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Article
Publication date: 28 June 2024

Mohanraj R., Abdul Basith S. N., Chandru S, Gowtham D and Pradeep Kumar M

Wire arc additive manufacturing (WAAM) is one of the most researched and fastest-growing AM technique because of its capability to produce larger components with medium…

305

Abstract

Purpose

Wire arc additive manufacturing (WAAM) is one of the most researched and fastest-growing AM technique because of its capability to produce larger components with medium complexity. In recent times, the use of WAAM process has been increased because of its ability to produce complex components economically when compared with other AM techniques. The purpose of this study is to investigate the capabilities of wire arc additive manufacturing (WAAM), which has emerged as a recognized method for fabricating larger components with complex geometries.

Design/methodology/approach

This paper provides a review of process parameters for optimizing and analyzing mechanical properties, hardness, microstructure and corrosion behavior achieved through various WAAM-based techniques.

Findings

Limited analysis exists regarding the mechanical properties of various orientations of Inconel 625 alloy. Moreover, there is a lack of studies concerning the corrosion behavior of Inconel 625 alloy fabricated using WAAM.

Originality/value

The review identifies that the formation of intermetallic phases reduces the desirability of mechanical properties and corrosion resistance of WAAM-fabricated Inconel 625 alloy. Additionally, the study reported notable results obtained by various research studies and the improvements to be achieved in the future.

Details

Rapid Prototyping Journal, vol. 30 no. 7
Type: Research Article
ISSN: 1355-2546

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Article
Publication date: 10 August 2015

R. Mohanraj, M. Sakthivel, S Vinodh and K.E.K. Vimal

The purpose of this paper is to apply a framework for value stream mapping (VSM) integrated with fuzzy quality function deployment (QFD) for enabling scientific prioritization of…

922

Abstract

Purpose

The purpose of this paper is to apply a framework for value stream mapping (VSM) integrated with fuzzy quality function deployment (QFD) for enabling scientific prioritization of improvement proposals to improve leanness.

Design/methodology/approach

The literature was reviewed from the perspectives of VSM, QFD and fuzzy logic applications. The current state map was developed for the case component; fuzzy QFD was used for prioritizing improvement proposals and prioritized proposals were incorporated in the future state map.

Findings

The approach enabled the scientific mapping of wastes with improvement proposals and thereby enabling systematic implementation of improvement proposals. The conducted pilot study resulted in 4 percent reduction in cycle time. As the lean implementation is a continuous process, furthermore improvements are expected in near future.

Research limitations/implications

The study was conducted in an Indian camshaft manufacturing organization. The improvements in terms of leanness parameters were quantified.

Practical implications

The findings determined from the study has practical relevance. Besides, managerial implications were also discussed.

Originality/value

The study presented in this paper was conducted in a real time manufacturing environment. Hence the contributions of study are found to be valuable among academic and practicing communities.

Details

The TQM Journal, vol. 27 no. 5
Type: Research Article
ISSN: 1754-2731

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Article
Publication date: 7 December 2020

Hichem Aouag, Mohyiddine Soltani and Mohamed Djamel Mouss

This paper aims to investigate an integrated approach that aims at enhancing the application process of value stream mapping (VSM) method. It also proposes an extended VSM called…

386

Abstract

Purpose

This paper aims to investigate an integrated approach that aims at enhancing the application process of value stream mapping (VSM) method. It also proposes an extended VSM called Economic and Environmental VSM(E-EVSM). The proposed approach highlights the improvement of economic and environmental performances.

Design/methodology/approach

The proposed approach has studied the integration of VSM, fuzzy decision-making trial and evaluation laboratory (DEMATEL) and fuzzy quality function deployment (QFD) to improve the economic and environmental performances of manufacturing processes. The VSM method is used for data collection and manufacturing process assessment, whereas fuzzy DEMATEL is used to analyse the current state map. Finally, fuzzy QFD is used to organize the improvement phase of VSM method.

Findings

The clear findings of this research prove the effectiveness of VSM method on the environmental and economic performances of manufacturing processes. In addition, the proposed approach will show the advantages of fuzzy DEMATEL and fuzzy QFD approaches in improving the application of the VSM method.

Research limitations/implications

The limitation of this study includes the lack of consideration of other dimensions such as social, technological and managerial. In addition, the proposed approach studied an average set of environmental and economic indicators.

Originality/value

The novelty of the proposed approach is proved by the development of an extended VSM method (E-EVSM). Also, the proposed approach contributes by a new methodology for analysing and improving the current state map of manufacturing processes.

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Article
Publication date: 10 April 2017

Katerina Kassela, Marina Papalexi and David Bamford

The purpose of this paper is to focus on the application of quality function deployment (QFD) in a Housing Association (HA) located in the UK. Facing the problem of improving a…

916

Abstract

Purpose

The purpose of this paper is to focus on the application of quality function deployment (QFD) in a Housing Association (HA) located in the UK. Facing the problem of improving a company’s performance, practitioners and academics have fashioned and applied a variety of models, theories and techniques.

Design/methodology/approach

The research questions were developed from a review of the quality and process improvement literature and tested using evidence from field-based, action research within a UK HA company. The case study provides insight to the benefits and challenges arising from the application of QFD.

Findings

The results provided insight to the benefits and challenges arising from the application of a specific tool, QFD. The primary findings were: QFD can be successfully adapted, applied and utilised within the challenging environment of social housing and other sectors, such as professional services; the model can be modified to use most processes/sub-processes; it must include both external and internal requirements and, to be useful, use more detailed process parameters appropriately.

Practical implications

The conclusions drawn add to ongoing commentaries on aspects of quality improvement, especially the application of QFD within the service sector. The authors develop questions for future research regarding improvement projects.

Originality/value

The conclusion proposes that the implementation of QFD should have a positive impact upon a company; if approached in the right manner. It provides a useful mechanism for developing evidence-based strategy of operational change, control and improvement. The research proposes questions for future research into aspects of operational quality and efficiency.

Details

The TQM Journal, vol. 29 no. 3
Type: Research Article
ISSN: 1754-2731

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Article
Publication date: 3 October 2016

Vikram Sharma, Amit Rai Dixit and Mohammad Asim Qadri

It is difficult for anyone to implement all the lean tools simultaneously. One of the core issues is identifying critical criteria for the successful implementation of lean…

977

Abstract

Purpose

It is difficult for anyone to implement all the lean tools simultaneously. One of the core issues is identifying critical criteria for the successful implementation of lean manufacturing (LM) and evaluating them. The purpose of this paper is to analyze the causal relationships of LM criteria in a machine tool manufacturing firm located in national capital region of India using the Decision-Making Trial and Evaluation Laboratory (DEMATEL) method.

Design/methodology/approach

The research paper presents a blend of theoretical framework and practical applications. Based on literature review, 17 LM criteria were extracted that were validated by experts. A questionnaire was developed that was answered by experts serving in the XYZ machine tool manufacturing firm. Then, the DEMATEL method was applied to analyze the importance of criteria and the casual relations among the criteria were developed.

Findings

Using DEMATEL, the lean criteria were divided into cause group and effect group. In this study, information technology, computer-integrated manufacturing, enterprise resource planning, training, fixed position layout, smart processes and automation and concurrent engineering were classified in the cause group. Just in time, value stream mapping, 5-S, single minute exchange of die, visual control, job scheduling, standardized work, cellular manufacturing, poka-yoke, and total quality management were categorized in the effect group. The DEMATEL framework indicates that “training” is the most influencing factor for the lean implementation process in machine tool sector.

Originality/value

To know the key lean criteria and relationship among them can help many organizations to develop lean competencies. If the authors want to obtain high performance in terms of the effect group factors, it would be necessary to control and pay a great deal of attention to the cause group factors beforehand. This study is perhaps among the first few with focus on segmenting the set of lean criteria into some meaningful portions in order to effectively facilitate its implementation. The paper provides useful insights to the lean production implementers, consultants, and researchers.

Details

Benchmarking: An International Journal, vol. 23 no. 7
Type: Research Article
ISSN: 1463-5771

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Article
Publication date: 5 October 2015

Vikram Sharma, Amit Rai Dixit and Mohammad Asim Qadri

The purpose of this paper is to investigate the impact of lean production practices on performance measures in machine tool industry and determines the lean criteria that can have…

2943

Abstract

Purpose

The purpose of this paper is to investigate the impact of lean production practices on performance measures in machine tool industry and determines the lean criteria that can have significant positive impact on performance.

Design/methodology/approach

The research paper presents a blend of theoretical framework and practical applications. Extant literature was reviewed and to achieve the research objectives, an exploratory survey was carried out in machine tool supply chains located in the national capital region of India. Reliability test, factor analysis and stepwise multiple regression analysis bring out several lean criteria that can affect key performance measures.

Findings

It was found that two lean criteria, namely, strategic partnership with suppliers and cross-functional cross-organizational design and development teams significantly influenced most of the key performance measures. Some lean criteria were found to negatively affect the overall competitive potential of machine tool firms.

Originality/value

The findings can encourage the management of non-adopter firms to adopt lean thinking and to select the lean production criteria that can be implemented to have significant positive impact on key performance indicators in machine tool value chains. This study is perhaps among the first few that focus on machine tool industry in India. The paper provides useful insights to the lean production implementers, consultants and researchers.

Details

Journal of Manufacturing Technology Management, vol. 26 no. 8
Type: Research Article
ISSN: 1741-038X

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Article
Publication date: 21 April 2022

Narpat Ram Sangwa and Kuldip Singh Sangwan

This paper proposes an integrated value stream mapping (VSM) for a complex assembly line to improve the leanness of a complex automotive component manufacturing organization.

1321

Abstract

Purpose

This paper proposes an integrated value stream mapping (VSM) for a complex assembly line to improve the leanness of a complex automotive component manufacturing organization.

Design/methodology/approach

This study depicts the application of VSM at the case organization, where top management is concerned about the challenges of higher cycle time and lower productivity. Gemba walks were conducted to establish the concept of “walk the flow, create the flow” along the assembly line. The multi-hierarchical cross-functional team developed the current value stream map to know the “as-is” state. Then, the team analysed the current VSM and proposed the future VSM for the “to-be” state.

Findings

The integrated VSM shows different processes and work cells, various wastes, non-value-added activities, cycle time, uptime and the material and information flows for both products of the assembly line on the same map. The integrated VSM reduced cycle time, non-value-added activities, work in process inventory and improved line efficiency and production per labour hour for both the products, simultaneously.

Research limitations/implications

The limitation of the study is that the study focussed only on the application of VSM for one complex assembly only. Future research may be conducted using the developed integrated VSM approach in other complex production environments.

Practical implications

Managers can identify and reduce system waste by incorporating the concept of integrated VSM in a complex production or assembly environment where two or more products are being manufactured/assembled with low similarity.

Originality/value

The application of VSM for assembly lines is highly challenging because of merging flows, a large number of child parts in the lines and assembly of more than one product on the same line.

Details

The TQM Journal, vol. 35 no. 4
Type: Research Article
ISSN: 1754-2731

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Article
Publication date: 15 September 2020

Jitendra Sharma

The purpose of this paper is twofold: to incorporate the symbolic relationships among the attributes of customer requirements (CRs) and engineering characteristics (ECs) as well…

385

Abstract

Purpose

The purpose of this paper is twofold: to incorporate the symbolic relationships among the attributes of customer requirements (CRs) and engineering characteristics (ECs) as well as to factor in the values numerically to enhance the prioritization process for an improved, comprehensive quality function deployment (QFD) analysis. The aim is to develop the concept of assimilating and factoring in the often-ignored interrelationships among CRs and ECs utilizing the weighted average method for the CR and EC correlations with overall calculations.

Design/methodology/approach

After a brief literature review of the methods utilized, the research paper discusses the framework for the correlation triangle challenge and introduces a novel mathematical solution utilizing triangle values in conjunction with computed initial raw weights for CRs and initial priority scores for ECs. The capability and applicability of the proposed model are demonstrated with a real-life example.

Findings

Through the proposed technique, the roof and the interrelationship triangle's signs and symbols are translated into numerical values for each permutation of ECs and CRs, and then the prioritization values are processed and finalized. The proposed model successfully modifies and removes vagueness from an otherwise overlooked part of the QFD process.

Practical implications

The illustrated case study aptly proves that the proposed methodology yields more revealing and informative outcomes for engineers and designers, thus adding much-needed reliability to the outcome and its analysis. The validation conducted through the rank comparison endorses the premise, and the results obtained reflect the strength and accuracy of the progressive QFD as a product planning tool.

Originality/value

The research article proposes a fresh and unique QFD approach that solves typical procedural complications encountered in a regular QFD. Whereas the traditional methods neglect the interrelationships among CRs and ECs, this new methodology employs them in an improved, numerical way by incorporating them in quantitative analysis, which leads to judicious and improved decision-making.

Details

The TQM Journal, vol. 33 no. 3
Type: Research Article
ISSN: 1754-2731

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Article
Publication date: 3 May 2021

Bharat Singh Patel, Murali Sambasivan, R. Panimalar and R. Hari Krishna

The purpose of this study is to categorize and analyse the drivers and barriers of Lean Manufacturing (LM) and subsequently, based on the structural model develop a house of lean…

1456

Abstract

Purpose

The purpose of this study is to categorize and analyse the drivers and barriers of Lean Manufacturing (LM) and subsequently, based on the structural model develop a house of lean management which will give an idea to the academicians and practitioners about the factors that are critical to implement lean practices in an organization.

Design/methodology/approach

A list of drivers and barriers was prepared based on the literature review and opinions from experts. Total Interpretive Structural Modelling (TISM) was utilized to build a structural hierarchy of the drivers and barriers of LM. The structural hierarchy was utilized to build the house of lean management.

Findings

Based on the hierarchy developed, the elements (drivers and barriers) of LM are classified into three groups: bottom-level, middle-level and top-level elements. To develop a house of lean management, bottom-level of elements were considered as a foundation, middle-level elements were considered as pillars and top-level elements were considered as a beam. Finally, foundation, pillars and beam of the house were used to support the roof (which is value to customers and profitability to firm).

Practical implications

The outcome of this research can assist researchers as well as practitioners to enhance the significant drivers and to reduce the impact of hazardous barriers for the better implementation of lean practices.

Originality/value

This research is a novel approach, as it visibly demonstrates both the drivers and barriers, examines the interrelationships among them in order and shows them pictorially as the house of lean management.

Details

The TQM Journal, vol. 34 no. 5
Type: Research Article
ISSN: 1754-2731

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Article
Publication date: 11 August 2022

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

This research aims to identify lean tools and techniques that are needed to be implemented to improve the performance in the fabrication industry. The objective is to find the…

540

Abstract

Purpose

This research aims to identify lean tools and techniques that are needed to be implemented to improve the performance in the fabrication industry. The objective is to find the wastes in manufacturing processes using value stream mapping (VSM) and prioritize the lean tools suitable to enable the attainment of leanness and streamline the processes.

Design/methodology/approach

VSM tool is applied in the industry to construct the current state map, identify improvement proposals and implement in future state. Fuzzy technique for order performance by similarity to ideal solution (TOPSIS), a multi-criteria decision-making technique (MCDM), is used to prioritize the identified improvement proposals. This study observed that mistake-proof processing and layout organization are the two techniques with the top priority that needs further improvement to enhance the leanness of the organization.

Findings

Upon successful implementation, the cycle time is reduced by 14.97%, and total inventory is reduced by 45.67% which leads to the improvement of value addition from 5.88 to 9.21%. Although lean has been adopted for many years, implementation of lean in the fabrication industry has been limited.

Practical implications

This study addresses the challenges in terms of implementing lean in fabrication industries and practical implications of lean tools and techniques and the prioritization of lean concepts against various lean criteria to enable leanness.

Originality/value

The deployment of improvement prioritization tool integrated with VSM in the context of a fabrication industry is the original contribution of the authors.

Details

The TQM Journal, vol. 35 no. 6
Type: Research Article
ISSN: 1754-2731

Keywords

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