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Article
Publication date: 10 October 2016

V. Raja Sreedharan and R. Raju

The purpose of this paper is to review Lean Six Sigma (LSS) literature and report different definitions, demographics, methodologies and industries.

5057

Abstract

Purpose

The purpose of this paper is to review Lean Six Sigma (LSS) literature and report different definitions, demographics, methodologies and industries.

Design/methodology/approach

This paper highlights various definitions by different researchers and practitioners. A total of 235 research papers has been reviewed for the LSS theme, research methodology adopted, type of industry, author profile, country of research and year of publication.

Findings

From the review, four significant LSS classifications were identified that deal with the spread of LSS in different industries followed by observation for classification.

Practical implications

LSS is a strategy for success, but it did not examine its presence in various Industries. From this paper, readers can understand the quantum of its spread before implementing LSS. For academicians, it will be a comprehensive list of papers for research.

Originality/value

This paper reviews 235 research papers for their year, author profile, research methodology and type of industry. Various characteristics of LSS definitions and their theme are also reviewed.

Details

International Journal of Lean Six Sigma, vol. 7 no. 4
Type: Research Article
ISSN: 2040-4166

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Article
Publication date: 15 February 2013

S. Udhayakumar, P.V. Mohanram, P. Keerthi Anand and R. Srinivasan

Identifying the most probable natural resting orientation of a part, in automatic handling, helps in the effective design of feeder and orientation devices. For parts with complex…

283

Abstract

Purpose

Identifying the most probable natural resting orientation of a part, in automatic handling, helps in the effective design of feeder and orientation devices. For parts with complex geometries and topologies, it is not always intuitively apparent what the natural resting probability of each orientation is. The purpose of this paper is to determine, by theoretical methods, the probability of occurrence of each natural resting orientation of eight different typical sector shaped parts.

Design/methodology/approach

Probability of natural resting orientations were found using theoretical methods and drop test. Pearson's χ 2 test was used to decide whether to accept or reject the expected data by comparing with the observed data.

Findings

Irrespective of dimensions and material, the most probable natural resting orientation was the same. Height of drop was influential in the probability of most probable natural resting orientation.

Research limitations/implications

The research does not include objects with minimum thickness (i.e. 2D objects).

Originality/value

The paper shows that determining the most probable natural resting orientation will help designers to design the part feeders effectively.

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Article
Publication date: 29 July 2014

S. Udhayakumar, P.V. Mohanram, S. Yeshwanth, Manas Ranjan Biswal and A. Sabareeswaran

The purpose of this paper is to discuss a linear vibratory part feeder for handling brake liners, typical sector-shaped components. Part feeders have been used in the industries…

181

Abstract

Purpose

The purpose of this paper is to discuss a linear vibratory part feeder for handling brake liners, typical sector-shaped components. Part feeders have been used in the industries for a long time to present the parts in a desired orientation. Berretty et al. (1999) discussed a class of mechanical filters that are capable of removing polygonal sections from the track of the feeder which are referred to as traps. The traps eliminate or reorient the parts until they reach the final desired orientation. A part feeder was developed using traps, to reorient the sector-shaped part to desired orientation. The desired orientation was the most probable natural resting orientation. The trap was mounted on a linear vibratory feeder. The adaptive part feeder developed was capable of identifying the size of the incoming part and adjust the trap to accommodate that. This set-up eliminates the use of different traps for different-sized sector-shaped parts and wastage of productive time in changing the traps for different sizes. A regression model was developed to predict the conveying velocity of part on the feeder.

Design/methodology/approach

A part feeder was developed using traps, to reorient the sector-shaped part to desired orientation. Acrylic material was found to be suitable for trap compared to aluminium. The adaptive part feeder developed was capable of identifying the size of the incoming part using proximity sensors. Depending on the size of the incoming part, the track width was adjusted dynamically with the help of a stepper motor, rack and pinion arrangement. A regression model was developed to predict the conveying velocity.

Findings

Typical brake liners in the size range of 40-60 mm (radius) were considered for developing the adaptive part feeder. Based on performance studies, the acrylic trap was found better than aluminium traps. The appropriate frequency and amplitude of vibration for maximum conveying velocity of the adaptive part feeder were found experimentally. Regression equation was developed to determine the conveying velocity based on input frequency and amplitude. The regression results were found to be in close agreement with the experimental results.

Research limitations/implications

The developed part feeder is suitable for handling sector-shaped parts only.

Originality/value

This paper demonstrates an inexpensive adaptive part feeding device for handling sector-shaped parts which can be extended for handling other asymmetric parts also.

Details

Assembly Automation, vol. 34 no. 3
Type: Research Article
ISSN: 0144-5154

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Book part
Publication date: 12 March 2019

Hamed Fazlollahtabar and Mohammad Saidi-Mehrabad

Abstract

Details

Cost Engineering and Pricing in Autonomous Manufacturing Systems
Type: Book
ISBN: 978-1-78973-469-0

Available. Open Access. Open Access
Article
Publication date: 28 November 2022

Elena Stefana, Paola Cocca, Federico Fantori, Filippo Marciano and Alessandro Marini

This paper aims to overcome the inability of both comparing loss costs and accounting for production resource losses of Overall Equipment Effectiveness (OEE)-related approaches.

2345

Abstract

Purpose

This paper aims to overcome the inability of both comparing loss costs and accounting for production resource losses of Overall Equipment Effectiveness (OEE)-related approaches.

Design/methodology/approach

The authors conducted a literature review about the studies focusing on approaches combining OEE with monetary units and/or resource issues. The authors developed an approach based on Overall Equipment Cost Loss (OECL), introducing a component for the production resource consumption of a machine. A real case study about a smart multicenter three-spindle machine is used to test the applicability of the approach.

Findings

The paper proposes Resource Overall Equipment Cost Loss (ROECL), i.e. a new KPI expressed in monetary units that represents the total cost of losses (including production resource ones) caused by inefficiencies and deviations of the machine or equipment from its optimal operating status occurring over a specific time period. ROECL enables to quantify the variation of the product cost occurring when a machine or equipment changes its health status and to determine the actual product cost for a given production order. In the analysed case study, the most critical production orders showed an actual production cost about 60% higher than the minimal cost possible under the most efficient operating conditions.

Originality/value

The proposed approach may support both production and cost accounting managers during the identification of areas requiring attention and representing opportunities for improvement in terms of availability, performance, quality, and resource losses.

Details

International Journal of Productivity and Performance Management, vol. 73 no. 11
Type: Research Article
ISSN: 1741-0401

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Article
Publication date: 8 May 2018

Raman Kumar and Harwinder Singh

The purpose of this paper is to explore the success factors for the assessment of manufacturing system output.

312

Abstract

Purpose

The purpose of this paper is to explore the success factors for the assessment of manufacturing system output.

Design/methodology/approach

Exploratory factor analysis and second-order confirmatory factor analysis were used to analyze data and test hypotheses, respectively. A total of 36 observed variables were transformed into nine success factors, namely role of management (ROM), technical strength, employee strength, organizational strength (OS), resources (RS), production system, market research, effective planning, and research and development (RD).

Findings

The finding indicates that only four success factors, namely ROM, RS, OS, and RD, are positively related to all four outputs. Moreover, all nine success factors are positively associated with profit.

Research limitations/implications

The outcomes of the present work provide meaningful implications for researchers and practitioners as well.

Originality/value

Earlier studies have laid focus on single output only in the manufacturing system. In the present study, an effort has been made to focus on four output dimensions, namely final product, customer relationship, reputation, and profit, which are further strengthened by incorporating the concept of performance in manufacturing systems.

Details

Benchmarking: An International Journal, vol. 25 no. 4
Type: Research Article
ISSN: 1463-5771

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Article
Publication date: 25 November 2019

Panagiotis H. Tsarouhas

As overall equipment effectiveness (OEE) is a metric to estimate equipment effectiveness of production systems, the purpose of this paper is to identify strategic management tools…

2689

Abstract

Purpose

As overall equipment effectiveness (OEE) is a metric to estimate equipment effectiveness of production systems, the purpose of this paper is to identify strategic management tools and techniques based on OEE assessment of the ice cream production line.

Design/methodology/approach

This paper presents the collection and the analysis of data for ice cream production under real working conditions. The data cover a period of eight months. A framework process to improve the OEE of an automated production system was proposed. Six major stoppage losses, i.e. equipment failure, setup and adjustment, idling and minor stoppage, reduced speed, defects in the process, and reduced yield, were examined with the help of Pareto analysis. In addition, the actual availability (A), performance efficiency () and quality rate (QR) measures, together with the complete OEE for each working day, week and month of the production line were shown.

Findings

The main goal of the study is to identify major stoppage losses, in order to examine and improve the overall equipment efficiency (OEE) of the ice cream production line through the application of an adequate management, i.e. TPM approach. Based on the obtained results, maintenance management strategy and production planning have been suggested to improve their maintenance procedures and the productivity as well.

Originality/value

The proposed method can be applied to each automated production system. The main benefits of this method are the improvement of productivity, quality enhancement of products, the reduction of sudden breakdowns and the cost of maintenance. Moreover, the analysis provides a useful perspective and helps managers/engineers make better decisions on the operations management of the line, and suggestions for improvement were proposed and will be implemented accordingly.

Details

International Journal of Productivity and Performance Management, vol. 69 no. 5
Type: Research Article
ISSN: 1741-0401

Keywords

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Article
Publication date: 29 July 2018

Max Schreder

This paper provides a quantitative review of the literature on the repercussions of idiosyncratic information on firms’ cost of equity (CoE) capital. In total, I review the…

477

Abstract

This paper provides a quantitative review of the literature on the repercussions of idiosyncratic information on firms’ cost of equity (CoE) capital. In total, I review the results of 113 unique studies examining the CoE effects of information Quantity, Precision and Asymmetry. My results suggest that the association between firm-specific information and CoE is subject to moderate effects. First, the link between Quantity and CoE is moderated by disclosure types and country-level factors in that firms in comparatively weakly regulated countries tend to enjoy up to four times greater CoE benefits from more expansive disclosure—depending on the type of disclosure—than firms in strongly regulated markets. Second, a negative relationship between Precision and CoE is only significant in studies using non-accrual quality proxies for Precision and risk factor-based (RFB)/valuation model-based (VMB) proxies for CoE. Third, almost all VMB studies confirm the positive association between Asymmetry and CoE, but there is notable variation in the conclusions reached when ex post CoE measurers are used.

Details

Journal of Accounting Literature, vol. 41 no. 1
Type: Research Article
ISSN: 0737-4607

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Article
Publication date: 22 September 2020

Aadithya B.G., Asokan P. and S. Vinodh

The purpose of the paper is to depict a study on analysis of barriers to lean adoption in fabrication industry using interpretive structural modelling (ISM).

386

Abstract

Purpose

The purpose of the paper is to depict a study on analysis of barriers to lean adoption in fabrication industry using interpretive structural modelling (ISM).

Design/methodology/approach

From the literature review, 22 barriers to lean adoption in fabrication industry have been recognized . Self-structure interaction matrix has been developed based on expert opinion. Computational steps of ISM are being done to develop the structural model. cross-impact matrix multiplication applied to classification (MICMAC) analysis is being done to group the barriers into four types.

Findings

Based on the study, it has been found that “lack of knowledge about lean (philosophy, principles, tools)”, “lack of top management support and commitment” and “poor leadership” are found to be the principal barriers. MICMAC analysis indicated that number of driving, dependent, linkage and autonomous barriers are 9, 8, 4 and 1, respectively.

Practical implications

The study has been executed based on the inputs from industrial practitioners and hence the inferences are found to have practical relevance.

Originality/value

The study is an attempt to analyze the barriers for lean concepts adoption in fabrication kind of industry.

Details

International Journal of Lean Six Sigma, vol. 12 no. 2
Type: Research Article
ISSN: 2040-4166

Keywords

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Article
Publication date: 11 September 2018

Raja Sreedharan V., Rajasekar S., Santhosh Kannan S., Arunprasad P. and Rajeev Trehan

Defective parts in manufacturing is a serious issue faced by every manufacturer. Even after proper care in design, material selection and manufacturing of product, there exists a…

846

Abstract

Purpose

Defective parts in manufacturing is a serious issue faced by every manufacturer. Even after proper care in design, material selection and manufacturing of product, there exists a defective part. The purpose of this paper is to explore the quality of the manufacturing, and find the use of effective quality tools to reduce the part defect rate in an electrical parts manufacturing unit, thereby, reducing the replaced cost of defective parts.

Design/methodology/approach

With the help of quality initiatives, like total quality management (TQM) and Lean Six Sigma (LSS), the firms can produce quality product in each stage of production. The paper focuses on the primary data collected from the XYZ electric manufacturer.

Findings

The main finding of this case analysis is that by the effective use of quality tools, the defective part return rate can be reduced, because of which the firm can observe reduction in replaced cost of almost INR24 lakh. In addition, 10A switch part contributes more in replacement cost. Further, it adds to the 35 percent of the overall part rejection.

Research limitations/implications

The study is more focused on particular type of switch product and can extend to other types of products. In addition, the analysis reveals the results of only 88 percent of the defective products.

Practical implications

The study provides results of the improved quality by effective use of quality tools and discusses the different types of defects in the electrical parts manufacturing. Introducing TQM and LSS to manufacturing can reduce the customer return rate to 1,300 parts per million (PPM) and even to 1,000 PPM in future.

Originality/value

The paper discusses the quality issues in the electrical manufacturer. Moreover, the case analysis briefs effective ways to improve the product quality and reduce the rejection rate.

Details

The TQM Journal, vol. 30 no. 6
Type: Research Article
ISSN: 1754-2731

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