Mass Production System Research Articles

Evolution of the Korean Marketplace From 1896 to 1938: A Historical Investigation of Western Clothing Stores’ Retail and Competition Strategies

The Korean economy has transformed from the domestic home-based to the global mass production-based one since the Korean–Japan Treaty of 1876. New technologies such as the sewing machine and mass production systems were introduced to Korea simultaneously, and the result was the two new clothing retail operation types: custom-made and ready-made clothing stores. After reviewing over 340 daily newspaper articles and advertisements published from 1896 to 1938, the findings show the key characteristics of two Western-style clothing store types, the key marketing strategies that these two store types used, and the survival strategies that custom-made stores employed to compete against ready-made stores. Within the context of the Korean clothing industry today, the results of this study present interesting insights into how the Korean clothing industry was born and grew during the early 20th century when the country was emerging from a home-based handmade economy to a factory-based machine-made one.

Small-Scale Public Rental Housing Development Using Modular Construction—Lessons learned from Case Studies in Seoul, Korea

Modular construction, which involves factory-based modular unit manufacturing followed by installation at a construction site, has been recognized as one of the sustainable construction methods. Its advantages are known to be implemented through (1) standardized design, (2) standardized production method, and (3) large-scale development (mass production system). These three conditions are basic requirements for modular construction market expansion, but it is difficult to define that these conditions are a prerequisite for judging whether modular construction applied or not. Nevertheless, public development companies in regions or countries where modular construction has just begun thought that modular construction should meet all three conditions that are suitable for applying public construction projects. This is because it is difficult to compare conventional construction projects with similar conditions to modular construction projects. This paper analyzes the cost and duration data of three small-scale public construction rental housing (PCRH) projects involving modular construction in Korea. These cases presented herein include a public college student dormitory, public low-rise rental housing, and public mid-rise rental housing in small-scale development projects. Those were applied not standardized design (common design and regulation), but were reflected in each project’s demands (different design and regulation). To compare it, this paper analyzed 91 public housing provision projects’ construction data from 2011 to 2017 from one of the public rental housing provision companies in Korea. Among them, 19 small-scale public rental housing data were extracted for comparing with modular construction project data. The results show that, even if not standardized, the design and production process, and modular construction durations, were more effective—but costs were similar or expensive. Based on the conclusion drawn from three cases, this paper presents important considerations for the application of modular construction in other small-scale public construction rental housing projects from the perspective of public development companies.

The human dimension of lean: a literature review

ABSTRACTInterest in lean, the managerial system exemplified by the Toyota Production System, has gradually spread throughout different industries since the 1980s. Compared to mass production systems, lean systems ultimately transform the way employees act within their work environment. Despite significant improvements in operations management, the human dimension of lean has received surprisingly limited attention from the academic realm, until recently. This study serves primarily as a literature review of articles at the crossroads between the technical part of lean and its human-related issues. We reviewed 95 articles and our analysis provides a clearer view of the evolution of lean literature with regard to its human elements. The different levels of analysis can be summarised as follows: lean’s impact on working conditions and employee outcomes, HR practices as facilitators of lean adoption, and employee development as a moderator of lean adoption. We conclude with a framework that serves as a potential guide to include the human dimension of lean in research.

The role of Chinese electronics products to sway middle-class buyers

The boom in Indian electronics market has received its fair amount of adrenaline dose from Chinese electronics industry. The customary mass production system of China has revolutionised the electronic product and its market is perceived by other countries. The Chinese electronics products being produced at large scale and having a competitive advantage when it boils down to pricing the product. China has always targeted the countries with large population with high purchasing capacity with cheap imports rates. These cheap imports generally attract the price conscious middle-class segment with its modern technology being available at very affordable rates. This study targets to investigate and analyse socio-economic factors and buying behaviour of consumer towards Chinese electronic products. The huge market potential has attracted Chinese products in plenty; the study aims to find out the relevant factors like brand personality of these products, price, other attractive features of the product which has given them a dedicated and numerous customer bases. The study also wants to analyse the socio-economic impact of these products in middle class purchasing decision making process.

Considering Product Life Cycle Stages and Worker Skill Level in Seru Production Systems

The product life cycle (PLC) stages can be considered as introduction, growth, maturity, and decline. Seru production systems has a potential to perform better where products have high demand variability and low volume during the introduction and decline stages. On the other hand, the assembly line is popular in the final processes of mass production systems due to its high efficiency, low product cost owing to economy of scale, and low labor cost by low-skilled workers. Therefore, an assembly line design is more successful for growth and maturity stages of a product where the demand is more stable. Likewise, if skill level of workers for different tasks have higher variation, assembly line can be considered as a better option. Hybrid system of assembly line and seru production system performs better with workers who have less skill variation. A worker is expected to improve his/her skill levels when performing a task continuously leading to seru production system with low skill level variation. Therefore, this study aims to introduce the details of a preliminary approach considering product life cycle stages and worker skill requirements.

Distributed Software Architecture for AGVs for Separation of Dynamic and Static Obstacles

The current trend towards mass customization confronts established mass production systems with specific challenges. In future production layouts will have to provide a high degree of flexibility and changeability in order to be able to respond to the demand for individualized mass products. This leads to a production network in which the work schedule of each product and thus the sequence of the individual production resources are flexibly arranged. A challenge in this scenario is the implementation of material transport between the machines. The use of mobile transport robots to realize a flexible connection of all material sources and sinks proves to be effective. However, the current design forms, as a monolithic AGV system or the use of flexible autonomous units, show specific weaknesses. The paper describes the research approach to establish an intralogistics service-based software architecture as an intralogistics execution system, which contains the elementary functions of a cross-platform use of mobile autonomous systems. One key application is to digitize the workspace of the mobile systems with a distributed system of infrastructural sensors. An embedded unit separates the scenario into static and dynamic obstacles. The method discussed also includes the aggregation of the images with static obstacles to a world model as a basis for global cross-platform routing. Thus, it is possible to include the static obstacles in an early phase of path planning. The researched architecture integrates a routing service, which offers a cross-platform map for each type of transport robots in use. The dynamic obstacles of the respective scenery are tracked directly by the embedded decentralized ceiling sensors. By combining the Hungarian method with a Kalman filter, the trajectory of the detected dynamic obstacles can be determined. Within the discussed method, this information is transmitted directly from the sensor units to the autonomous systems and allows the local path planner to avoid collisions. Within the implementation of both methods in an industrial demonstrator, the functionality of both services could be validated. The necessary real-time capability for a valid collision avoidance was not achieved due to the computing capacities in use.

Dynamic Predictive Maintenance in industry 4.0 based on real time information: Case study in automotive industries

In order to respond to today’s dynamic needs of customers, customized mass production systems have been more and more developed that, are facing with different challenges. Maintenance planning and scheduling is one of the most important manufacturing components in such systems, due to importance of availability and high investment for this kind of system. In order to consider real machine operation state, recently, predictive maintenance method is proposed. However, in traditional methods, historical failure data is the main source for this planning. In this paper, we propose a methodology for dynamic predictive maintenance for a real case in automotive industries with considering multi-component structural and positive economic dependencies between them. In our methodology, we propose to gather data science with mathematical optimization method. Prediction of Remaining Useful Life (RUL) of machine parts has been made by Artificial Neural Network method with considering sensors data. With this RUL values and other cost values and optimization model parameters, and by solving proposed mathematical model, an optimal schedule is achieved with minimization of maintenance costs. Through a dynamic proposed procedure, when a new data is received, RUL values and model parameters are readjusted and new optimal solution for maintenance planning and scheduling can be achieved. Further, some scenarios are defined for analyzing the dynamicity of the proposed procedure and relating results, conclusion and perspectives of these researched are discussed.

Fabrication of micro piezoelectric rod array using metallic mold system for mass production

LIGA process was carried out to fabricate the copper mold insert for a micro piezoelectric array. X-ray mask was fabricated using UV lithography and PMMA which is the X-ray photoresist was bonded to the titanium substrate done lapping. The bonded PMMA was exposed to X-ray exposure with the total amount of 4.0 kJ/cm3. Copper was then electroplated above the PMMA. After the post-processing, the copper mold insert with the pattern size 400 μm, the height 924 μm, was fabricated. To replicate the patterned micro rod array, PIM process was used. The entire optimized PIM process corresponding to the previous research was applied. The fabricated copper mold insert was used in injection molding process. The ejection pins were also fabricated using the same LIGA process for metal mold and used to extract the injection-molded specimens. After injection molding, two-step debinding and sintering processes were conducted and finally, micro piezoelectric rod array with a pattern size of 322 μm was fabricated without any defects such as collapse and break. The dimension accuracy was ensured through the SEM image analysis and dilatometry results. The physical and piezoelectric properties of sintered part were measured to confirm the part performance made by PIM process. Results indicated the possibility of using the metal mold for mass production system to produce the micro piezoelectric rod array.

Customized CAD Modeling and Design of Production Process for One-Person One-Clothing Mass Production System

Following the development of the Industrial Revolution 4.0, many new types of systems are being designed, introduced, or attempted, even in almost every traditional industry. The clothing industry is no exception. The use of continuously developing production equipment and Information and Communication Technology (ICT) has a single objective, providing a customized service to all customers. Thus, in this study, the primary research task was to identify ill-balanced aspects or disadvantages of the services previously analyzed to construct a more complete online customized service. This was accomplished by analyzing an automated Computer-Aided Design (CAD) output file containing customer requirements regarding individual clothing items. The secondary research task was to plan and design a clothing manufacturing process to which a one-person one-item mass production system has been applied to achieve a customized service. As a result, for the primary research task, the customers’ requirements for each dress were reflected in attributes, such as color, pattern, or size, and it was possible to obtain an automated CAD output file for each element. Such CAD output files can be used in the production process directly. To find the possibility of upgrading the existing dressmaking process and implement the one-person one-item system, the entire manufacturing process was simulated for the test.

Estimating development and temperature thresholds of Ephestia kuehniella: toward improving a mass production system.

The development of the Mediterranean flour moth, Ephestia kuehniella (Zeller), was evaluated at 10, 15, 17.5, 20, 22.5, 25, 27.5, 30 and 32.5°C with no lighting. None successfully completed development at 10 and 32.5°C. The total development time from egg to adult emergence was 164, 140, 98, 76, 61, 62 and 50 days, respectively, at the remaining temperatures. The developmental rate of E. kuehniella was described by the common linear model and six non-linear models. The lower temperature threshold for the immature stages and the thermal constant for E. kuehniella were 9°C and 1111 degree-days (DD) to complete development from egg to newly emerged adult. Non-linear models estimated the lower and upper thermal thresholds (Tmin and Tmax) and optimal temperature (Topt). The values of Tmax calculated by three nonlinear models ranged from 34°C to 46°C; Topt for each stage of development varied from 24 and 31°C, consistent with the temperature (30°C) at which the most rapid development occurred. Information on the threshold temperatures for development and thermal requirements can be utilized to predict E. kuehniella population dynamics and phenology and to evaluate optimal temperature conditions for mass rearing in stored products.

Expression and characterization of monomeric variable lymphocyte receptor B specific to the glycoprotein of viral hemorrhagic septicemia virus (VHSV)

Monomeric variable lymphocyte receptor B (VLRB) is one of the smallest binding scaffold (20–25 kDa) from jawless vertebrates, hagfish and lamprey. This relatively new class of binding scaffold has various advantages: i) it has a single peptide composition, amenable to molecular engineering for enhancing its stability and affinity; ii) it has a small size, contributing better tissue penetration and easier production using microorganism expression system. Monomeric arVLRB142, which can specifically bind to the glycoprotein of viral hemorrhagic septicemia virus (VHSV), was expressed in Pichia pastoris. High quantity recombinant monomeric arVLRB142 (rVLR142mono) was purified from 100 ml of culture with a resulting yield of 2.6 ±1.3 mg of target protein. Functional studies revealed that the purified rVLR142mono can specifically recognize low levels of the target antigen (recombinant glycoprotein) (i.e. as low as 0.1 nM), but also the native glycoprotein of VHSV. The expressed rVLR142mono exhibited high levels of stability and it retained it binding capacity over broad temperature (4 °C ~ 60 °C) and pH ranges (pH 1.5–12.5). We developed an effective expression system for mass production of monomeric VLRB based on P. pastoris. The recombinant protein that was obtained offers promising binding avidity and biophysical stability and its potential use in various biotechnological applications.

Operations flow effectiveness: a systems approach to measuring flow performance

PurposeEffective operations management systems (OMS) measurement remains a critical issue for theorists and practising managers (Neely, 2005; Bititci et al., 2012). Traditional labor efficiency measures sufficed when all that was made could be sold or when mass production systems filled warehouses with stock and the OMS had little relationship with “the consumer.” Modern manufacturing systems require a different form of flow optimization (beyond labor efficiency) measurement (Schmenner, 2015). The essential unit of measure for all OMS designs is the optimal use of time for process value adding and the flow of materials into and from the conversion process. Timely flow, therefore, satisfies the needs of multiple organizational stakeholders including cash flow (accounting), consumer reaction times (marketing) and the general steady state flow of materials (sales and supply chain). The purpose of this paper is to present the results of testing a new performance measure of operations flow effectiveness (OFE) with ten purposively selected cases.Design/methodology/approachThe paper is theory building using ten, purposively selected, longitudinal case studies drawn from the UK high-value manufacturing (HVM) sector using a pluralist methodology of interviews, observation and secondary data.FindingsThe OFE measure provides a holistic view of material flow through the input-process-output cycles of a firm. The measure highlights OMS design weaknesses and flow inhibitors that reduce cash flow using a time-based approach to measuring OMS performance. The study validates the OFE measure and has identified six key design elements that enable high flow performance.Originality/valueThe paper tests a new process-focused flow performance measure. The measure supports a holistic approach to the manufacturing enterprise and allows different OMS designs to be evaluated so that organizational learning may be enacted to support performance improvement.

A Study on the Diamond Wear Mechanism of Conditioner during W CMP in 3D NAND

The memory device fabrication system has already applied a lot of CMP processes for various purposes. As memory device integration increased, more CMP processes are needed. Typically CMP process can be divided into Oxide CMP, W CMP, Cu CMP, etc. These CMP technologies are important solution that can be used as memory mass production technologies develop. 3D NAND devices are being highlighted and developed as a way increase the integration method, due to the nature of its structures, 3D NAND device needs various CMP processes. In particular, the number of W CMP processes has several times multiplied over than 2D devices. In addition, more W CMP processes will be required as the device's generation evolves. However, a period of change pad, in W CMP process, is shorter than other CMP processes. Hence, it will lead to lower productivity and higher costs in fabrication system. Productivity and cost in mass production system are very important competitiveness. Thus, it is necessary to make improvements to the same level as others. There are several reasons why the W CMP process has a shorter pad replacement cycle in the 3D NAND device. One of the causes is that slurry directly or indirectly affects the wear of diamonds on conditioner. As a result, ability of polishing is decrease, pad and conditioner have no choice but to replace. In this study, we figured out which components of W slurry are being applied by W CMP in the 3D device and how they affect the wear of diamonds. And we have carried out experimental study to improve it and we will discuss the results.

Machine Tool Service for Mass-Production Machining Systems

Mass-production machining systems that are comprised of machine tools are often configured in series by dividing the machining processes in order to manage the large production volume. This indicates that if one of the machines stops owing to a mechanical malfunction, the entire production line needs to be stopped. Thus, machine tools in mass-production systems are required to be highly reliable and easy to maintain. Predictive maintenance, which enables operators to detect any signs of failure in the machine tool components, needs to be performed for the machines as well. In this work, various approaches for the improvement of the maintainability of machine tools used in a mass-production system are reported.

Purification and characterization of immunogenic recombinant virus-like particles of porcine circovirus type 2 expressed in silkworm pupae.

Porcine circovirus type 2 (PCV2) is a primary causative agent of postweaningmultisystemic wasting syndrome (PMWS), which has a significant economic impact on the swine industry. The capsid protein (Cap) encoded by ORF2 of the viral genome has been used effectively as a vaccine against PCV2 infection. The Cap protein can spontaneously assemble into virus-like particles (VLPs) that are safe and highly immunogenic for vaccine applications. Several expression systems, including bacteria, yeast and insect cells, have been utilized to produce PCV2 VLPs. However, in some cases, the recombinant Cap (rCap) proteins produced in bacteria and yeast do not assemble spontaneously. In this study, we expressed rCap protein using a silkworm-baculovirus expression vector system (silkworm-BEVS) for mass production of PCV2 VLPs and established a simple three-step protocol for its purification from pupae: extraction by detergent, ammonium sulfate precipitation and anion exchange column chromatography. Size-exclusion chromatography (SEC) analysis and transmission electron microscope (TEM) observation showed that purified rCap proteins formed VLPs with a similar morphology to that of the original virus. Furthermore, the VLPs produced in silkworms were capable of inducing neutralizing antibodies against PCV2 in mice. Our results demonstrated that the silkworm system is a powerful tool for the production of PCV2 VLPs and will be useful for the development of a reliable and cost-effective PCV2 vaccine.

Expression and identification of an antimicrobial peptide VIP in Pichia pastoris

With the sequence of the vasoactive intestinal peptiepeptide (VIP) from humans and according to the condon bias of Pichia pastoris, we designed PCR primers of VIP and obtained the sequence of VIP by SOE-PCR. Then VIP gene was cloned into Pichia pastoris secretory expression vector and the cell secretary system GS115-pPICZαA-vip was constructed. The recombinant strain was induced by methanol for 96 hours, and we collected the supernatant and identified the VIP by mass spectrometry. The molecular weight of VIP was consistent with theoretical molecular weight. The final result showed that the target peptide VIP was successfully expressed. The experimental investigations of agarose gel diffusion revealed that the recombinant expression modified VIP had relatively strong antibacterial activity to E. coli ATCC25922 and S. aureus ATCC25923. The minimal inhibitory concentration (MIC) of VIP to E. coli ATCC25922 and S. aureus ATCC25923 was 8 mmol/L and 16 mmol/L. Further cytotoxicity and hemolytic experiments indicated that recombinant VIP was non-toxic to normal cells NCM460 and IPEC-J2, had little hemolysis activity to SD rat erythrocytes. Meanwhile, by transmission electron microscopy, we found that VIP mainly inhibited bacteria by disrupting the cell membrane. These experiments established a useful system for further studies, application and mass production of antimicrobial peptide VIP.

Interpretive multi-criteria ranking of production systems with ordinal weights and transitive dominance relationships

The paper deals with the situation of manufacturing of customized engineering products under intense competitive environment. Such customized engineering products can be manufactured by different types of production systems such as job production, batch production, mass production, and flexible manufacturing systems. It then becomes an important decision to choose the best one among these production systems which is also dependent on multiple criteria. The three basic criteria predominantly considered in the context of manufacturing are cost, quality, and flexibility. The paper applies the efficient interpretive ranking process (IRP) as an interpretive multi-criteria ranking method to demonstrate its utility in this context. It considers the design of the decision problem by treating the cross-interaction matrix of ‘Alternatives × Criteria’ as a unit matrix, i.e. each alternative is linked with each criterion. In this type of decision problem, the IRP method is implemented with transitive dominance relationships. Further, it carries out the sensitivity analysis concerning different ordinal weights of various criteria. The paper also makes a methodological contribution in IRP by way of computing dominance index rather than simply considering net dominance (which would be either positive or nil or negative). The dominance index gives a better depiction of the dominance of one alternative over the others.

Development of industrial ultrasound system for mass production of collagen and biochemical characteristics of extracted collagen

Collagen is a widely used material in food and cosmetic products, but it has high price because of complicated extraction process and low yields. In order to overcome these problems, a mass production system of collagen from fish skin has developed using an industrial scale of ultrasound extraction equipment. Collagen was extracted from flatfish skin using 0.05M acetic acid solution for a total of 3h in an ultrasound system and was collected by centrifugation. The collagen yields by this method were ∼31.3 and 46.2% after 1.5 and 3h, respectively, which were 1.5 and 2 times higher than those by the conventional method. The pepsin digestibility was examined to confirm whether the extract was native collagen. Despite pepsin treatment, the α1 (α3), α2, β chains of the collagen extracted by the industrial ultrasound system did not change, whereas gelatin were degraded almost completely and low molecular weight components were increased. In addition, the amino acid analysis result showed that the extract contained high contents of glycine, proline, and hydroxyproline, indicating that the extract has a typical collagen composition. Therefore, it was confirmed that the component extracted by the industrial ultrasonic system was native collagen.

Optimal design of spoke type motor and magnetizer using FEM and RSM

PurposeThis study aims to propose criteria for both optimal-shape and magnetizer-system designs to be used for a high-output spoke-type motor. The study also examines methods of reducing high-cogging torque and torque ripple, to prevent noise and vibration.Design/methodology/approachThe optimal design of the stator and rotor can be enhanced using both a response surface method (RSM) and finite element method (FEM). In addition, a magnetizer system is optimally designed for the magnetization of permanent magnets for use in the motor.FindingsThe criteria not only improve performance but also reduce manufacturing costs. The criteria are verified FEM together with an RSM. These methods are used to optimize the stator and rotor shape and the magnetization system. These methods allow us to produce an efficient system for mass production of the motor.Originality/valueThis study proposed a design method that uses rare earth magnets in a system to replace the spoke-type IPM. To verify the optimal design, torque characteristics were analysed using FEM and RSM. Excellent results were achieved regarding the reduction of cogging torque and torque ripple. In addition, the design of the magnetizer enables a cost-effective mass production system for the motor.

A SUGGESTED FRAMEWORK FOR REDUCING COST AND LEVERAGING BETTER ENVIRONMENTAL PERFORMANCE THROUGH LEAN PRODUCTION: CASE STUDY

With the development of production mechanisms and the use of advanced management methods, the first goal of the study is to reduce costs and use of modern technology in production and achieve sustainable development; and this was the motive of the researcher to do this reseach. Companies began to implement the total quality concept in order to survive and achieve competitive advantage in the global market. It is a system for managing and developing production and operations, establishing a network of suppliers and developing relations with customers so that the production process is done with minimal effort, less space, less time and with the least number of defective units to satisfy their customers’ needs as compared to mass production system. The researchers studied the stages of development of the production systems in the business environment, where as the manufacturing systems developed and appear the flexible manufacturing system instead of the mass production system then appear JIT system. The researchers then explained the beginnings of the lean production system, its concept, principles and tools. The researchers introduced the value stream cost (VSC), the process of the value stream, and how to apply the value steam cost and types of those costs are also explained by sustainable development. The researchers applied the value steam cost to a company (a case study) Finally, the study concluded that while using the lean production, the VSC system is an alternative and suitable for the traditional cost system. The aime of lean production is to remove the waste which helps in satisfy their customers’ needs, thus enhancing the competitive advantages of the establishment and achieve sustainable development. The value steam cost which use when following lean production, it helps to reduce costs by eliminating the costs that do not pertain to the value stream. The researcher recommended that companies using lean production should use a value stream cost that is an appropriate system for lean production for ease and accuracy.