Advanced manufacturing technology adoption - the German experience

The decision process that organisations utilise when evaluating technology investment opportunities is a complex and even political process; however, the correct decision can provide the organisation with considerable operational and competitive benefits. The research presented in this paper presents the findings of a postal survey of the benefits provided by technology investments to large German manufacturers. It was found that only where middle management generated the idea for the advanced manufacturing technology (AMT) investment was success in that investment significantly more likely. Respondents who established a project team to plan the technology proposal, regardless of the department which generated the ideas for technology investment, were not significantly associated with a greater likelihood for success.

The respondents typically took between 3 and 12 months before making the final decision to invest, irrespective of the department generating the idea for the AMT, and a further 6 months to implement the AMT. Respondents who utilised a discounted cashflow analysis took significantly longer to make the final decision to invest. The greatest number of manufacturing outcomes of significantly higher importance was identified for respondents where Engineering, IT or R&D generated the AMT ideas. It was also determined that the respondents most frequently considered AMT investments in computer hardware or software and technical training for process workers to be necessary at the time of considering the investment. Middle management were found to be significantly more concerned than managers on other levels about opposition of workers to the AMT, while the process workers were significantly more concerned about interruptions to the process during installation.

Managing manufacturing technology investments: An intelligent learning system approach

This paper proposes an intelligent decision-support system for managing manufacturing technology investments. The intelligent system is a hybrid integration of two information processing modules: case-based reasoning and fuzzy ARTMAP – a supervised adaptive resonance theory (ART) neural network with a multi-dimensional map. The developed system captures a company's strategic information, provides facilities to quantify qualitative attributes and analyses them alongside the quantitative attributes in an evaluation framework. Through the system, similar cases can be retrieved to enable managers to make effective use of their knowledge and experience of previously delivered technologies and projects as an input to the prioritization of future projects. Other salient features of the system include its ability to adapt and absorb new knowledge and responses pertaining to significant events in the business environment, as well as to extract and elucidate information from the knowledge database for explaining and justifying its analysis. The applicability of the developed system is evaluated using a real case study in collaboration with a pharmaceutical manufacturing firm.

A learning laboratory approach for business improvement : the case of discontinuous innovation

This paper considers the current situation within Australian manufacturing SMEs and their approaches to innovation and international competitive advantage. Using the viewpoint and language of complexity theory, we consider the variety of possibilities available to SMEs in this area. We then consider a particular international project on Discontinuous Innovation, how this has been deployed in Europe and Australia and the knowledge gained from our interactions with Australian SMEs to date around this project. Finally we consider the general development of a “Learning Laboratory” approach to working with SMEs and the differences required to make such approach successful in Europe and in different settings in Australia.

Pervasive limitations : innovating with ambient intelligence (AmI) technologies and restricted absorptive capacity in Australian SME manufacturers

The last 25 years have seen rapid increases in the number and sophistication of technological and process innovations in large manufacturers, producing dramatic improvements in productivity and efficiency. However, smaller manufacturers’ adoption of such innovations has been uneven. Ambient Intelligence (AmI) technologies are being positioned as the next performance and productivity enhancing purchase for manufacturers. This paper defines and gives examples of AmI technologies in current use, summarises AmI technologies of potential interest to small and medium enterprise (SME) manufacturers, and identifies potential impacts of restricted absorptive capacity in SMEs on the adoption of AmI technologies. Comparing two SME manufacturers, one from Germany and one from Australia illustrates a potential application of generic AmI technology based business solutions to a range of SME manufacturers.

Microstructure and mechanical properties of wrought and additive manufactured Ti-6Al-4V cylindrical bars

Titanium alloys are widely used in various engineering design application due to its superior material properties. The traditional manufacturing of titanium products is always difficult, time consuming, high material wastage and manufacturing costs. Selective laser melting (SLM), an additive manufacturing technology has widely gained attention due to its capability to produce near net shape components with less production time. In this technical paper,microstructure,chemical composition,tensile properties and hardness are studied for the wrought and additive manufactured SLM cylindrical bar. Microstructure,mechanical properties and hardness were studied in both the longitudinal and transverse directions of the bar to study the effect of orientation. It was found that additive manufactured bar have higher yield strength, ultimate tensile strength and hardness than the wrought bar. For both conventional and SLM test samples, the yield strength, ultimate tensile strength and hardness was found to be high in the transverse direction. The difference in the properties can be attributed to the difference in microstructure as a result of processing conditions. The tensile fracture area was quantified by careful examination of the fracture surfaces in the scanning electron microscope.

Building a local design and entrepreneurship ecosystem

Design and creativity are becoming greatly sought out skills in leading industries around the world, big businesses are developing the “Chief Design Officer” to engage with strategic and company shaping discussions. Design as an economic driver is now abundantly clear with companies such as Nike and Apple leading this way of thinking, but how do we as Australian industry capture this and how do we instil “creativity” into our secondary school and university level education to drive the next level of innovation and development. The local region where Deakin University is situated has undergone significant changes in the last 10 years, what was once an economy dominated by oil, automotive and metal production industries has been wound down to a local economy dominated by health, services and education. However, manufacturing and design being the front end of manufacturing is still a key economic driver this study is looking at the embryonic initiatives undertaken to build an ecosystem of design and entrepreneurship in a regional area. Several aspects will be looked at, high school and university student engagement in the process, established SME's and start-up culture. With the establishment of an ecosystem it is believed that success will breed success. With student engagement showing that being creative and playing can yield tangible results, it also gets students comfortable with the element of risk. The efforts of Deakin University is about providing the framework and scaffolding for students to pursue a start-up idea and test it validity. The final part of the ecosystem is for SME's and recent start-ups to share their success stories and acting as mentors as future start-ups emerge. By creating an ecosystem that is driven by design, manufacturing and entrepreneurship key economic outcomes will be generated; a regional area will be more resilient to economic uncertainty and ultimately a cohort of innovative thinkers that will generate value for their community.

Simulation-based support tool for operator performance in batch manufacturing

In industry, the workload and utilization of shop floor operators is often misunderstood. In this paper, we will present several real case studies, using Discrete Event Simulation (DES) models, which allow us to better understand operators in a batch manufacturing environment. The first study investigates labour in a machining plant consisting of multiple identical CNC machines that batch produce parts. The second study investigates labour in an eight station, gravity die casting rotary table. The results from these studies have shown that there can be potential improvements made by the production planners in the current labour configuration. In the first case study, a matrix is produced that estimates what the operator's utilization levels will be for various configurations. From this, the preferred operator to machine ratio over a range of cycle times is presented. In the second study, the results have shown that by reducing the casting cycle time, the operator would be overloaded. A discrete event simulation of these two cases highlighted areas that were misunderstood by plant management, and provided them with a useful decision support tool for production planning.