Analisi ed efficientamento di un impianto tecnologico di lavorazione a freddo delle lamiere per la produzione di elettrodomestici in serie: il caso Electrolux S.p.A.

L'elaborato di tesi prende in esame il processo di produzione della linea “Pordenone”, in funzione nello stabilimento forlivese, di Electrolux S.P.A., azienda leader mondiale nella produzione di elettrodomestici e apparecchiature per l'uso domestico. Ragione del presente studio è l’acquisizione dell’opportuna comprensione del funzionamento dell’impianto al fine di individuare le inefficienze, le causali di fermata per la pianificazione della produzione o per gli interventi di manutenzione correttiva dei guasti, in modo da poter suggerire azioni di miglioramento. Per monitorare il processo di produzione è stato applicato all'oggetto di indagine lo studio del diagramma di Pareto, che ha permesso di evidenziare le principali causali all'origine della riduzione di produttività. Oltre a suggerire ipotesi di azioni di miglioramento, si è sottolineata l'importanza del coinvolgimento motivazionale degli operatori nelle procedure di lavoro, e l'opportunità di una maggiore implementazione del sistema informatico. Ragioni di carattere economico o di sicurezza dell'operatore, non hanno permesso di accogliere alcuni suggerimenti proposti, mentre sono state apportate migliorie nella produzione attraverso la riduzione delle fermate di lavoro. Nell'attuale clima di incertezza produttiva e di calo di domanda da parte di alcuni mercati, non è facile elaborare strategie di produzione innovative, tali da garantire la qualità del prodotto offerto e i risultati economici attesi, nel rispetto autentico dell'ambiente della collettività. Tuttavia, si ritiene che le informazioni generate da un adeguato monitoraggio del sistema offrano la possibilità di guardare avanti verso i progressi, piuttosto che concentrare la propria attenzione sulle opportunità mancate, e che le stesse informazioni possano trasformare l'agire dalla reattività (azione dopo il fatto) alla proattività (agire in anticipo) per migliorare efficacemente il processo di produzione.

“Razionalizzazione ed efficientamento del sistema produttivo: Il Caso C.M.I Cerniere Meccaniche Industriali”

Nel mondo dell’industria, la produzione senza sprechi costituisce fonte di vantaggio competitivo. Per questo, molte aziende cercano di efficientare i propri processi attraverso gli strumenti della Lean Manufacturing. L’obiettivo di questa tesi è proprio quello di trovare una soluzione per la minimizzazione degli sprechi all’interno del contesto aziendale in cui sono stato inserito come tirocinante. In primis, si cercherà di descrivere in modo dettagliato l’azienda pressa la quale si è svolta l’attività di tirocinio. Successivamente verrà illustrato lo stato AS-IS dell’azienda insieme alle problematiche che sta fronteggiando in questo momento. Dopo la descrizione del problema all’interno del contesto aziendale, si analizzeranno i dati presi direttamente sul campo di lavoro. A seguire, dopo l’approvazione da parte del top management della soluzione migliorativa trovata, avverrà la descrizione dello stato TO-BE. In conclusione, verranno messi a confronto i dati dello stato AS-IS con quelli del TO-BE per costruire il dato aggregato dell’attività svolta in azienda. Questo riassume brevemente il lavoro di tesi svolto in azienda, che ha permesso di ridurre di qualche punto percentuale i fermi macchina e di efficientare il sistema produttivo.

Understanding the strategies of late-movers in International Manufacturing

This paper analyzes the internationalization of new multinationals from emerging countries. It also focuses on Production`s role in firm internationalization, a subject seldom addressed because the discipline of International Manufacturing is still embryonic, while International Business tends to overlook production. The authors integrate International Business and International Manufacturing concepts and frameworks in order to analyze new multinationals from emerging countries, using the empirical evidence of a survey plus case studies of Brazilian multinationals for understanding late-movers` strategies and competences, with emphasis on production. (C) 2009 Elsevier B.V. All rights reserved.

Complementarity between technology make and buy in innovation strategies: Evidence from Belgiam manufacturing firms

This paper characterizes the innovation strategy of manufacturing firms andexamines the relation between the innovation strategy and importantindustry-, firm- and innovation-specific characteristics using Belgiandata from the Eurostat Community Innovation Survey. In addition to importantsize effects explaining innovation, we find that high perceived risks andcosts and low appropriability of innovations do not discourage innovation,but rather determine how the innovation sourcing strategy is chosen. Withrespect to the determinants of the decision of the innovative firm toproduce technology itself (Make) or to source technology externally (Buy),we find that small firms are more likely restrict their innovation strategyto an exclusive make or buy strategy, while large firms are more likely tocombine both internal and external knowledge acquisition in their innovationstrategy. An interesting result that highlights the complementary nature ofthe Make and Buy decisions, is that, controlled for firm size, companies forwhich internal information is an important source for innovation are morelikely to combine internal and external sources of technology. We find thisto be evidence of the fact that in-house R&D generates the necessaryabsorptive capacity to profit from external knowledge acquisition. Also theeffectiveness of different mechanisms to appropriate the benefits ofinnovations and the internal organizational resistance against change areimportant determinants of the firm's technology sourcing strategy.

Lean Six Sigma in a Manufacturing Lead Time Improvement Project

The objective of this research is to demonstrate the use of Lean Six Sigma methodology in a manufacturing lead time improvement project. Moreover, the goal is to develop working solutions for the target company to improve its manufacturing lead time. The theoretical background is achieved through exploring the literature of Six Sigma, Lean and Lean Six Sigma. The development will be done in collaboration with the related stakeholders, by following the Lean Six Sigma improvement process DMAIC and by analyzing the process data from the target company. The focus of this research is in demonstrating how to use Lean Six Sigma improvement process DMAIC in practice, rather than in comparing Lean Six Sigma to other improvement methodologies. In order to validate the manufacturing system’s current state, improvement potential and solutions, statistical tools such as linear regression analysis were used. This ensured that all the decisions were as heavily based on actual data as possible. As a result of this research, a set of solutions were developed and implemented in the target company. These solutions included batch size reduction, bottleneck shift, first-in first-out queuing and shifting a data entry task from production planners to line workers. With the use of these solutions, the target company was able to reduce its manufacturing lead time by over one third.

Strategies for Lean Product Development

The essence of lean is very simple, but from a research and implementation point of view overwhelming. Lean is the search for perfection through the elimination of waste and the insertion of practices that contribute to reduction in cost and schedule while improving performance of products. This concept of lean has wide applicability to a large range of processes, people and organizations, from concept design to the factory floor, from the laborer to the upper management, from the customer to the developer. Progress has been made in implementing and raising the awareness of lean practices at the factory floor. However, the level of implementation and education in other areas, like product development, is very low.

Generic strategies and performance: evidence from manufacturing firms

Purpose – The purpose of this study is to examine the relationship between business-level strategy and organisational performance and to test the applicability of Porter's generic strategies in explaining differences in the performance of organisations. Design/methodology/approach – The study was focussed on manufacturing firms in the UK belonging to the electrical and mechanical engineering sectors. Data were collected through a postal survey using the survey instrument from 124 organisations and the respondents were all at CEO level. Both objective and subjective measures were used to assess performance. Non-response bias was assessed statistically and it was not found to be a major problem affecting this study. Appropriate measures were taken to ensure that common method variance (CMV) does not affect the results of this study. Statistical tests indicated that CMV problem does not affect the results of this study. Findings – The results of this study indicate that firms adopting one of the strategies, namely cost-leadership or differentiation, perform better than “stuck-in-the-middle” firms which do not have a dominant strategic orientation. The integrated strategy group has lower performance compared with cost-leaders and differentiators in terms of financial performance measures. This provides support for Porter's view that combination strategies are unlikely to be effective in organisations. However, the cost-leadership and differentiation strategies were not strongly correlated with the financial performance measures indicating the limitations of Porter's generic strategies in explaining performance heterogeneity in organisations. Originality/value – This study makes an important contribution to the literature by identifying some of the gaps in the literature through a systematic literature review and addressing those gaps.

Activity based costing, time-driven activity based costing and lean accounting: differences among three accounting systems' approach to manufacturing

Choosing an appropriate accounting system for manufacturing has always been a challenge for managers. In this article we try to compare three accounting systems designed since 1980 to address problems of traditional accounting system. In the first place we are going to present a short overview on background and definition of three accounting systems: Activity Based costing, Time-Driven Activity Based Costing and Lean Accounting. Comparisons are made based on the three basic roles of information generated by accounting systems: financial reporting, decision making, and operational control and improvement. The analysis in this paper reveals how decisions are made over the value stream in the companies using Lean Accounting while decisions under the ABC Accounting system are taken at individual product level, and finally we will show how TD-ABC covers both product and process levels for decision making. In addition, this paper shows the importance of nonfinancial measures for operational control and improvement under the Lean Accounting and TD-ABC methods whereas ABC relies mostly on financial measures in this context.

Identifying innovation strategies: insights from the Greek food manufacturing sector

This paper examines the concept of innovation that is widely recognised as very important for all companies across different business sectors. The paper initially provides a review of the innovation literature in terms of types, classifications and sources of innovation that have been proposed over time. Then, the paper examines innovation in the context of the food industry, and in particular, it attempts to identify innovation strategies followed by Greek food manufacturing companies based on a specific model. Evidence from the Greek food manufacturing sector indicates that companies tend to innovate along the dimension of offerings that is more related to the traditional view of innovation (product and process innovation).

A study of the impact of lean on UK manufacturing organisations that view it as a philosophy

There were three principal research aims: primarily, Lean is and always should be regarded as a business model as depicted by Toyota who is dedicated towards finding better ways of producing cars; consequently an investigation of whether organisations embracing Lean as a philosophy were indeed more triumphant. An adapted balanced scorecard was used which embraced strategic, operation and indices focused towards the future prospects of an organisation. Secondly, it was obligatory to explicitly and precisely determine whether an organisation espoused Lean as a philosophy as opposed to another process or strategy. Thirdly, since Lean has to be envisaged as a never-ending journey; it was important to map out the Lean journey and to be able to categorize the juncture an organisation occupies at any particular phase of its overall implementation. This affords an opportunity to advise an organisation of specific requirements it needs to satisfy should it wish to embrace Lean as a philosophy. The methodological approach focused on the effective deployment of survey questionnaires in sixty-eight organisations and seven extensive case studies in manufacturing organisations of varying sizes. The CIMA organisational classification, the Puttick grid and the Product-Process matrix were used to analyse the range of organisations used in this investigation. Whilst there was a requirement to investigate whether Lean indeed equates to success, pertinent performance measurement was considered decisive; the DMP Model (Maltz et al., 2003) was modified to perform this role. An unremitting theme both in literature concerning the implementation of Lean and in the research evolves around the notion of corporate cultures. Its relevance is explored further within the analysis. In accepting the premise that Lean incorporates a journey, it was fundamental to identify the voyage. Prevalent frameworks are deficient in identifying the sustainability and ideological facets of Lean. Consequently, an extensive Lean audit was developed and piloted in twenty disparate organisations.

Research on rework strategies for reconfigurable manufacturing system considering mission reliability

Rework strategies that involve different checking points as well as rework times can be applied into reconfigurable manufacturing system (RMS) with certain constraints, and effective rework strategy can significantly improve the mission reliability of manufacturing process. The mission reliability of process is a measurement of production ability of RMS, which serves as an integrated performance indicator of the production process under specified technical constraints, including time, cost and quality. To quantitatively characterize the mission reliability and basic reliability of RMS under different rework strategies, rework model of RMS was established based on the method of Logistic regression. Firstly, the functional relationship between capability and work load of manufacturing process was studied through statistically analyzing a large number of historical data obtained in actual machining processes. Secondly, the output, mission reliability and unit cost in different rework paths were calculated and taken as the decision variables based on different input quantities and the rework model mentioned above. Thirdly, optimal rework strategies for different input quantities were determined by calculating the weighted decision values and analyzing advantages and disadvantages of each rework strategy. At last, case application were demonstrated to prove the efficiency of the proposed method.

Strategies for sustaining manufacturing competitiveness:comparative case studies in Australia and Sweden

Purpose - The purpose of this paper is to report an investigation of local sustainable production in Australia and Sweden aimed at exploring the factors contributing to survival and competitiveness of manufacturing companies. Design/methodology/approach - In Australia, six companies were studied in 2010, with comparisons being made with three of them from earlier projects. In Sweden, eight manufacturing companies were studied on two occasions 30 years apart, in 1980 and 2010. To provide a valid comparative perspective a common format for data collection and analysis was used. Findings - There has been a shift in the nature of competition in both Sweden and Australia due to an increasing complexity of the global business environment as well as changes in technology and customer expectations. Despite the differences in country context, the findings suggest that all the manufacturing companies have a good awareness of the elements of the market environment and the relationships with their competitive strategy. However, in general, the Swedish companies have more experience of managing the risks and benefits from operating in the international environment. Research limitations/implications - The results of the research are based on a relatively small sample of case companies in a limited number of industrial sectors. There are methodology implications for future research in the area. Practical implications - The research results have practical implications for the manufacturing industry, especially for companies operating in a competitive international environment. Originality/value - The paper is based on original case research and comparative analysis of data from different geographical contexts. It contributes to both theory and management practice about the strategic resources, decision choices, competitive environments and firm values needed to address external market demands as well as in building internal capabilities.

The knowledge gap: A perspective on trade, industry, technology and policy from pre-war Australian music technology manufacturing (1903-30)

Australia struggles to achieve economic competitiveness, prevent expansion of the trade deficit and develop value-added production despite applications of policy strategies from protectionism to trade liberalisation. This article argues that these problems were emerging at the turn of the century, and that an investigation of music technology manufacturing in the first two decades of this century reveals fundamental problems in the conduct of relevant policy analysis. Analysis has focused on the trade or technology gap which is only symptomatic of an underlying knowledge gap. The article calls for a knowledge policy approach which can allow protection without the negative effects of isolation from global markets and without having to resort to unworkable utopian free-trade dogma. A shift of focus from a 'goods traded' view to a knowledge transaction (or diffusion) perspective is advocated.