Product variety and just-in-time conflict and challenge

This paper addresses the question of how just-in-time can be implemented within high variety manufacture. To illustrate some of the principles in relation to the high variety-low volume situation the case of a computer manufacturer is considered in detail. For contrast the paper also considers the case of the manufacture of highly-configured four wheel drive vehicles where both variety and volumes are high. The most important issue in high variety/low volume production is that JIT operation should be seen in terms of the tactical holding of inventory in upstream buffers within the supply chain so that value is not added to work in progress prematurely. Tactical buffers ensure that service levels are maintained and the risk of stock-outs is minimized. In high variety/high volume production schedule integrity is the key factor, unreliable schedules being a major inhibitor to the introduction of JIT.

Gestión de la cadena de suministro de Bimbo

El presente trabajo es un informe final sobre los procesos de producción, logística y distribución de la empresa Bimbo. El informe está conformado por aspectos teóricos y prácticos, de esta manera, brinda información clara y concreta sobre los antecedentes más importantes de esta organización y su contribución a la productividad del país. La información presentada ha sido recolectada mediante una revisión teórica y una visita a sus instalaciones en Veracruz, México. De esta manera, se han estudiado sus procesos y logística de producción y cómo contribuyen en la eficiencia y calidad de la empresa; así mismo, son fundamentales para diagnosticar los aspectos a mejorar de la entidad. Por otro lado, gracias a la visita, se logró desarrollar habilidades administrativas que hasta el momento solo estaban en teoría. Llegar a un contexto real y con problemáticas evidentes permitió consolidar el aprendizaje que se obtuvo durante años en la carrera para plasmarlos en la labor. Así mismo, el detallar las instalaciones de Bimbo permitió alcanzar una mayor perspectiva con respecto a los aspectos importantes dentro del panorama organizacional; tales como la producción, la gestión y mejora de los procesos de la compañía. Esto se logró realizando labores correspondientes a la inspección, observación, revisión de logística y el análisis de los procesos productivos. El trabajo práctico indudablemente sirvió para acrecentar los conocimientos obtenidos en la universidad.

A systematic approach for selecting lean strategies and assessing leanness in manufacturing organizations

Lean strategies have been developed to eliminate or reduce manufacturing waste and thus improve operational efficiency in manufacturing processes. However, implementing lean strategies requires a large amount of resources and, in practice, manufacturers encounter difficulties in selecting appropriate lean strategies within their resource constraints. There is currently no systematic methodology available for selecting appropriate lean strategies within a manufacturer's resource constraints. In the lean transformation process, it is also critical to measure the current and desired leanness levels in order to clearly evaluate lean implementation efforts. Despite the fact that many lean strategies are utilized to reduce or eliminate manufacturing waste, little effort has been directed towards properly assessing the leanness of manufacturing organizations. In practice, a single or specific group of metrics (either qualitative or quantitative) will only partially measure the overall leanness. Existing leanness assessment methodologies do not offer a comprehensive evaluation method, integrating both quantitative and qualitative lean measures into a single quantitative value for measuring the overall leanness of an organization. This research aims to develop mathematical models and a systematic methodology for selecting appropriate lean strategies and evaluating the leanness levels in manufacturing organizations. Mathematical models were formulated and a methodology was developed for selecting appropriate lean strategies within manufacturers' limited amount of available resources to reduce their identified wastes. A leanness assessment model was developed by using the fuzzy concept to assess the leanness level and to recommend an optimum leanness value for a manufacturing organization. In the proposed leanness assessment model, both quantitative and qualitative input factors have been taken into account. Based on program developed in MATLAB and C#, a decision support tool (DST) was developed for decision makers to select lean strategies and evaluate the leanness value based on the proposed models and methodology hence sustain the lean implementation efforts. A case study was conducted to demonstrate the effectiveness of these proposed models and methodology. Case study results suggested that out of 10 wastes identified, the case organization (ABC Limited) is able to improve a maximum of six wastes from the selected workstation within their resource limitations. The selected wastes are: unnecessary motion, setup time, unnecessary transportation, inappropriate processing, work in process and raw material inventory and suggested lean strategies are: 5S, Just-In-Time, Kanban System, the Visual Management System (VMS), Cellular Manufacturing, Standard Work Process using method-time measurement (MTM), and Single Minute Exchange of Die (SMED). From the suggested lean strategies, the impact of 5S was demonstrated by measuring the leanness level of two different situations in ABC. After that, MTM was suggested as a standard work process for further improvement of the current leanness value. The initial status of the organization showed a leanness value of 0.12. By applying 5S, the leanness level significantly improved to reach 0.19 and the simulation of MTM as a standard work method shows the leanness value could be improved to 0.31. The optimum leanness value of ABC was calculated to be 0.64. These leanness values provided a quantitative indication of the impacts of improvement initiatives in terms of the overall leanness level to the case organization. Sensitivity analsysis and a t-test were also performed to validate the model proposed. This research advances the current knowledge base by developing mathematical models and methodologies to overcome lean strategy selection and leanness assessment problems. By selecting appropriate lean strategies, a manufacturer can better prioritize implementation efforts and resources to maximize the benefits of implementing lean strategies in their organization. The leanness index is used to evaluate an organization's current (before lean implementation) leanness state against the state after lean implementation and to establish benchmarking (the optimum leanness state). Hence, this research provides a continuous improvement tool for a lean manufacturing organization.

Condition monitoring and operational decision making in semiconductor manufacturing

Today, the majority of semiconductor fabrication plants (fabs) conduct equipment preventive maintenance based on statistically-derived time- or wafer-count-based intervals. While these practices have had relative success in managing equipment availability and product yield, the cost, both in time and materials, remains high. Condition-based maintenance has been successfully adopted in several industries, where costs associated with equipment downtime range from potential loss of life to unacceptable affects to companies’ bottom lines. In this paper, we present a method for the monitoring of complex systems in the presence of multiple operating regimes. In addition, the new representation of degradation processes will be used to define an optimization procedure that facilitates concurrent maintenance and operational decision-making in a manufacturing system. This decision-making procedure metaheuristically maximizes a customizable cost function that reflects the benefits of production uptime, and the losses incurred due to deficient quality and downtime. The new degradation monitoring method is illustrated through the monitoring of a deposition tool operating over a prolonged period of time in a major fab, while the operational decision-making is demonstrated using simulated operation of a generic cluster tool.

Canonical solution groups of a homomorphism : manipulator kinematics, nonparametric regression and distributed object systems

The kinematic mapping of a rigid open-link manipulator is a homomorphism between Lie groups. The homomorphisrn has solution groups that act on an inverse kinematic solution element. A canonical representation of solution group operators that act on a solution element of three and seven degree-of-freedom (do!) dextrous manipulators is determined by geometric analysis. Seven canonical solution groups are determined for the seven do! Robotics Research K-1207 and Hollerbach arms. The solution element of a dextrous manipulator is a collection of trivial fibre bundles with solution fibres homotopic to the Torus. If fibre solutions are parameterised by a scalar, a direct inverse funct.ion that maps the scalar and Cartesian base space coordinates to solution element fibre coordinates may be defined. A direct inverse pararneterisation of a solution element may be approximated by a local linear map generated by an inverse augmented Jacobian correction of a linear interpolation. The action of canonical solution group operators on a local linear approximation of the solution element of inverse kinematics of dextrous manipulators generates cyclical solutions. The solution representation is proposed as a model of inverse kinematic transformations in primate nervous systems. Simultaneous calibration of a composition of stereo-camera and manipulator kinematic models is under-determined by equi-output parameter groups in the composition of stereo-camera and Denavit Hartenberg (DH) rnodels. An error measure for simultaneous calibration of a composition of models is derived and parameter subsets with no equi-output groups are determined by numerical experiments to simultaneously calibrate the composition of homogeneous or pan-tilt stereo-camera with DH models. For acceleration of exact Newton second-order re-calibration of DH parameters after a sequential calibration of stereo-camera and DH parameters, an optimal numerical evaluation of DH matrix first order and second order error derivatives with respect to a re-calibration error function is derived, implemented and tested. A distributed object environment for point and click image-based tele-command of manipulators and stereo-cameras is specified and implemented that supports rapid prototyping of numerical experiments in distributed system control. The environment is validated by a hierarchical k-fold cross validated calibration to Cartesian space of a radial basis function regression correction of an affine stereo model. Basic design and performance requirements are defined for scalable virtual micro-kernels that broker inter-Java-virtual-machine remote method invocations between components of secure manageable fault-tolerant open distributed agile Total Quality Managed ISO 9000+ conformant Just in Time manufacturing systems.

Using a simulation model for capacity management

A simulation model has been constructed of a valve manufacturing plant with the aim of assessing capacity requirements in response to a forecast increase in demand. The plant provides a weekly cycle of valves of varying types, based on a yearly production plan. Production control is provided by a just-in-time type system to minimise inventory. The simulation model investigates the effect on production lead time of a range of valve sequences into the plant. The study required the collection of information from a variety of sources, and a model that reflected the true capabilities of the production system. The simulation results convinced management that substantial changes were needed in order to meet demand. The case highlights the use of simulation in enabling a manager to quantify operational scenarios and thus provide a rational basis on which to take decisions on meeting performance criteria.

Estructuración de un modelo de gestión eficiente para AJ Colombia SAS

En la mayoría de los países, los negocios familiares representan un alto porcentaje de todas las empresas constituidas. Colombia no es la excepción a este comportamiento, donde las empresas familiares representan el 70% de todas las compañías, según la Superintendencia de Sociedades, en las que se incluyen PYMES y grandes grupos económicos. Este trabajo de grado tiene como objetivo estructurar un modelo de gestión eficiente para la empresa AJ Colombia S.A.S. una empresa mediana que se ha venido estructurando de manera empírica, por lo que tras el análisis de sus procesos encontramos posibles mejoras usando herramientas como el Cambio Estratégico y la Reingeniería, además de la generación de valor por medio de los Inventarios.

Estrategia del Grupo Volkswagen de México para la reducción del impacto ambiental generado por sus procesos productivos

El siguiente escrito pretende mostrar las estrategias que el Grupo Volkswagen de México implementó para reducir el impacto que generan sus dos fábricas en México al medio ambiente. La primera de ellas, y la más grande en cuanto a infraestructura, recurso humano, complejidad y productividad entre ambas, se ubica en el Estado de Puebla, en su capital Puebla. Se dedica a la fabricación de varios modelos de vehículos para el mercado interno y mundial. La segunda fábrica se ubica en la ciudad de Silao en el Estado de Guanajuato, esta fábrica se dedica principalmente a la fabricación de motores, los cuales posteriormente son distribuidos a distintos complejos productivos alrededor del mundo para allí ensamblarse en carrocerías. En primera instancia se describe la estrategia general con los debidos alcances establecidos desde la dirección de la empresa. Posteriormente se prosigue a desglosar cada una de las sub-estrategias, explicándolas y relacionándolas en contexto, tomando de esta manera, paso a paso, como se ha construido una campaña que ha logrado adquirir una identidad propia ampliamente reconocida tanto por la fuerza laboral de la compañía e inclusive por los agentes del mercado en el que se encuentran. Finalmente se reúnen datos numéricos relevantes en cuanto a la reducción del impacto ambiental que por último se ven reflejado en un ahorro económico para la empresa.

A Cost Model for the Effect of Setup Time Reduction in Stainless Steel Strip Production

Setup time reduction facilitate the flexibility needed for just-in-time production. An integrated steel mill with meltshop, continuous caster and hot rolling mill is often operated as decoupled processes. Setup time reduction provides the flexibility needed to reduce buffering, shorten lead times and create an integrated process flow. The interdependency of setup times, process flexibility and integration were analysed through system dynamics simulation. The results showed significant reductions of energy consumption and tied capital. It was concluded that setup time reduction in the hot strip mill can aid process integration and hence improve production economy while reducing environmental impact.

Haptics and virtual reality in modern manufacturing

Product assembly is one of the most studied processes in modern manufacturing. In recent years a number of computer-based virtual reality systems have been proposed, developed and adopted by the manufacturing industries. Such systems have major advantages over conventional training practices for product assembly. Significant cost savings can be realized due to shorter training-scenario development times and reuse of existing engineering math models. In addition, the time span from the product design to full production can be shortened due to non-reliance on actual components and subsystems for training. Such training systems are effective if the knowledge required to be transferred is just process sequence such as assembly sequence. However, knowledge transfer for procedural and cognitive learning as well as skills development is very limited, due to the lack of user interactivity and immersion.

This talk will focus on a research technology platform where haptics and virtual reality are integrated to create an effective environment for production assembly operators’ training. In this system virtual reality provides the grounds for realistic visualization, as well as immersion, whereas haptics enforces physical constraints within the virtual world generating the feelings of realistic interaction, making it accessible for formal learning and better understanding during task performance.

The developed research technology platform imitates real physical training scenarios by providing comprehensive user interaction, constrained within the physical limitations of the real world. Through the utilization of a haptics device, providing realistic force feedback, users are able to engage in product assembly training with a stronger sense of ‘reality’.

Facilitating learning in a real time strategy computer game

The aim of this project was to implement a just-in-time hints help system into a real time strategy (RTS) computer game that would deliver information to the user at the time that it would be of the most benefit. The goal of this help system is to improve the user’s learning in terms of their rate of learning, retention and avoidance of stagnation. The first stage of this project was implementing a computer game to incorporate four different types of skill that the user must acquire, namely motor, perceptual, declarative knowledge and strategic. Subsequently, the just-in-time hints help system was incorporated into the game to assess the user’s knowledge and deliver hints accordingly. The final stage of the project was to test the effectiveness of this help system by conducting two phases of testing. The goal of this testing was to demonstrate an increase in the user’s assessment of the helpfulness of the system from phase one to phase two. The results of this testing showed that there was no significant difference in the user’s responses in the two phases. However, when the results were analysed with respect to several categories of hints that were identified, it became apparent that patterns in the data were beginning to emerge. The conclusions of the project were that further testing with a larger sample size would be required to provide more reliable results and that factors such as the user’s skill level and different types of goals should be taken into account.

Assembly line balancing the comparison of COMSOAL and MSNSH technique in Motorcycle manufacturing company

Today’s highly competitive market influences the manufacturing industry to improve their production systems to become the optimal system in the shortest cycle time as possible. One of most common problems in manufacturing systems is the assembly line balancing problem. The assembly line balancing problem involves task assignments to workstations with optimum line efficiency. The line balancing technique, namely “COMSOAL”, is an abbreviation of “Computer Method for Sequencing Operations for Assembly Lines”. Arcus initially developed the COMSOAL technique in 1966 [1], and it has been mainly applied to solve assembly line balancing problems [6]. The most common purposes of COMSOAL are to minimise idle time, optimise production line efficiency, and minimise the number of workstations. Therefore, this project will implement COMSOAL to balance an assembly line in the motorcycle industry. The new solution by COMSOAL will be used to compare with the previous solution that was developed by Multi‐Started Neighborhood Search Heuristic (MSNSH), which will result in five aspects including cycle time, total idle time, line efficiency, average daily productivity rate, and the workload balance. The journal name “Optimising and simulating the assembly line balancing problem in a motorcycle manufacturing company: a case study” will be used as the case study for this project [5].