An integrated manufacturing strategy for implementation of lean manufacturing, six sigma and cadcam methodologies in a small medium manufacturing environment (SMME).
AuthorEsan, Adedeji O.
SupervisorKhan, M. Khurshid
Manufacturing resource planning
Small medium manufacturing environment (SMME)
The University of Bradford theses are licenced under a Creative Commons Licence.
InstitutionUniversity of Bradford
DepartmentSchool of Engineering, Design and Technology
MetadataShow full item record
AbstractThe world is changing rapidly for the engineering community. Sustainability in every sense has become the watchword¿in terms of product manufacture and performance, and responding to global market and environmental pressures. A well thought-out manufacturing strategy can help organisations make choices that support its overall business objectives, respond to new opportunities and challenges as they arise. However, manufacturing strategy configuration and deployment in SMME¿s is a neglected field in manufacturing strategy literatures. More importantly, the application of lean manufacturing, Six Sigma and CIM strategies are said to be more applicable to batch production environments and large manufacturing organisations but not to SMMEs that operates a job shop type operating characteristics and with limited resource availability. With recognition that most of these methodologies were originally conceptualised and implemented in large manufacturing environments with batch and flow type manufacturing architecture, the need to develop solutions specific to SMME¿s with job shop type operating characteristics (tooling reclamation industry in particular) is imperative. The fundamental essence of this research is the development of an integrated manufacturing strategy which is based on Lean-Six Sigma-MRP-CADCAM methodologies at the case company. The framework for deploying this strategy is based on inputs from a business environment analysis, a lean strategic planning module (based on production planning and manufacturing/product cost structure analysis) and a lean resource planning interface that is predicated on value stream analysis and simulation models. The material and information flows of the case company manufacturing systems were studied. The approach taken emphasis the well know value engineering concepts of multiple-stage manufacturing system accumulating costs/time between individual stages as well as by transfer/material handling and work-in-process. The study shows that maximisation of capacity and resource utilisation, queue less work flow and flexible labour policies that support the case company¿s manufacturing system offer potential for reform which can substantially enhance customer service, product quality and overall improvement in investment returns.
Showing items related by title, author, creator and subject.
Integrated manufacturing strategy for deployment of CADCAM methodology in a SMMEEsan, Adedeji O.; Khan, M. Khurshid; Qi, Hong Sheng; Craig, N. (2013)Purpose – Cost reduction through the use of technology has become the competitive strength of companies. The beneﬁts of technology integration are quite credible and have been effective in business competition. The purpose of this paper is to describe an integrated manufacturing strategy for the deployment of a CAD/CAM system in a small, medium manufacturing enterprise (SMME). Design/methodology/approach – A case study of a SMME is utilised in deploying an integrated CAD/CAM system for practical application of manufacturing technology for achieving sustainable growth through lean systems design (LSD). The paper presents a techno-economic and technology change management framework, with an application of a holistic set of lean deployment tools that include establishing a strategic and operational plan for implementing CAD/CAM systems as a means to achieving world-class performance. Findings – The paper shows that the CAD/CAM integration within the case company increased knowledge of CAD/CAM technology, productivity, and ﬂexibility whilst reducing throughput times. Based on the literature review and the current case study, a framework for ideal CAD/CAM implementation has been proposed. The paper also shows that management and organisational structures are key inhibitors for successful implementation of technology integration. Research limitations/implications – The paper uses a single case study to validate deployment of the integrated manufacturing strategy in SMMEs. Hence there is a limitation to its generality. Practical implications – ThepaperprovidesanopportunitytofurtherunderstandCAD/CAMsystem implementation protocols within a well structured framework and its conﬁguration within SMMEs. Social implications – The CAD/CAM implementation framework will allow the SMMEs to achieve Lean manufacturing (thereby minimising wastes) leading to improved growth and employment rates. Originality/value – The presentation of conceptualisation, development and implementation of an integrated CAD/CAM system in support of organisational wide Lean manufacturing initiative in SMMEs is an originality of this paper.
The development of a hybrid knowledge-based system for the design of a Low Volume Automotive Manufacturing (LVAM) systemMohamed, N.M.Z.Nik; Khan, M. Khurshid (2012)A conceptual design approach is an important stage for the development of a hybrid Knowledge-Based System (KBS) for Low Volume Automotive Manufacturing (LVAM). The development of a hybrid KBS, which is a blend of KBS and Gauging Absences of Pre-requisites (GAP), is proposed for LVAM research. The hybrid KB/GAP system identifies all potential elements of LVAM issues throughout the development of this system. The KBS used in the system design stage of the LVAM system analyses the gap between the existing and the benchmark organisations for an effective implementation through the GAP analysis technique. The proposed KBLVAM model at the design stage explores three major components, namely LVAM car body parts manufacturing perspective, LVAM competitive priorities perspective and LVAM lean environment perspective. Initial results reveal that the KBLVAM system has identified, for each perspective modules and sub-modules, the Problem Categories (PC) in a prioritised manner.
The Development of a Hybrid Knowledge-Based System for Designing a Low Volume Automotive Manufacturing Environment. The Development of A Hybrid Knowledge-Based (KB)/Gauging Absences of Pre-Requisites (GAP)/Analytic Hierarchy Process (AHP) System for the Design and Implementation of a Low Volume Automotive Manufacturing (LVAM) Environment.Khan, M. Khurshid; Hussain, Khalid; Mohamed, N.M.Z.Nik (University of BradfordSchool of Engineering, Design and Technology, 2013-03-26)The product development process for the automotive industry is normally complicated, lengthy, expensive, and risky. Hence, a study on a new concept for Low Volume Automotive Manufacturing (LVAM), used for niche car models manufacturing, is proposed to overcome this issue. The development of a hybrid Knowledge Based (KB) System, which is a blend of KB System, Gauging Absences of Pre-requisites (GAP), and Analytic Hierarchy Process (AHP) is proposed for LVAM research. The hybrid KB/GAP/AHP System identifies all potential elements of LVAM issues throughout the development of this system. The KB System used in the LVAM analyses the gap between the existing and the benchmark organisations for an effective implementation. The novelty and differences in the current research approach emphasises the use of Knowledge Based (KB) System in the planning and designing stages by suggesting recommendations of LVAM implementation, through: a) developing the conceptual LVAM model; b) designing the KBLVAM System structure based on the conceptual LVAM model; and c) embedding Gauging Absences of Pre-requisites (GAP) analysis and Analytic Hierarchy Process (AHP) approach in the hybrid KBLVAM System. The KBLVAM Model explores five major perspectives in two stages. Planning Stage (Stage 1) consists of Manufacturer Environment Perspective (Level 0), LVAM Manufacturer Business Perspective (Level 1), and LVAM Manufacturer Resource Perspective (Level 2). Design Stage (Stage 2) consists of LVAM Manufacturer Capability ¿ Car Body Part Manufacturing Perspective (Level 3), LVAM Manufacturer Capability ¿ Competitive Priorities Perspective (Level 4), and LVAM Manufacturer Capability ¿ Lean Process Optimisation Perspective (Level 5). Each of these perspectives consists of modules and sub-modules that represent specific subjects in the LVAM development. Based on the conceptual LVAM model, all perspectives were transformed into the KBLVAM System structure, which is embedded with the GAP and AHP techniques, hence, key areas of potential improvement are recommended for each activity for LVAM implementation. In order to be able to address the real situation of LVAM environment, the research verification was conducted for two automotive manufacturers in Malaysia. Some published case studies were also used to check several modules for their validity and reliability. This research concludes that the developed KBLVAM System provides valuable decision making information and knowledge to assist LVAM practitioners to plan, design and implement LVAM in terms of business organisation, manufacturing aspects and practices.