazil. Design/methodology/approach – Five research questions were proposed, and an exploratory field study was carried out. A sample of 103 questionnaires was obtained. In total, 26 independent variables were analyzed, with a factor analysis reducing this number to 14, for which three main constructs were observed. Findings – Large manufacturing industries are implementing the Six Sigma program in Brazil. Three main constructs were observed to be critical for the success of Six Sigma. The strengths and weaknesses of the 14 independent variables studied within each construct were found. Practical implications – This paper has practical implications in that companies can use the conclusions of this study to improve their implementation of the Six Sigma program. Social implications – This research may initiate cooperation between the companies within the study and academia, which may lead to a better understanding of Six Sigma within these organizations. Originality/value – The originality of this study is that the survey was conducted with companies in Brazil, a country that suffers from a lack of information on Six Sigma programs. A robust methodological strategy was used that determined the three most important constructs for successful implementation of Six Sigma.

Basic formation in streamlining lean practices in manufacturing operations - a review

Lean production, also known as lean manufacturing was a popular social-technical management philosophy, and widely accepted as an effective approach in improving the operational performance management since it was first introduced in the early 90s. However, most of lean practice is often adopted based on own understanding with reference to the success achieved by others. This potentially creates the gap and eventually affects its implementation performance. Therefore, the aims of this article is to propose based on literature, the basic concept of lean practices that can be considered by manufacturers as a starting point or to strengthen the performance of its regardless of firm size (small, medium or large manufacturing industry). By referring to the nine categories of manufacturing waste (inventory, waiting time, transportation, inefficient energy utilisation, over-processing, over-production, unnecessary motion, and defects), lean practices can be streamlined through the four formation stages, i.e., planning and product development, production planning and scheduling, manufacturing processes, and functional and visual inspection. This can be realised by focusing on three dimensions of implementation, namely input, product revolutionary processes, and output. The proposed concept is useful as a basic guideline, primarily for manufacturers to plan and develop a better strategy for a better performance results.

The Role of Host Country Factors and Institutional Framework for FDI Spillovers in Ethiopia: The Case of Manufacturing Sector

The Role of Host Country Factors and Institutional Framework for FDI Spillovers in Ethiopia: The Case of Manufacturing Sector

Magnitude and Factors of Occupational Injury among Workers in Large Scale Metal Manufacturing Industries in Ethiopia

Background: The burden of occupational injury in most developing countries including Ethiopia is becoming a public health problem. Therefore, information that shows the magnitude and predictors of occupational injury in most risky work places in Ethiopia such as large scale metal manufacturing industries is indispensable for proper health intervention programs. Objectives: The aim of this study was to assess the magnitude and factors affecting occupational injuries among workers engaged in large scale metal manufacturing industries in Addis Ababa, Ethiopia. Methods: Facility based cross sectional study was conducted among 829 workers engaged in large scale metal manufacturing industries in Addis Ababa, Ethiopia from February 1 to March 30, 2010. Fifty percent (50%) of large scale metal manufacturing industries were selected by simple random sampling after stratification. Then, calculated sample size was allocated for each industry by probability to proportional sample size. Subjects were stratified by working sections and those who were directly engaged in the work were selected from each stratum by simple random sampling after preparing a frame from payroll of those industries. The data were collected by pretested structured questionnaire. Observational checklist and in-depth interview with key informants were held to triangulate the information with quantitative findings. Both bivariate and multivariate logistic regressions were done to identify factors of occupational injury. Results: The magnitude of occupational injury was 489 per 1000 exposed workers per year. Twenty nine percent of injured workers were hospitalized of which 98 (82.4%) for 24 or more working hours. Sex of workers [AOR: 3.32, 95% CI: (1.88, 5.85)], safety and health supervision [AOR: 1.60, 95% CI: (1.03, 2.60)], hours worked per week [AOR: 2.37, (95% CI: (1.55, 3.61)], cigarette smoking [AOR: 3.36, 95% CI: (1.73, 6.50) ] and presence of functional danger signs/posts [AOR: 2.65, (95% CI: (1.67, 4.19)] were significantly associated factors with magnitude of occupational injury. Conclusion: The burden of occupational injury in metal manufacturing industry is really significant public health problem. Emphasis should be given to provide health and safety services on sex of workers, safety and health supervision, hours worked per week, cigarette smoking and functional danger signs.

Landscape of Industry: Transformation of (Eco) Industrial Park through history

The landscape of industry has been changing over time. Industry has transformed and many tangents have emerged from the sporadic home-based cottage industries to geographically scattered large manufacturing industries to co-located industrial parks to environment friendly eco-industrial parks. Curiosity about the catalysts that bring about the transformation of industrial landscape is the motivation of this article. Through the narrative on Industrial Park and the gradual shift towards Eco-Industrial Park, this article aims to shed light on the context and conditions that act as catalysts for industrial transformations, so as to serve as a reference for predicting future changes in industrial landscape.

Study on Design Proposal of Computerized Numerical Control Machine Networking

At present, the majority of enterprise technology management and production management have entered the network era. The demand for people who are occupied in 3D product design, numerical control advanced engineering technology is gradually increased. In order to speed up the production development of factories, we need to greatly improve the productivity of CNC machine. Therefore, CNC networking and management is imperative. This article describes background of the implementation of the numerical network management as well as its necessity. According to the industry characteristics of design and manufacturing and production management, this paper analyzes proposals on the network management system of CNC and describes the main functions of the machine network system and the results after the implementation. The network system of CNC is to improve the productivity of CNC machine, and give references to the application of CNC machine networking in large machine manufacturing industry.

Collaboration of large equipment complete service under cloud manufacturing mode

This paper focuses on the need of the large equipment manufacturing industry to adapt collaborative operation to transform the industry to cloud manufacturing services and to solve the new problem of federal resources coordination in complete service operation. We systematically study federal resources cooperation under cloud manufacturing mode to complete a large complex project. The primary research contents are divided into four points. First, a system structure of cloud manufacturing service mode is presented. Second, a synergy logic framework from the global system perspective is designed based on generalised partial global planning. Third, a multi-level system coordination mechanism is established by integrating various methods, including the bidding game mechanism for enterprise external resources, the planning control mechanisms for enterprise internal resource and the global collaborative optimisation mechanism for enterprise global federal resources. Finally, a cloud manufacturing service platform for a typical enterprise is developed by combining theory with practice. The results can realise collaborative management in resource selection and configuration, service process planning control and service information feedback in cloud manufacturing service, as well as achieve overall synergy effect for the system.

Dynamic-Model Assembly Line Scheduling

The assembly line scheduling solution is restricted to two assembly lines that fulfill the requirement of small manufacturing industry by identifying the least cost path. Problem arises when large manufacturing industry comes under discussion where more than two assembly lines say three to fulfill the job, In this case two types of assembly line cost are involve: switching from one assembly line to another; switching from one station to the next. This study considers a solution for above mentioned scenario by least cost path identification, path cost calculation through back tracking, and a derived solution formula in order to reduce the computational complexity of scheduling at latter stages for n station. That provides the understanding for m number of assembly lines at the same time.

Model to Plan and Control the Generational Transition of DRAM Industry

DRAM industry is not only among the largest manufacturing industries in the world, but also the most competitive. Furthermore, due to DRAM business is characterized by short life cycles, along with highly competition, the manufacturers are forced to migrate to advanced technology quickly. Under this circumstance, the manufacturers have to launch new technology and purchase generational equipment to meet the market demand and reduce manufacturing cost frequently. This paper investigates the technology generational transition of DRAM industry from manufacturing and planning perspectives. The concept of TOC is applied to schedule the production plan of the new/old products. Regarding to shop floor control, three definitions of cycle time are used to diagnose the production status. Finally, the workload ratio of bottleneck is used for the release decision to adjust the rhythm of production.

조선에서 대량 맞춤화의 영향

One of the goals of mass customization is to permit changes in the product to meet specific customer requirements without substantially impacting the cost or delivery schedule. In large assembly manufacturing industries, such as shipbuilding and commercial airplane production, customization takes place by changing components and/or modules, sometimes called interim products. Using shipbuilding as a case study, it is possible to study the impact of such changes using mass customization principles on the schedule. In large assembly manufacturing, mass customization changes would cause changes in engineering time and production time, based on the amount of change required by the customization. This work first proposes a structure for implementing mass customization in shipbuilding and then uses simulation of a simplified, theoretical shipbuilding process to evaluate the impacts of various levels of change on delivery performance.

Innovation in services: Cases of Brazilian manufacturing industries

The service sector is currently being transformed in the face of economic, technological and social change and is expanding its markets and increasing the complexity of its activities. Innovation process in services is new in academic literature and is still largely debated. The goal of this study is to analyze the service innovation process in two large manufacturing industries, associating the service innovation models found in the literature to the organizational practices adopted by the case study under consideration, so that a set of inferences can be made in regards to a model for understanding the process of service innovation within the realm of industrial organizations. For this purpose, a literature review pertaining to the subject was done and in-depth interviews were conducted with managers from these large manufacturing industries. The findings indicated that innovations in services present challenges that need to be clarified as innovation process, related to properly understanding the unique nature of services by structures originally designed for manufacturing, as well as the assumption of a new paradigm related to creating and developing relationships with clients on a long-term perspective. Key words: Innovation, services, Brazilian industry.

How does FDI influence industry-level knowledge production efficiency in China?

Based on the knowledge production function (KPF) framework, this article uses industry-level data of Chinese large and medium size manufacturing industries from 2001–2009 to explore the impacts of intra-industry and inter-industry foreign direct investment (FDI) presence on the efficiency of knowledge production (in terms of product-related and patent-related knowledge production). The empirical results reveal that intra-industry FDI presence has a positive effect on knowledge production, especially for product-related knowledge production efficiency. In contrast, inter-industry FDI presence has a negative effect on patent-related knowledge production efficiency, and a positive but insignificant effect on product-related knowledge production efficiency. Our study provides empirical evidence of the potential effect the difference between intra-industry and inter-industry FDI presence has on knowledge production. In addition, this study indicates that the contribution of FDI presence to knowledge production efficiency is more associated with product-related knowledge production than with patent-related knowledge production.

Neigbourhood Effects of Sustainable Industrial Land Use on Property Values: Case Study of Agbara, Ogun State, Nigeria

The study aims at examining the effect of sustainable industrial land use on residential property values using Agbara industrial village, Nigeria as a case study. Two sets of structured questionnaires were administered differently to 500 inhabitants of Agbara Village and Housing Estate, and the 16 identified large manufacturing industries operating in the area. However, 452 copies of the returned questionnaire were used for this study. The actual sampled inhabitants were obtained through simple random sampling technique. Data collected were presented in tables of frequencies and percentage while trend analysis of rental values in Agbara was computed for the period 1997 to 2008. The study revealed positive change in property rental values due to the industrial concerns in the community. Both government and private businessmen are therefore, advised to site their manufacturing industries in the rural areas to improve such places. It is also recommended that developers should seize the opportunity of high demand for housing in industrial zones and invest in residential developments.

Improved Methods for Production Manufacturing Processes in Environmentally Benign Manufacturing

How to design a production process with low carbon emissions and low environmental impact as well as high manufacturing performance is a key factor in the success of low-carbon production. It is important to address concerns about climate change for the large carbon emission source manufacturing industries because of their high energy consumption and environmental impact during the manufacturing stage of the production life cycle. In this paper, methodology for determining a production process is developed. This methodology integrates process determination from three different levels: new production processing, selected production processing and batch production processing. This approach is taken within a manufacturing enterprise based on prior research. The methodology is aimed at providing decision support for implementing Environmentally Benign Manufacturing (EBM) and low-carbon production to improve the environmental performance of the manufacturing industry. At the first level, a decision-making model for new production processes based on the Genetic Simulated Annealing Algorithm (GSAA) is presented. The decision-making model considers not only the traditional factors, such as time, quality and cost, but also energy and resource consumption and environmental impact, which are different from the traditional methods. At the second level, a methodology is developed based on an IPO (Input-Process-Output) model that integrates assessments of resource consumption and environmental impact in terms of a materials balance principle for batch production processes. At the third level, based on the above two levels, a method for determining production processes that focus on low-carbon production is developed based on case-based reasoning, expert systems and feature technology for designing the process flow of a new component. Through the above three levels, a method for determining the production process to identify, quantify, assess, and optimize the production process with the goal of reducing and ultimately minimizing the environmental impact while maximizing the resource efficiency is effectively presented. The feasibility of the method is verified by a case study of a whole production process design at the above three levels.

PERILAKU EKSPOR PERUSAHAAN MANUFAKTUR DI INDONESIA, 1990-2000

This paper examines export behaviour of manufacturing firms in Indonesia. We use firm-level data from survey of medium and large Indonesian manufacturing industries over the period 1990-2000. Using panel data regression technique, we find the following regularities. First, there is a persistency in the firm’s decision to export as well as proportion of exported output. Second, higher wage, larger number of production employment, higher productivity and higher share of foreign ownership lead to higher probability of a firm to export. Third, higher wage leads to higher proportion of exported output. However, higher productivity or higher share of foreign ownership leads to lower proportion of exported output. Fourth, while real exchange rate does not significantly affect the probability of firms to export, it significantly affects the proportion of exported output. Fifth, both probability to export and proportion of exported output was significantly much lower during the 1997/1998’s Asian crisis. Finally, looking at the export behaviour across industries, the estimation results show that there is a variation of export behavior across industries.Keywords: Export, manufacture, Indonesia.JEL Classification: F14, F13, D21

EXPORT BEHAVIOUR OF MANUFACTURING FIRMS IN INDONESIA, 1990-2000

This paper examines export behaviour of manufacturing firms in Indonesia. We use firm-level data from survey of medium and large Indonesian manufacturing industries over the period 1990-2000. Using panel data regression technique, we find the following regularities. First, there is a persistency in the firm’s decision to export as well as proportion of exported output. Second, higher wage, larger number of production employment, higher productivity and higher share of foreign ownership lead to higher probability of a firm to export. Third, higher wage leads to higher proportion of exported output. However, higher productivity or higher share of foreign ownership leads to lower proportion of exported output. Fourth, while real exchange rate does not significantly affect the probability of firms to export, it significantly affects the proportion of exported output. Fifth, both probability to export and proportion of exported output was significantly much lower during the 1997/1998’s Asian crisis. Finally, looking at the export behaviour across industries, the estimation results show that there is a variation of export behavior across industries.Keywords: Export, manufacture, Indonesia.JEL Classification: F14, F13, D21

Integrated model for line balancing with workstation inventory management

Article history: Received 13 May 2010 Received in revised form 14 May 2010 Accepted 14 May 2010 Available online 15 May 2010 In this paper, we address the optimization of an integrated line balancing process with workstation inventory management. While doing so, we have studied the interconnection between line balancing and its conversion process. Almost each and every moderate to large manufacturing industry depends on a long and integrated supply chain, consisting of inbound logistic, conversion process and outbound logistic. In this sense an approach addresses a very general problem of integrated line balancing. Research works reported in the literature so far mainly deals with minimization of cost for inbound and outbound logistic subsystems. In most of the cases conversion process has been ignored. We suggest a generic approach for linking the balancing of the line of production in the conversion area with the customers’ rate of demand in the market and for configuring the related stock chambers. Thus, the main aim of this paper is to translate the underlying problem in the form of mixed nonlinear programming problem and design the optimum supply chain so that the total inventory cost and the cost of balancing loss of the conversion process is jointly minimized and ideal cycle time of the production process is determined along with ideal sizes of the stock chambers. A numerical example has been added to demonstrate the suitability of our approach. © 2010 Growing Science Ltd. All rights reserved.

Automatic Collection Method of Machining Progress Information for Large-size Workpieces Based on Reference Power Curve

Large-size workpieces are the common parts in the large equipment manufacturing industry. It is very significant for management staff to know the on-site machining progress information of the large-size workpieces in order to ensure the timely completion of jobs,improve production efficiency,optimize production management and support dynamic optimal schedule. Because the machining period of a large-size workpiece is long and in many cases only a single workpiece is machined,it is difficult to automatically collect the machining progress information. Based on this,the automatic collection method of machining progress information for large-size workpieces is proposed by using the power consumption information of the machine tool's main transmission system. The reference power curve of the machining workpiece is established based on the starting power database and the idle power database of the spindle transmission system of machine tools,which is obtained in advance,and the relative machining parameters,such as cutting parameters,workpiece material,and process time. Although the reference power curve is not exactly precise,the shape of the curve is enough to reflect the machining process of the workpiece. The machining progress information of the workpiece is collected by comparing the real-time data power curve with the reference power curve. The qualitative information is obtained by comparison of the shape characteristics of the two power curves ,and the quantitative progress data is calculated by analyzing the time of the two power curve. The case study of machining the large-size workpiece in a certain metallurgical equipment manufacturing workshop shows the method is practical.

Firm strategy and the Canadian Voluntary Climate Challenge and Registry (VCR)

AbstractThe Canadian VCR is a climate change mitigation program that relies on firms' desire to signal environmental responsibility to external stakeholders through voluntary information disclosure. We analyze indicators of strategic behavior through three measures of engagement with the VCR program (annual participation behavior, quality of action plans and repeat participation), and test for differences in these measures among firms subjected to different regulatory climates that arise over time, across provinces and across economic sectors. Our findings suggest an increased perception of a regulatory threat in later years, as evidenced by an increase in participation rates, higher quality of action plans and higher rates of repeat participation. We also find higher levels of engagement with the VCR program in provinces with large petroleum (Alberta) and manufacturing (Ontario) industries and that have established provincial level greenhouse gas reporting mechanisms, and in certain sectors such as petroleum, electric utilities and to some extent services. Copyright © 2007 John Wiley & Sons, Ltd and ERP Environment.

A Look Into Jordan's Large Manufacturing Industries' Risks

Jordan is an emerging developing country. Large manufacturing industries in Jordan are bombarded by multi-dimensional risks from all directions. The main objectives of this paper were to identify and classify the different risks into types and categories, also analyze their probabilities and impacts for clear and better understanding of these risks. A risk identification breakdown structure was constructed. Risk levels, as well as their main components; probability of occurrence and impact, were gathered by means of questionnaires and statistically analyzed, and risks were ranked according to their levels. The most critical risks were found to be the political and financial risks that are external to the company.