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Reports on a new methodology for formation of virtual (“extended”) machining cells using generic capability patterns termed “resource elements”. Resource elements are used to uniquely describe the processing requirements of the component mix and dynamically match them to the processing capabilities of the machining shop. The virtual cell formation methodology is based on four steps: component requirement analysis and generation of processing alternatives; definition of virtual cell capability boundaries; machine tool selection; and system evaluation. The proposed methodology facilitates the dynamic formation of virtual manufacturing structures by providing accurate assessment of the component processing requirements and their matching with the available capabilities of the existing manufacturing facilities.

The development of reconfigurable modular production systems is one of the crucial factors for manufacturers to sustain their competitive advantage in areas such as precision assembly. To ensure the effective and cost efficient configuration and successive reconfigurations it is of critical importance to involve all stakeholders in the decision‐making process. The reported research is targeting the development of an integrated Web‐enabled decision‐making environment that supports some of the key assembly system engineering stages from user requirement specification to system implementation. The focus is on the design of assembly workstations based on detailed process requirements with a target of developing highly efficient and cost‐effective solutions. The paper presents an application framework for collaborative distributed design supported by domain ontologies and is illustrated using an industrial case study.

One of the key factors for success in assembly automation at present is the ability of system integrators to deliver more reliable and customised systems within shorter periods of time. Despite the active research in the development of distributed engineering support systems, there is a clear need for practical methods and tools to support the interactions between different stakeholders at the early product and assembly system design stages. This paper reports on the development of assembly process and equipment data models using context free grammars. The models enable a web‐based decision‐making for formation of assembly workstations using distributed linguistic approach.

To present a methodology for requirements specification for assembly system reconfiguration.

Industrial needs were analysed through a series of interviews with personnel involved in the design and sales process. This was then compared to reported research in literature and a new method has been derived and demonstrated.

An improved methodology for requirements specification leading to more efficient design and deployment of reconfigurable assembly systems.

Provides a structured mechanism for performing requirements specification tasks that are currently done on an ad hoc basis.

Advancements in responsive manufacturing have been supporting companies over the last few decades. However, manufacturers now operate in a context of continuous uncertainty. This research paper explores a mechanism where companies can “elastically” provision and deprovision their production capacity, to enable them in coping with repeated disruptions. Such a mechanism is facilitated by the imitability and substitutability of production resources.

An inductive study was conducted using Gioia methodology for this theory generation research. Respondents from 20 UK manufacturing companies across multiple industrial sectors reflected on their experience during COVID-19. Resource-based view and resource dependence theory were employed to analyse the manufacturers' use of internal and external production resources.

The study identifies elastic responses at four operational levels: production-line, factory, company and supply chain. Elastic responses that imposed variable-costs were particularly well-suited for coping with unforeseen disruptions. Further, the imitability and substitutability of manufacturers helped others produce alternate goods during the crisis.

While uniqueness of production capability helps manufacturers sustain competitive advantage against competitors during stable operations, imitability and substitutability are beneficial during a crisis. Successful manufacturing companies need to combine these two approaches to respond effectively to repeated disruptions in a context of ongoing uncertainties. The theoretical contribution is in characterising responsive manufacturing in terms of resource heterogeneity and resource homogeneity, with elastic resourcing as the underlying mechanism.