Deals with the basic requirements for world‐class manufacturing and discusses the role of total productive maintenance (TPM) in helping to achieve world‐class manufacturing…
Abstract
Deals with the basic requirements for world‐class manufacturing and discusses the role of total productive maintenance (TPM) in helping to achieve world‐class manufacturing. Examines the roles of TPM in TQM and JIT. Finally, impacts of TPM on the culture and structure of the organization are discussed and pitfalls of TPM implementation are dealt with. Provides an in‐depth look at the development of Japanese manufacturing strategy and concludes with the view that the first step to world‐class manufacturing is to implement TPM successfully and to create an active organization.
Details
Keywords
Hajime Yamashina and Shunsuke Otani
The purpose of this paper is to properly plan the preventive maintenance schedule for multiple elevators and optimize the number of maintenance workers.The total amount of the…
Abstract
The purpose of this paper is to properly plan the preventive maintenance schedule for multiple elevators and optimize the number of maintenance workers.The total amount of the maintenance cost consisting of the labor cost, the part cost, and the quality cost (the loss evaluated in terms of cost, to be incurred when an elevator breaks down) is to be minimized.The method is presented of setting up the optimal preventive maintenance schedule on a long‐term basis by rescheduling the contents of schedule dynamically and flexibly in accordance with the ever‐changing maintenance conditions, taking the possibility of the future occurrence of failure into consideration. From numerical experiments, the validity of the proposal procedure for planning the preventive maintenance schedule and the effectiveness of considering the possibility of the future occurrence of failure in planning the schedule are shown, and the optimal number of maintenance workers can be decided.
Details
Keywords
Suebsakul Tonjang and Natcha Thawesaengskulthai
This research aimed to create inventive principles in managing quality and innovation systems that can be used as a guide for the development of effective innovation projects in…
Abstract
Purpose
This research aimed to create inventive principles in managing quality and innovation systems that can be used as a guide for the development of effective innovation projects in hospitals.
Design/methodology/approach
Total quality and innovation management in healthcare (TQIM-H) framework and theory of inventive problem-solving (TRIZ) were integrated with results from in-depth interviews with 30 healthcare experts, resulting in TQIM-H inventive principle. The developed inventive principle was validated using 50 effective innovation projects from one of the largest healthcare conglomerates in Southeast Asia.
Findings
The TQIM-H inventive principle consisted of 7 dimensions and 72 procedures for creating innovation in hospitals under the medical quality framework. The principle effectively helps innovators develop innovative solutions that still strictly comply with medical guidelines.
Originality/value
Innovation is recognized as a critical factor that helps organizations adapt to global changes and increases the potential for competition, especially in hospitals. However, creating innovation in hospitals has a lower success rate than in other industries because, in general, ineffective innovation development strategies are used and the created innovation is not aligned with regulations and restrictions regarding healthcare quality in the healthcare system.
Details
Keywords
Hajime Yamashina and Shunsuke Otani
Elevator manufacturers are responsible for securing the safety and maintaining the performance, cleanliness and cosmetic appearance of the elevators which they sell.The purpose of…
Abstract
Elevator manufacturers are responsible for securing the safety and maintaining the performance, cleanliness and cosmetic appearance of the elevators which they sell.The purpose of this paper is to develop a cost‐optimized after‐sales strategy for the maintenance of an elevator part. First, in order to find an optimum maintenance method, the replacement probability and the inspection probability of the part are theoretically derived using each of the three maintenance methods: Time Based Maintenance (TBM), Condition Based Maintenance (CBM), and Breakdown Maintenance (BM). Then, the approach to plan a cost‐optimized maintenance method is presented and the relationship between the failure characteristics of the part and the cost‐optimized maintenance method is discussed.The results of using the proposed approach are compared with those obtained by Online Quality Engineering (Taguchi methods). Finally, from numerical experiments, it is shown that this approach can provide a more cost‐effective and better maintenance method than the method provided by Online Quality Engineering.
Details
Keywords
In most automated assembly systems, each product is inspected after every assembly operation and, if it is found to be defective, it will be repaired or scrapped immediately. This…
Abstract
In most automated assembly systems, each product is inspected after every assembly operation and, if it is found to be defective, it will be repaired or scrapped immediately. This ensures the quality of the outputs of the systems, but it also causes a short stop of the assembly line. This paper shows that the number of short stops can be reduced by installing inspection stations and repair stations strategically. Then, an optimizing problem of placing these stations under a given assembly sequence is formulated and an algorithm is given to this problem. Further, the problem of not only placing these stations but also determining the assembly sequence is formulated and an algorithm to solve the problem is developed. Finally, numerical examples are given to illustrate the efficiencies of the algorithms.
Details
Keywords
N. Muthukumar, K. Ganesh, Sanjay Mohapatra, K. Tamizhjyothi, R. M. Nachiappan and M. Bharati
Lai Wan Hooi and Tat Yuen Leong
The purpose of this paper is to examine the multidimensionality of total productive maintenance (TPM) and its relationship with manufacturing performance improvement in the…
Abstract
Purpose
The purpose of this paper is to examine the multidimensionality of total productive maintenance (TPM) and its relationship with manufacturing performance improvement in the Malaysian manufacturing sector. Specifically, this study evaluates the contribution of each TPM success factors in improving manufacturing performance.
Design/methodology/approach
Data from 89 employees who participated in the survey were used to test the proposed research framework. A structured questionnaire adopted from Ahuja and Khamba (2006) was used to assess the Malaysian context.
Findings
The analytical results reveal that traditional maintenance initiatives and TPM implementation initiatives significantly affect manufacturing performance, but not top management leadership and maintenance organisation. Top management roles and commitment are critical in the early stage to determine the master plan and initiate the implementation of the whole programme. However, traditional maintenance and TPM implementation initiatives gradually enable engagement, proper planning, right execution and continuous improvement, ultimately improving the manufacturing performance indicators significantly. The findings further unveil that TPM is not sustainable in Malaysia’s manufacturing organisations in the long run.
Practical implications
This analysis is vital for senior managers of manufacturing organisations that have implemented TPM or are considering introducing TPM in their organisations.
Originality/value
This study contributes to the literature by examining beyond the introduction and stabilisation phase of TPM to provide an insight of whether TPM is sustainable in the long run.
Details
Keywords
Luis Alejandro Gólcher-Barguil, Simon Peter Nadeem, Jose Arturo Garza-Reyes, Ashutosh Samadhiya and Anil Kumar
Equipment performance helps the manufacturing sector achieve operational and financial improvements despite process variations. However, the literature lacks a clear index or…
Abstract
Purpose
Equipment performance helps the manufacturing sector achieve operational and financial improvements despite process variations. However, the literature lacks a clear index or metric to quantify the monetary advantages of enhanced equipment performance. Thus, the paper presents two innovative monetary performance measures to estimate the financial advantages of enhancing equipment performance by isolating the effect of manufacturing fluctuations such as product mix price, direct and indirect characteristics, and cost changes.
Design/methodology/approach
The research provides two measures, ISB (Improvement Saving Benefits) and IEB (Improvement Earning Benefits), to assess equipment performance improvements. The effectiveness of the metrics is validated through a three stages approach, namely (1) experts' binary opinion, (2) sample, and (3) actual cases. The relevant data may be collected through accounting systems, purpose-built software, or electronic spreadsheets.
Findings
The findings suggest that both measures provide an effective cost–benefit analysis of equipment performance enhancement. The measure ISB indicates savings from performance increases when equipment capacity is greater than product demand. IEB is utilised when equipment capacity is less than product demand. Both measurements may replace the unitary cost variation, which is subject to manufacturing changes.
Practical implications
Manufacturing businesses may utilise the ISB and IEB metrics to conduct a systematic analysis of equipment performance and to appreciate the financial savings perspective in order to emphasise profitability in the short and long term.
Originality/value
The study introduces two novel financial equipment performance improvement indicators that distinguish the effects of manufacturing variations. Manufacturing variations cause cost advantages from operational improvements to be misrepresented. There is currently no approach for manufacturing organisations to calculate the financial advantages of enhancing equipment performance while isolating production irregularities.
Details
Keywords
Ali Mohammadi, Jiami Yang, Yuri Borgianni and Yong Zeng
The purpose of this paper is to analyze theory of inventive problem-solving (TRIZ) in terms of knowledge, skill, workload and affect to understand its effectiveness in enabling…
Abstract
Purpose
The purpose of this paper is to analyze theory of inventive problem-solving (TRIZ) in terms of knowledge, skill, workload and affect to understand its effectiveness in enabling designers to achieve their optimized mental performance.
Design/methodology/approach
TASKS framework, which aims to capture the causal relations among Task workload, affect, skills, knowledge and mental stress, is adopted as our methodology. The framework supports the analysis of how a methodology influence designer’s affect, skills, knowledge and workload. TRIZ-related publications are assessed using the TASKS framework to identify the barriers and enablers in TRIZ-supported design.
Findings
TRIZ has limitations on its logic and tools. Nevertheless, it could create a beneficial impact on mental performance of designers.
Originality/value
This paper provides a theory-driven TRIZ usability analysis based on the materials in the literature following the TASKS framework. The impact of TRIZ, as an enabler or a barrier, has been analyzed in accomplishing a design task.
Details
Keywords
Chia Tai Angus Lai, Wei Jiang and Paul R. Jackson
The purpose of this paper is to demonstrate how Internet of Things (IoT) technology can enable highly distributed elevator equipment servicing by using remote-monitoring…
Abstract
Purpose
The purpose of this paper is to demonstrate how Internet of Things (IoT) technology can enable highly distributed elevator equipment servicing by using remote-monitoring technology to facilitate a shift from traditional corrective maintenance (CM) and time-based maintenance (TBM) to more predictive, condition-based maintenance (CBM) in order to achieve various benefits.
Design/methodology/approach
Literature review indicates that CBM has advantages over conventional CM and TBM from a theoretical perspective, but it depends on continuous monitoring enhancement via advanced IoT technology. An in-depth case study was carried out to provide practical evidence that IoT enables elevator firms to achieve CBM.
Findings
From a theoretical perspective, the CBM of elevators makes business sense. The challenges lie in data collection, data analysis and decision making in real-world business contexts. The main findings of this study suggest that CBM can be commercialized via IoT in the case of elevators and would improve the safety and reliability of equipment. It would, thus, make sense from technological, process and economic perspectives.
Practical implications
Our longitudinal real-world case study demonstrates a practical way of making the CBM of elevators widespread. Integrating IoT and other advanced technology would improve the safety and reliability of elevator equipment, prolong its useful life, minimize inconvenience and business interruptions due to equipment downtime and reduce or eliminate major repairs, thus greatly reducing maintenance costs.
Originality/value
The main contribution of this paper lies in the empirical demonstration of the benefits and challenges of CBM via IoT relative to conventional CM and TBM in the case of elevators. The authors believe that this study is timely and will be valuable to firms working on similar research or commercialization strategies.