Manufacturing Lead Time Research Articles

A systematic analysis of digital supply chain, big data and manufacturing lean time in industrial companies

PurposeThis paper aims to systematically review the literature on digital supply chain (DSC), big data (BD) and manufacturing lead time (MLT) in industrial companies.Design/methodology/approachThis study provides a systematic review of the 99 research on this subject that was published between 2015 and 2022. Studies were found in the Scopus database. This review also identifies gaps in the literature, highlights conflicting results, examines prospective data sources for empirical researchers and offers suggestions for choosing promising research subjects in the future.FindingsThis study performed a thorough literature review to a developing field of inquiry in order to identify the impact of the digital supply chain, BD and manufacturing lean time, an area that has received little attention in the literature. Future pathways and ramifications are also offered based on the literature content search. The results showed that BD improves DSC performance through resilience and innovation of the DSC. MLT and DSC integration were found to be positively correlated, according to the results.Originality/valueAlthough the production lead time is preferable to boost customer value and supply reliability, the long lead time hurts the DSC’s ability to compete. DSC integration also improves coordination and streamlines processes. The researchers suggest fostering organizational flexibility, information exchange to accomplish DSC integration and adaptable behaviors including responsiveness and alertness.

Manufacturing Lead Time Using the Value Stream Mapping (VSM) Approach in the Oyster Mushroom Baglog Production Process

Manufacturing Lead Time Using the Value Stream Mapping (VSM) Approach in the Oyster Mushroom Baglog Production Process

Fabrication of Shaping Fixture for Cylindrical Rod to Reduce Manufacturing Lead Time

Fabrication of Shaping Fixture for Cylindrical Rod to Reduce Manufacturing Lead Time

PENERAPAN LEAN SIX SIGMA DALAM PENGENDALIAN KUALITAS PRODUK: STUDI KASUS PERUSAHAAN TEKSTIL

The increasing number of fabric defects over the past three years has caused the company's performance to decline in terms of production. The data obtained is defect data in the period December 2019 to January 2023 from internal company data, while waste data is obtained by waste assessment questionaire and waste relationship matrix. The DMAIC method is the main method in this study, starting from defining problems and measuring process capabilities based on defects, continued with WRM and WAQ for waste type analysis, and the root of the problem in defects and waste is analyzed with fishbone diagrams. The results of this study show that the most common types of defects are holes, broken threads, and broken needles, while the types of waste that occur are waiting, overprocessing, defects, and overproduction. The root of the problem is that there are no QC procedures for raw materials, machine operating procedures, and periodic inspection procedures. By providing improvement proposals and implementing improvements, it was concluded that there was a reduction in production costs of up to 4%, an increase in work efficiency of up to 2.48%, and a manufacturing lead time of up to 35.98%.

Deformation and crack growth in multilayered ceramic capacitor during thermal reflow process: numerical and experimental investigation

PurposeThis study aims to investigate the possible defects and their root causes in a soft-termination multilayered ceramic capacitor (MLCC) when subjected to a thermal reflow process.Design/methodology/approachSpecimens of the capacitor assembly were subjected to JEDEC level 1 preconditioning (85 °C/85%RH/168 h) with 5× reflow at 270°C peak temperature. Then, they were inspected using a 2 µm scanning electron microscope to investigate the evidence of defects. The reliability test was also numerically simulated and analyzed using the extended finite element method implemented in ABAQUS.FindingsExcellent agreements were observed between the SEM inspections and the simulation results. The findings showed evidence of discontinuities along the Cu and the Cu-epoxy layers and interfacial delamination crack at the Cu/Cu-epoxy interface. The possible root causes are thermal mismatch between the Cu and Cu-epoxy layers, moisture contamination and weak Cu/Cu-epoxy interface. The maximum crack length observed in the experimentally reflowed capacitor was measured as 75 µm, a 2.59% difference compared to the numerical prediction of 77.2 µm.Practical implicationsThis work's contribution is expected to reduce the additional manufacturing cost and lead time in investigating reliability issues in MLCCs.Originality/valueDespite the significant number of works on the reliability assessment of surface mount capacitors, work on crack growth in soft-termination MLCC is limited. Also, the combined experimental and numerical investigation of reflow-induced reliability issues in soft-termination MLCC is limited. These cited gaps are the novelties of this study.

Optimizing Manufacturing Lead Time through Automation

Optimizing Manufacturing Lead Time through Automation

A Review of Game Theory Models to Support Production Planning, Scheduling, Cloud Manufacturing and Sustainable Production Systems

Cyber-physical systems, cloud computing, the Internet of Things, and big data play significant roles in shaping digital and automated landscape manufacturing. However, to fully realize the potential of these technologies and achieve tangible benefits, such as reduced manufacturing lead times, improved product quality, and enhanced organizational performance, new decision support models need development. Game theory offers a promising approach to address multi-objective problems and streamline decision-making processes, thereby reducing computational time. This paper aims to provide a comprehensive and up-to-date systematic review of the literature on the application of game theory models in various areas of digital manufacturing, including production and capacity planning, scheduling, sustainable production systems, and cloud manufacturing. This review identifies key research themes that have been explored and examines the main research gaps that exist within these domains. Furthermore, this paper outlines potential future research directions to inspire both researchers and practitioners to further explore and develop game theory models that can effectively support the digital transformation of manufacturing systems.

Numerical investigation of thermal fatigue crack growth behavior in SAC305 BGA solder joints

PurposeThis study aims to investigate the reliability issues of microvoid cracks in solder joint packages exposed to thermal cycling fatigue.Design/methodology/approachThe specimens are subjected to JEDEC preconditioning level 1 (85 °C/85%RH/168 h) with five times reflow at 270°C. This is followed by thermal cycling from 0°C to 100°C, per IPC-7351B standards. The specimens' cross-sections are inspected for crack growth and propagation under backscattered scanning electronic microscopy. The decoupled thermomechanical simulation technique is applied to investigate the thermal fatigue behavior. The impacts of crack length on the stress and fatigue behavior of the package are investigated.FindingsCracks are initiated from the ball grid array corner of the solder joint, propagating through the transverse section of the solder ball. The crack growth increases continuously up to 0.25-mm crack length, then slows down afterward. The J-integral and stress intensity factor (SIF) values at the crack tip decrease with increased crack length. Before 0.15-mm crack length, J-integral and SIF reduce slightly with crack length and are comparatively higher, resulting in a rapid increase in crack mouth opening displacement (CMOD). Beyond 0.25-mm crack length, the values significantly decline, that there is not much possibility of crack growth, resulting in a negligible change in CMOD value. This explains the crack growth arrest obtained after 0.25-mm crack length.Practical implicationsThis work's contribution is expected to reduce the additional manufacturing cost and lead time incurred in investigating reliability issues in solder joints.Originality/valueThe work investigates crack propagation mechanisms of microvoid cracks in solder joints exposed to moisture and thermal fatigue, which is still limited in the literature. The parametric variation of the crack length on stress and fatigue characteristics of solder joints, which has never been conducted, is also studied.

Process Modularity Impact on Manufacturing Lead Time and Throughput Rate in Terms of Mass Customization

As mass customization becomes more pervasive in many sectors, researchers need to update traditional approaches to the optimization of critical performance and design parameters in order to help companies in their effort to implement this strategy. In general, implementation of mass customization from a manufacturing perspective is frequently focused on shortening cycle times, reducing production cost, and increasing throughput rate of parts. In this paper, process structure modularity impact on manufacturing lead times and throughput rates is explored. An important precondition to explore these relationships is the awareness that process modularity is conceptualized and quantified in an appropriate way. For this purpose, three independent modularity measures were employed to provide more reliable assessment of this system property. The relationships were investigated on the basis of simulation experiments using deterministic models of alternative process structures. For the purpose of the relationships exploration, two case studies were conducted, theoretical and practical ones. The results from the experiments showed that there are moderate correlations between process modularity and manufacturing lead time (ρ = −0.45), as well as between process modularity and throughput rate (ρ = 0.45).

Measuring Supply Chain Performance for Khanh Hoa Sanest Soft Drink Joint Stock Company: An Application of the Supply Chain Operations Reference (SCOR) Model

As Khanh Hoa Sanest Soft Drink Joint Stock Company attempts to satisfy consumer requirements and maintain market share in the salangane nest industry, it is important to monitor the efficiency of its supply chain (SC). This paper identified metrics to evaluate the firm’s SC performance, using secondary data from firm records, primary data from a survey of 200 sales agents, and the Supply Chain Operations Reference (SCOR) model. Production records revealed a manufacturing lead time of 11 days and a production time of 24 h plus 7 days for refrigeration and observation. Order fulfillment delivery times ranged from 13 to 16 days. About 86.0 percent of customers rated the product as good or very good, and 60.5 percent claimed benefits from consuming the product. SC management costs of goods sold were 75.27% of total costs, while production cost was 41.99% of total costs. Total assets increased 16.6% from 2019 to 2021, but profits declined by 32.9% for the same period, while return on assets fell 42.4%. To maintain a competitive advantage, the company should apply information technology to improve SC performance. The results showed that the SCOR model is appropriate for evaluating the performance of this firm and similar business enterprises.

Mechanical characteristics of concrete under initial steam curing using solar energy

In this article, the study is based on the effect of initial steam curing using solar energy on the mechanical characteristics of concrete for precast concrete production. During the early hours of heating, the concrete reaches the minimum strength considered essential for the rotation of the molds, with which he is able to support loads without deform or loss of bearing capacity. The curing period and temperature, is an important parameter in the steam curing process. An experimental program was conducted to investigate the effect of hardening time by steam curing on the mechanical characteristics of concrete. The concrete specimens were cast with a water/cement ratio of 0.40 and were subjected to steam hardening according to two cycles of covering steam curing of two periods of the year hot and cold at 45 and 29 °C for each one 8 hours, then they are left in the open air cured for 3 and 7 days. The results show that a gain of time and shorter manufacturing lead times to reach the mechanical strengths (compressive strength and flexural) at 28 days in the free air after a one day steam curing and 3 days of hardening in the free air.

Penurunan Lead Time Manufacturing Dengan Pendekatan Lean Manufacturing Studi Kasus Di PT. MKM

In the industrial world, it is very important to pay attention to the efficiency of production capacity where the manufacturing lead time for making shoe outsole is influenced by activities that are not value-added (Non Value Added) and activities that are not value-added but necessary (Necessary Non Value Added) in which there is some extravagance that occurs. These activities are in the form of temporary storage in the cooling room and the process of reworking defective products. The method used is Lean Manufacturing, the tools used are Value Stream Mapping (VSM) and Process Activity Mapping (PAM). VSM is used to identify activities that have cycle times exceeding takt time, followed by mapping the Activity Mapping process to analyze activities that are not Value Added. Based on the results of research from 4110 seconds, the process lead time of 3600 seconds is a non-value added activity. The rework process and material storage in the cooling room were identified as having the largest value contributing to lead time, so rework must be eliminated. the percentage of Process Cycle Efficiency (PCE) has increased. The reduction of the finished sheet material process is cooled to the cooling room and the rework process can save about 60 minutes of working time. Saving working hours can increase outsole production capacity so that productivity increases and targets are achieved.Keywords: Lead Time Manufacture, Lean Manufacturing, Value Stream Mapping, Prose Activity Mapping. Process Cycle Activity.

Determination of Customer Order Decoupling Point (CODP) Based on Mass Customization Concept to Minimize Manufacturing Lead Time

Determination of Customer Order Decoupling Point (CODP) Based on Mass Customization Concept to Minimize Manufacturing Lead Time

Influence of Manufacturing Process Modularity on Lead Time Performances and Complexity

In principle, modular or integral character of manufacturing lines depends on the topological designs of products and determined operation tasks. On the other hand, in specific situations there is an articulated need for modular design in smart manufacturing systems since modular layouts are a crucial step towards agile production via smart manufacturing. The aim of this paper is to explore how the modular layout relates to manufacturing lead time (MLT) and to operational complexity of smart manufacturing systems. For this purpose, topologically different models of alternative process layouts were simulated and tested, while MLT values were obtained using Tecnomatix Plant Simulation. The obtained positive findings of this research could be useful not only in selection of the most suitable process design from the alternative ones, but especially in deepening the knowledge and bettering understanding of the concept of optimal network modularity.

Investigation of the Importance of Machine Sequence Flexibility on A Flexible Manufacturing System Performance

Machine sequence flexibility is defined as the combination of operation and routing flexibilities in this study. Its importance in the performance level of a flexible manufacturing cell (FMC) is investigated in this study. Studies related to the effects of various flexibility types, such as routing flexibility, are available in the literature. For example, studies related to routing flexibility try to measure the effects of routing flexibility on the performance levels in the operation of manufacturing systems under their own manufacturing environments. Similarly, this study also aims to present a performance measurement model based on Taguchi methods to evaluate the effects of machine sequence flexibility factors on the FMC performance and obtain an optimum and robust performance level. Two crucial responses, such as manufacturing lead time (MLT) and surface roughness (SR) are analysed to optimize the FMC performance. Robot speed, cutting tool type, and work-part material type are taken as the three other input factors to show the importance of machine sequence flexibility with respect to the other inputs. The study presented in this paper points out that machine sequence flexibility is the most effective input factor among the four input factors in the performance of the FMC.

PERANCANGAN ECONOMICAL BALANCE DONGKRAK ULIR ELEKTRIK DWI HASTA

The Dwi Hasta lifting crew jack is a tool that assist the car maintenance mechanician. It tool support the car at an elevationfor the maintenance working and lay it down after the mechanician done. The objective of study is to obtain the cost of themanufacturing from production stage to selling. In which, it device is for assisting the mechanician repaired a car. Manufacture system would obtain economic values and production time at one unit. The investigation is started from design, and to the manufacturing system. Regards to the planning of the manufacturing, the production cost, the selling cost, and time of refund are obtained at the cost calculation. The money refund is the production cost will get after selling. The experiment method is conducted at operating process chart (OPC), manufacturing lead time (MLT), production time, production flow, production capacity and break event point (Q). The experiment results showed economic value from raw material to one-unit machine. MLT is of about 53,83 hours. Production time performs is for 346,7 min. Production capacity is 6 units per month. Break Event Point (Q) will be started after 3 months. The profit taking back is Rp 6.181. 964. Money will be payback after 3 month

Sustainability Analysis of Rapid Tooling-Based Investment Casting: A Comprehensive Review

Abstract Investment casting (IC) is the most precise and second most widely employed casting process after sand casting. Despite its huge application potential, the process has certain inherent techno-commercial drawbacks, such as taking a long time to market, poor material efficiency, high specific energy consumption, continuous human resource requirements, environmental emissions, etc. The development of tooling for IC processes is found to be the prime cause of the drawbacks. To overcome these drawbacks, the rapid prototyping (RP)-based tooling development (also called rapid tooling [RT]) approach has the potential to deal with the limitations of the IC. However, the performance and sustainability of the RP-based tooling need to be studied for their commercial level acceptance over traditional hard tooling. Authors in this review paper have comprehensively reviewed the research works related to sustainability analysis of IC tooling developed through RP processes. Most research studies focus on specific energy consumption or life cycle analysis for sustainability assessment of RT-IC. Manufacturing lead time, production cost, and surface finish are the most investigated parameters for RT-IC. The review highlighted that through the RT approach, lead time for product development can be reduced from months to weeks, overall cost savings of 50–90 % can be achieved, and environmental risk could be reduced up to 50 %. Moreover, it is also observed that fused deposition modeling is the first choice for the RT process, whereas acrylonitrile butadiene styrene and polylactic acid are the most frequently used materials for RT-based IC tooling development at the present time. Most of the research on RT is focused on energy consumption analysis, whereas operator safety and personal health, like social indicators, need further research attention. To understand the current research trends, a decision matrix has been prepared from the key research papers with a close resemblance to the theme of the current review paper.

Reduction of Manufacturing Lead Time by Value Stream Mapping of a Selected RMG Factory in Bangladesh

Bangladesh is a fast-growing economy powered by the readymade garments (RMG) industry which has promoted the country in the world through the motto ‘Made in Bangladesh’. The RMG industry has become the lifeline of the economy of Bangladesh. However, this industry faces several significant obstacles to its continued, sustainable expansion. The trading climate has become very competitive because of the phase-out of the export quota system. Additionally, with today’s rapid fashion, consumers want items with short lead times and affordable prices. Adopting the lean methodology across the board in the garment business is essential for long-term sustainability in this cutthroat context. Lean manufacturing is a philosophy to deliver the finest goods on time with minimum endeavor and less price. Lean manufacturing aims to cut lead times and remove wastes that don’t impose value on products. The purpose of this research is to identify wastes and to reduce manufacturing lead time by eliminating or reducing the excess tasks that cause higher lead time by implementing lean concepts. But implementing lean philosophy is a difficult task. During the visit to the selected RMG factory, the Short Sleeve T-shirt, one of their products, was selected for conducting this research. All the processes were observed required for the transformation of raw materials into a finished T-shirt. During the observations, the methodology of time study was applied to collect the data. Necessary information was gathered by observing the processes and interacting with the executives. Then, the current state of the value stream mapping was drawn. Wastes, responsible for a longer time, were ranked by taking the help of an 80-20 rules diagram. After this, root cause analysis was performed to find the reasons for the unwanted time consumption. Improvement strategies were introduced to reduce waste. Lean tools like Kanban to reduce WIP, Single Minute Exchange of Die to reduce changeover time, and Total Productive Maintenance to reduce machine breakdown were used to minimize the waste. Based on improvement strategies, The value stream mapping’s future state was illustrated, showing the refinement where total manufacturing lead time was reduced by 61.20%. Finally, this research has suggested some recommendations to the management of the selected RMG factory to minimize waste and increase efficiency and reduce waste in the operations. This research illustrates the usual conditions of the RMG industry of Bangladesh by presenting the current state of the value stream. The Bangladeshi clothing sector must completely embrace lean principles and embark on the direction of sustainable growth.

A critical study on the implementation of operation, control and maintenance techniques for flexible manufacturing systems in small scale industries

Small industries have a lot of roles in the Indian economy and the strength of their product lies in their competitiveness in the whole world market. In spite of this highly progress rate, the huge potential in Indian small-scale industries (SSI) has not been tapped. Hence, there is the requirement to improve these industries, so that they can bloom to their fullest. To achieve the increased competitiveness, the manufacturing in SSI need to change or supplement its previous methods of production with more flexible and dynamic production systems, such as flexible manufacturing system (FMS) which is characterized by shorter product development and manufacturing lead time, Best quality and flexibility, team-based work union, short setup/change with time, as a construction strategy and multi-functional labor. FMS can help SSI to improve its process and align it to the requirements of its customers. Therefore, a discussion on the issues of SSI and presents the key features for the confirmation of FMS in SSI. Despite the fact that the efficiency was minimal, the equipment provided for the production were competent and excellent for delivering and gathering the pieces of joint. The reason for this was the machine's idle season, the growth of under creation portion (work in process stock) is high due to the lack of adequate design and unbalancing line circumstances, and finally the association of direct work on the floor. As a result, the creation was adequate, but the efficiency was low. All of these elements necessitated the development of a feasible framework in order to maximise efficiency while minimising lead time. The Adaptable Assembling Framework is then familiar with achieving success on uncontrolled bounds. To control, we used a closed consecutive circle type FMS. In a perfect world, efficiency would be maximised.

Improving the time-based performance of the preparatory stage in textile manufacturing process with value stream mapping

PurposeThe evaluation of time-based performance is a valued approach in the lean management thinking which is based on delivering value from customer's perspective. This approach contributes for long-term competitiveness and success in today's business environment. The focus of this study is to analyse the cycle time and manufacturing lead time with value stream mapping (VSM) in the preparatory stage of the textile fabric manufacturing process and to identify and improve the non-value adding activities in the value chain (VC). The study presents an insight on the translation of performance improvement across functions and how upstream supply chain (SC) segments can be linked in the performance improvement program. It also covers how the application of VSM improves visibility and planning flexibility in textile fabric manufacturing process.Design/methodology/approachThe time-based performance was evaluated using VSM and recording of the activity times in the existing process. The impact of the quality of supplier's raw material was also measured contributing to identify the strategy for procurement and the means to establish a feedback system to the upstream segments of the SC. The methodology of VSM, observation of the practice and the expertise of the individuals involved with the process were utilised to develop the value stream maps and to identify value adding activities, non-value adding activities, existing gaps and plans for improvement.FindingsThe means for improving the time-based performance were identified and their impact was measured. The factors responsible for improvement are related to the production system and with the procurement strategy. The improvement was achieved in terms of available capacity utilisation, balancing the work flow in the preparatory stages, visibility of the process by measuring its capability and flexibility for the planning function. The study revealed that the effectiveness and enhancement of VSM and related tools should be adopted to address the issue of limiting success rates of long term and repeating application of such tools. Continuous improvement, innovations and the systematic embedding of VSM in the process life cycle provide the ways for achieving long-term success.Research limitations/implicationsThe paper presents a real and in-depth study on the application of VSM in the textile manufacturing process. The scope of the study is broad; it covers activities across functions with actual estimates of activity times in the manufacturing process for the focused value streams. It offers researchers the opportunity to analyse the translation of productivity improvement across functions and how upstream SC segments can be linked in a performance improvement program.Practical implicationsThe study offers useful insight for the managers in textile manufacturing and other sectors for improving the time-based performance and achieving higher utilisation of capacity. It identified the production factors and their impact on warping and sizing cycle time in selected value streams and those which share common activities. It also identified the directions for future research when repeating the application of VSM in the continuous improvement cycle. Furthermore, since the industries need to progress towards advanced systems including Industry 4.0 standards, adoption of advanced VSM tool with relevant technology can align their production systems to develop the required capability. This will also bring a sustainable competitive advantage in the system.Social implicationsThe focused sector is stagnant in terms of productivity and innovation. The adoption of the advanced tools can facilitate the implementation of continuous improvement and innovation strategies.Originality/valueThe main focus of this study is to analyse and improve the cycle time in the preparatory stage of the fabric manufacturing process. This has impact on other important and tangible measures including capacity utilisation and work flow and intangible measures including production planning flexibility and process visibility. The improvement impact is across departments.