Jon Bokrantz, Anders Skoogh, Torbjörn Ylipää and Johan Stahre
A common understanding of what events to regard as production disturbances (PD) are essential for effective handling of PDs. Therefore, the purpose of this paper is to answer the…
Abstract
Purpose
A common understanding of what events to regard as production disturbances (PD) are essential for effective handling of PDs. Therefore, the purpose of this paper is to answer the two questions: how are individuals with production or maintenance management positions in industry classifying different PD factors? Which factors are being measured and registered as PDs in the companies monitoring systems?
Design/methodology/approach
A longitudinal approach using a repeated cross-sectional survey design was adopted. Empirical data were collected from 80 companies in 2001 using a paper-based questionnaire, and from 71 companies in 2014 using a web-based questionnaire.
Findings
A diverging view of 21 proposed PD factors is found between respondents in manufacturing industry, and there is also a lack of correspondence with existing literature. In particular, planned events are not classified and registered to the same extent as downtime losses. Moreover, the respondents are often prone to classify factors as PDs compared to what is actually registered. This diverging view has been consistent for over a decade, and hinders companies to develop systematic and effective strategies for handling of PDs.
Originality/value
There has been no in-depth investigation, especially not from a longitudinal perspective, of the personal interpretation of PDs from people who play a central role in achieving high reliability of production systems.
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Jon Bokrantz, Anders Skoogh, Cecilia Berlin and Johan Stahre
Scholars and practitioners within industrial maintenance management are focused on understanding antecedents, correlates and consequences of the concept of “Smart Maintenance,”…
Abstract
Purpose
Scholars and practitioners within industrial maintenance management are focused on understanding antecedents, correlates and consequences of the concept of “Smart Maintenance,” which consists of the four dimensions, namely, data-driven decision-making, human capital resource, internal integration and external integration. In order to facilitate this understanding, valid and reliable empirical measures need to be developed. Therefore, this paper aims to develop a psychometric instrument that measures the four dimensions of Smart Maintenance.
Design/methodology/approach
The results from two sequential empirical studies are presented, which include generating items to represent the constructs, assessment of content validity, as well as an empirical pilot test. With input from 50 industrial experts, a pool of 80 items that represent the constructs are generated. Thereafter, using data from 42 industrial and academic raters, the content validity of all items is assessed quantitatively. Finally, using data from 59 manufacturing plants, the dimensionality and factor structure of the instrument are tested.
Findings
The authors demonstrate content validity and provide evidence of good model fit and psychometric properties for one-factor models with 8–11 items for each of the four constructs, as well as a combined 24-item four-factor model.
Originality/value
The authors provide recommendations for scholarly use of the instrument in further theory-testing research, as well as its practical use to assess, benchmark and longitudinally evaluate Smart Maintenance within the manufacturing industry.
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Tor Guimaraes, Nils Martensson, Johan Stahre and Magid Igbaria
As the increase in manufacturing competitiveness forces organizations to use more sophisticated and complex software, system performance depends on clever systems design…
Abstract
As the increase in manufacturing competitiveness forces organizations to use more sophisticated and complex software, system performance depends on clever systems design, efficient planning and scheduling of the related processes. For these advanced manufacturing systems the dependence on human competence is greater. However, previous studies indicate that the human aspects for successfully implementing such systems have been neglected. The objective here is to test the hypotheses that system complexity is inversely related to performance, and that training of system operators, and the quality of the man/machine interface reduces the negative impact of system complexity. A sample of discreet manufacturing systems from 128 organizations was used to test these hypotheses empirically. Moderated multivariate regression indicates that man/machine interfaces are significant contributors to reducing the negative effect of systems complexity. With a lower level of significance, operator training has a similar impact. For complex manufacturing systems software, it behoves managers to insure that the man/machine interface provides the desirable features outlined in this study.
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Åsa Fasth‐Berglund and Johan Stahre
The paper aims to discuss the importance of considering both the physical and cognitive automation when aiming for a flexible or reconfigurable assembly system. This is done in…
Abstract
Purpose
The paper aims to discuss the importance of considering both the physical and cognitive automation when aiming for a flexible or reconfigurable assembly system. This is done in order to handle the increased demand for mass customized production and to maintain or improve the social sustainability within the company.
Design/methodology/approach
The methodologies used in this paper are a theoretical review about task allocation and levels of automation and a methodology called DYNAMO++ for the industrial case studies.
Findings
The paper provides both theoretical and empirical insights about the importance of considering both the cognitive and physical automation when aiming for a reconfigurable assembly system.
Research limitations/implications
The paper will only discuss the cognitive strategy from a social sustainability perspective and not from an economical or environmental angle.
Practical implications
The paper presents data from three industrial case studies, mostly in the automotive industry. The result points towards a need for a more structured and quantitative method when choosing automation solutions, furthermore an increased use of cognitive automation solution.
Social implications
The results from the case studies show that when the complexity and variety of products increases, a cognitive support for the operators is needed. This strengthens the theory of a need for a cognitive automation strategy within companies.
Originality/value
The paper demonstrates an advance in the state of the art in task allocation. The concept model and the DYNAMO++ method can be seen as a step closer towards quantitative measures of task allocation (i.e. changes in both physical and cognitive LoA) and dynamic changes over time.
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Sabina Fjällström, Kristina Säfsten, Ulrika Harlin and Johan Stahre
This paper seeks to identify information enabling and supporting production ramp‐up processes, by exploring critical events and the role of information in such events.
Abstract
Purpose
This paper seeks to identify information enabling and supporting production ramp‐up processes, by exploring critical events and the role of information in such events.
Design/methodology/approach
The research approach was based on empirical and theoretical investigations. A selection of 30 events, considered the most critical for production ramp‐up realization and/or performance at one Swedish automotive company, were categorized and constituted the base for the analysis which focused information types and sources enabling event handling.
Findings
Information enabling event handling is a balanced combination of problem and domain information, regardless of event category. However, a differentiation concerning preference and usage of information types between experienced and less experienced personnel is identified. Problem‐solving information has the character of pragmatic information, composed of complementary parts of confirmation and novelty in terms of domain and problem information. The preferred information source in all event categories was “other people”.
Research limitations/implications
The study focuses on the application of information in relation to critical events during production ramp‐up. General information theory is not addressed in depth.
Practical implications
Information type and information source are not dependent on certain event categories, which allows a general information strategy enabling production ramp‐up. To facilitate production ramp‐up and event handling managers and key personnel need to apply a holistic perspective and need to be updated on domain information of the products, the equipment, and the production process during production ramp‐up.
Originality/value
The originality is in the focus and role of information to achieve an efficient production ramp‐up performance. A supporting model is developed which describes the structure of pragmatic information for personnel with various levels of experience, regardless of event category.
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G. Citybabu and S. Yamini
Lean Six Sigma 4.0 has brought about a paradigm shift in customization, automation, value creation and digitalization to achieve excellence in human factors, operations and…
Abstract
Purpose
Lean Six Sigma 4.0 has brought about a paradigm shift in customization, automation, value creation and digitalization to achieve excellence in human factors, operations and sustainable development. Despite its potential, LSS 4.0 is still in its nascent stage, with researchers striving to identify the key and relevant components of LSS in relation to Industry 4.0. The present study aims to address this knowledge gap through a literature review and subsequently provide a conceptual framework for LSS within the context of digital transformation.
Design/methodology/approach
In this study, the authors have conducted a thorough review of reputable articles published between 2011 and 2022, focusing on the integration of Lean Six Sigma (LSS) and Industry 4.0 (I4.0). By using appropriate keywords, the authors identified around 85 relevant articles. The main objective of this integrative literature review was to analyze and extract valuable knowledge from the existing literature on LSS and I4.0. Based on the authors’ findings, a conceptual framework was developed.
Findings
The review revealed the motivators, building blocks, tools and challenges of LSS 4.0. The conceptual framework delves into the key aspects of LSS 4.0, focusing on the dimensions of people, process and technology, as well as their subdimensions. These subdimensions serve as the building blocks for developing LSS 4.0 capabilities. The proposed framework visually represents the conceptualization and the relationships among its components.
Research limitations/implications
Only a few conceptual approaches to LSS are developed that include the concepts, new roles and elements of I4.0. As a result, this research investigates the gap in current LSS models preceding I4.0 and develops a conceptual framework to provide a novel and comprehensive summary of the new concepts and components driving nascent and current LSS practices in the digital era.
Practical implications
This study offers practical guidance for implementing LSS in the context of I4.0, emphasizing digital transformation. The findings highlight motivators, building blocks, tools, challenges and spread of LSS 4.0 practices, and present a conceptual framework of LSS 4.0. These insights can help organizations enhance their LSS capabilities and achieve excellence in human factors, operations and sustainable development.
Originality/value
This study aims to make a significant contribution to the model-building efforts of researchers focusing on LSS 4.0. By offering practical guidance, the points discussed in this study help enhance the implementation efforts of practitioners and organizations in the context of I4.0, with a specific focus on digital transformation. The guidance provided takes into account the perspectives of people, processes and technology, providing valuable insights for successful integration.
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Alessandro Giacotto, Henrique Costa Marques and Alberto Martinetti
Providing a comprehensive literature review to consolidate existing knowledge, advancements and future directions in the field. By synthesizing the state of research, this work…
Abstract
Purpose
Providing a comprehensive literature review to consolidate existing knowledge, advancements and future directions in the field. By synthesizing the state of research, this work enhances the understanding of Prescriptive Maintenance (PsM) methodologies, applications and potential benefits to assist researchers in identifying fruitful avenues for further investigation, and guide practitioners in implementing PsM strategies to improve maintenance outcomes in their industries.
Design/methodology/approach
Through a systematic, multistage, specialists audited analysis of peer-reviewed articles, conference papers, books sections, thesis, magazines and industry reports, this work provides a literature review analyzing PsM origins, definitions, enablers, outputs and emerging trends.
Findings
PsM concept evolved in recent years representing a shift from traditional maintenance, leveraging prescriptive analytics, data-driven modeling and optimization techniques to enable proactive decision-making and optimal resource allocation. By harnessing PsM, organizations can anticipate and mitigate failures, optimize maintenance actions and enhance asset reliability.
Research limitations/implications
Existing literature points out the following challenges for PsM implementation: prescriptive analytics improvement, scalability of frameworks, development of prototypes, processes integration; PsM maturity assessment; asset health prognostics assertiveness, real-time data availability and adoption of cost functions to grasp business and environmental, social and governance (ESG) costs.
Practical implications
Optimal deployment of resources with little or no human intervention in the maintenance decision process and the creation of new services improving reliability and operational performance.
Social implications
By optimizing maintenance, not only direct costs diminish but also environmental, social and governance (ESG) related costs decrease by reducing energy waste during equipment’s operating phase, assessing the ecological impact of providing maintenance to operators and line maintenance stakeholders and, consequently, minimizing or even eliminating harmful effects on the environment and the human.
Originality/value
Work consolidating existing PsM-related knowledge and indicating future work is a gap in the literature. This paper fills this gap.
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Tom A.E. Aben, Wendy van der Valk, Jens K. Roehrich and Kostas Selviaridis
Inter-organisational governance is an important enabler for information processing, particularly in relationships undergoing digital transformation (DT) where partners depend on…
Abstract
Purpose
Inter-organisational governance is an important enabler for information processing, particularly in relationships undergoing digital transformation (DT) where partners depend on each other for information in decision-making. Based on information processing theory (IPT), the authors theoretically and empirically investigate how governance mechanisms address information asymmetry (uncertainty and equivocality) arising in capturing, sharing and interpreting information generated by digital technologies.
Design/methodology/approach
IPT is applied to four cases of public–private relationships in the Dutch infrastructure sector that aim to enhance the quantity and quality of information-based decision-making by implementing digital technologies. The investigated relationships are characterised by differing degrees and types of information uncertainty and equivocality. The authors build on rich data sets including archival data, observations, contract documents and interviews.
Findings
Addressing information uncertainty requires invoking contractual control and coordination. Contract clauses should be precise and incentive schemes functional in terms of information requirements. Information equivocality is best addressed by using relational governance. Identifying information requirements and reducing information uncertainty are a prerequisite for the transformation activities that organisations perform to reduce information equivocality.
Practical implications
The study offers insights into the roles of both governance mechanisms in managing information asymmetry in public–private relationships. The study uncovers key activities for gathering, sharing and transforming information when using digital technologies.
Originality/value
This study draws on IPT to study public–private relationships undergoing DT. The study links contractual control and coordination as well as relational governance mechanisms to information-processing activities that organisations deploy to reduce information uncertainty and equivocality.