Abstract: India is emerging as a new manufacturing destination and many companies are seeking ways to increase the value of their products and services by eliminating unnecessary processes and wasteful practices from their production systems. The powerful lean manufacturing approach that has proved successful as an operations model in developed economies, as well as in some large Indian companies, is now increasingly being recognised by the small- and medium-size enterprises (SMEs). The purpose of this research is to investigate the adoption of lean production in India and to examine the lean practices deployed by the SMEs. The case study methodology was utilised and this article presents the findings of four SMEs in India that have implemented lean strategy to drive significant improvement in manufacturing performance.

Abstract: Sustainable manufacturing appears to be a rapidly developing field and it would be expected that there is a growing body of knowledge in this area. Initial examination of the literature shows evidence of sustainable work in the areas of product design, supply chain, production technology and waste avoidance activities. Manufacturers publish metrics showing significant improvements in environmental performance at high level but information on how these improvements are achieved is sparse. Examining peer-reviewed publications focused on production operations there are few cases reporting details and there has been little prior analysis of published sustainable manufacturing activity. Moreover, the mismatch between academic and practitioner language leads to challenges in interpretation. This article captures and analyses the types of sustainable manufacturing activities through literature review. In turn, this can help manufacturers to access examples of good practice and help academics identify areas for f...

Abstract: The aim of this article is to analyse the key factors behind the successful implementation of world-class manufacturing practices. Two distinct modelling approaches have been employed to examine th...

Abstract: Environmentally responsible manufacturing, green supply chain management (GSCM), and related principles have become important strategies for companies to achieve profit and gain market share by lowering their environmental impacts and increasing their efficiency. As environment has become a key strategic consideration in supply chains, this study examines the components and elements of GSCM and suggests a novel GSCM evaluation framework. It also provides a real-case study of Ford Otosan, one of the pioneering companies about environmental subjects in Turkey, to illustrate the industrial application of our theoretical assessment model. The identified components are integrated into a strategic assessment and evaluation tool using analytical network process (ANP). The dynamic characteristics and complexity of the GSCM analysis environment make the ANP technique a suitable tool for this study. Moreover, to cope with ambiguity and vagueness of the decision maker's evaluations, the fuzzy extension of the ANP me...

Abstract: This article reviews the literature on production planning and control (PPC) for remanufacturing. The objectives are threefold: to determine whether the gaps identified by Guide (Guide Jr, V.D.R., 2000. Production planning and control for remanufacturing: industry practice and research needs. Journal of Operations Management, 18, 467–483) on the subject with respect to the main complicating characteristics of remanufacturing have been fulfilled; to classify the literature based on an appropriate structure to obtain a better understanding of the subject identifying sources of future research and to provide a useful source for scholars and practitioners. Seventy-six papers were examined and classified. It was found that none of the studies deals simultaneously with all of the complicating characteristics, and that more practical research is needed. In addition it was found that we lack studies regarding forecasting and aggregate planning considering disassembly of returned products, material matching restri...

Abstract: Recently, product lifecycle management (PLM) has become a popular topic in academic literature. However, although it shares the same title, contemporary PLM is quite different from the early twentieth century's PLM culture, which was established upon the basis of the classical life cycle body of theory, which continued to be refined, right up to the end of 1960s. A comprehensive understanding of the creation and deployment of different strands of PLM strategy requires a knowledge of the basis of such paradigms – that is, the variety of product life cycle theories available to the researcher, and how these have come about. This article reviews relevant product life cycle models presented historically in the literature and divides them into two categories – the long-established marketing product life cycle model, and the emergent engineering product life cycle model. An explanation of the former model leads to an understanding of its perceived shortcomings, and the reason for the take-up of later models. A ...

Abstract: Collaborative supply networks in the international clothing industry are of major economic significance in many countries, particularly in developing economies. The sector has gone through substantial changes in the last decade with the abolition of trade barriers and the increasingly dominant position of major retailers and brand owners in supply networks. The sustainability of clothing supply networks is subject to increasing public scrutiny. In this work, the characteristics and operation of collaborative clothing supply networks have been analyzed. Two contrasting supply networks – one for a major leading brand retailer and one for a major supermarket retailer - are analyzed and compared from a sustainability perspective. The challenges in assessing economic, social and environmental aspects of sustainability at a network level are highlighted. The results show a minimum compliance culture in the supermarket supply network, whereas the leading brand retailer demonstrates a much higher level of proactive and positive sustainability practices and actions across the network. The study highlights the benefits of a strongly collaborative network in helping to facilitate and enhance a sustainability agenda. The implications of the study are discussed for retailers, manufacturers and policy makers, as well as for the governance of collaborative supply networks more generally.

Abstract: Born in manufacturing environment, only recently Lean Management has been implemented in services. In particular, the role of automation and information technology in leaning processes is controversial and literature still lacks a strong empirical evidence to clarify how Lean Management can be applied in a pure service context, such as banking services, where there is an intensive use of automation and Information Systems. This study aims to define a methodology to streamline and automate processes in pure service-providing companies. To achieve the research aim, we conducted a case study. Based on the empirical investigation, a framework was developed. We found out that the automation of a process that is not streamlined can generate problems that can slow down the flow and increase errors. A process should first be mapped to highlight waste. Only when the new process is streamlined, it can be automated. In doing so, the new process will automate only value-added activities recognised by the customers. T...

Abstract: This article discusses the successful implementation of Six Sigma methodology in a high precision and critical process in the manufacture of automotive products. The Six Sigma define–measure–analyse–improve–control approach resulted in a reduction of tolerance-related problems and improved the first pass yield from 85% to 99.4%. Data were collected on all possible causes and regression analysis, hypothesis testing, Taguchi methods, classification and regression tree, etc. were used to analyse the data and draw conclusions. Implementation of Six Sigma methodology had a significant financial impact on the profitability of the company. An approximate saving of US$70,000 per annum was reported, which is in addition to the customer-facing benefits of improved quality on returns and sales. The project also had the benefit of allowing the company to learn useful messages that will guide future Six Sigma activities.

Abstract: Supply chain management (SCM) strategy is framed on the basis of competitive strategy (CS) of the firm. Three supply chain strategies (SCS) are evident in SCM literature: cost efficiency, time responsiveness and hybrid of the two. For each of these strategies, three types of supply chains are prescribed: lean, agile and leagile, respectively. Thus, for a firm to achieve strategic alignment between CS and SCS, it is a matter of utter importance to focus on relevant constructs. However, there is a deficiency of standard constructs for these types of supply chains in the SCM literature. Thus, this article addresses the issue of lack of standard constructs in frameworks of lean, agile and leagile supply chain. This objective is achieved by evaluating reliability and validity of lean, agile and leagile supply chain constructs in Indian manufacturing industry. Principle component analysis is performed on these constructs to find out the pillars of each type of supply chain followed by evaluating reliability and...

Abstract: Perishable goods are a fundamental source of revenue for the retail sector; their management, however, constitutes a severe challenge for retailers and supply chain partners. A significant cost in particular is the fraction of products perished through the supply chain, which also constitutes an ethical and environmental concern. Supply chain organisation and operative characteristics have a significant influence on this matter, as in fact ensuring suitable temperature conditions for the stock-keeping units throughout the supply chain is mandatory for perishable products. Recent developments in sensing and communication technologies allow detailed monitoring and control of cold chain; however, depending on the characteristics of the supply chain, an inherent risk of perished products is often inevitable, even in the hypothesis of perfect control. This article proposes a methodology to evaluate the performance of a cold chain in terms of expected product quality at the retail store, and to estimate the exp...

Abstract: Six Sigma is viewed as a systematic, scientific, statistical and smarter approach for management of innovation and focuses on establishing world class business performance. The main identifiers and supreme features of Six Sigma amongst other improvement techniques are: its rich ground which covers many customer oriented and problem solving techniques and its scientific methodology which is based on statistics. One of the most important factors of achieving success is selection of the right Six Sigma projects. This article presents a case study in which both Six Sigma project is selected and Six Sigma methodology is adopted to reduce the energy cost by the optimisation of material transferring heat loss in an automotive supplier industry. To cope with ambiguity and vagueness in the Six Sigma project selection problem, the Fuzzy Analytic Hierarchy Process has been used. This article also describes how various tools and techniques are employed in the different phases within the Six Sigma methodology and how ...

Abstract: Our research focuses on CO2 emissions along supply chains, from freight energy use to inventories storage. These supply chains are Collaborative Networked Organisations (CNOs) linking together actors operating along the same value stream. A supply chain model using a discrete event simulation was developed. Our CNO model is able to simulate a three tier supply chain. Four tuneable variables are provided: manufacturing capability, locations, mode of transportation and types of products. The product data are from Carrier, a large manufacturer and distributor of heating, ventilating and air conditioning systems. Their purpose is to compare levels of CO2 emitted for differing configurations of different scenarios. Some results are logical, but others are unexpected. The principal objectives of this study are twofold: providing a realistic decision support for simulating and promoting sustainable collaborative networks (CNs), helping managers to select eco-friendly supply chains.

Abstract: Offering a well-designed reverse supply chain programme can significantly improve the ability of any organisation to differentiate itself, and even to take market share away, from its competitors. Reverse supply chain considerations should be a part of an organisation's corporate strategy. From a macro-level perspective, value propositions of reverse supply chains in for an organisation, and/or the industry in which the organisation operates, include considerations for both strategies (to reuse, repair, refurbish, remanufacture, retrieve parts or cannibalise components, recycle, scrap, redesign returned products, etc.) and effective operations (to handle and sort returns by value and ease of remanufacture) to sustain and even enhance organisational competency. In this article, we examine the role of sorting used products before disassembly for parts retrieval and remanufacturing under stochastic variability based on customer demand using a Markov decision process. We address a problem of managing costs in...

Abstract: The purpose of the study was to construct a model in order to understand the empirical effects of the task environment on reverse logistics resource commitment and the resulting performance. The Taiwanese computer, communication, and consumer electronics (3C) manufacturing and retail industries were investigated by questionnaire administration. Structural equation modelling was employed to model relationships among the latent constructs of the task environment, resource commitment, and environmental and economic performances. From 349 valid responses, it was found that the task environment has a positive and significant influence on resource commitment. In turn, resource commitment positively and significantly influences the economic and environmental performances of reverse logistics separately. Additionally, environmental performance significantly and positively influences economic performance, thus showing that it pays to be green. Under a climate of increasingly strict international regulations, governmental legislation and the increase in consumer environmentalism, firms are advised to appropriately reappraise their RL resource commitments.

Abstract: The opportunity of improving production sustainability through waste minimisation is getting more and more interesting because of remarkable waste generation and the contribution to increase the productivity of natural resources. The article is intended to propose an environmental costing method to enable a proper analysis of the flows of products, by-products and wastes produced by a whole production plant or simply by a section of this plant, in order to properly prioritise a list of likely interventions and to make better decisions to head for higher level of eco-efficiency, hence sustainability. The proposed method origins from a general activity-based environmental costing (ABEC) and, unlike traditional ABEC, considers as cost objects not only the expected products, but also by-products and wastes as in the material flow cost accounting (ISO 14051). Thanks to detail given by the proposed method, it is actually possible to go back to the sources of inefficiency of the process and to simulate the impac...

Abstract: This article investigates the linkage between the total quality management (TQM) practices and the learning organisation (LO) in the manufacturing sector from the context of a developing nation. The empirical data were gathered from 206 Malaysian manufacturing organisations that have been ISO 9000 certified through the use of structured questionnaire. Structural equation modelling analysis was used to test the research model. The findings indicate that four TQM practices (process management, human resource focus, leadership and information and analysis) are positively related to LO, whereas strategic planning and customer focus have no significant relationships with LO. Theoretically, it provides a clearer perspective as the TQM dimensions chosen are predominantly essential in attaining a high level of LO in a developing country such as Malaysia. Furthermore, it also fills the current literature gap and confirms the linkage between TQM and LO. Practically, the results of this study have proven that four T...

Abstract: The food industry is under pressure to improve food product safety, implement efficient risk management and rapid response capability, and manage quality ‘from farm to fork’. In this article, a new risk assessment approach is proposed to perform structured analysis of aggregative food safety risk in the food supply chain by using the concepts of fuzzy set theory and analytical hierarchy process. The novelty of this research lies in performing structured risk assessment and establishing an aggregative food safety risk indicator. It provides a single value representing the risk rating which can be effectively employed in incorporating the safety objectives into operations planning. It can function as a part of practical food safety management tool and help managers to understand how the risk changes and transfers in a supply chain. It will therefore improve food safety and quality through integrating the risk control with supply chain management.

Abstract: The supply chain of perishables, often referred to as a ‘Cold Chain’, can be considered to be a series of equipments and processes, used to protect perishables, starting from source until consumption. Cold chain data, which have so far been underutilised, could be used to better measure performance of the cold chain. The purpose of this article is to identify the key performance attributes (KPA) and key decision factors (KDF) to evaluate cold chain performance and then implement continuous improvement. An additional aim of this article is to propose a framework for cold chain performance evaluation and improvement using a novel consistent measurement scale (CMS). The identification of KPA and KDF, and the development of CMS are based on actual scenarios of the cold chain in one of the emerging economies, namely the Indian market. A twin-graph theory (TGT) based methodology has been developed for supporting the cold chain performance and improvement framework. The proposed framework, along with the sensiti...

Abstract: Radio Frequency Identification (RFId) adoption process is receiving a lot of attention in literature; studies assessing its potentials in supply chains (SCs) are now well documented. Despite this rising interest, the diffusion pattern of RFId systems in the vertical SCs has been only scarcely addressed and theoretical contributions explaining dynamics and drivers are still missing. This study shows that the diffusion of innovation theory can be effectively used to explore these questions in a vertical SC. However, three major considerations emerged: (1) the factors influencing, facilitating or inhibiting the adoption process change over time and during the adoption process; (2) facilitators such as business associations play an important role in the SCs composed of small and medium enterprises; and (3) the position of adopters within the SC greatly influences the diffusion process.

Abstract: High-technology Small and Medium Enterprises (SMEs) have regularly shown their capacities for creating and developing innovative services. However, their reduced size often confines them to vertical applications and limits the possibilities for broader development. Strategies grouping SMEs into collaborative networks are possible but sometimes need a strong leader to ensure credibility. On the other hand, large integrator–operators cannot be proficient in all the necessary domains, particularly when applications move very fast. They very much need the diversity and the dynamics of these SMEs to provide service packages with a common service backbone. Uniting the different actors is a challenge displaying good promises from various perspectives including sustainability. However, it is necessary that the links between the different partners and their corresponding activities be correctly represented in a model to be understood. This article proposes a new model for activities and processes in firms collabor...

Abstract: Ongoing scientific and technological advances have led to public awareness of environmental protection and motivated the development of green products. Customer requests to comply with environmental protection regulations are heeded until a corrective action is taken by the enterprise. Given this trend, this study presents a strategic model for building a green manufacturing system that is based on quality function deployment technique to help industry exploit this trend. Two-stage deployment, the operational capability plan and the action plan, is considered in constructing the strategic adjustment model. The result of this study shows that strengthening the quality assurance and procurement capability are the most important missions for building green manufacturing system. Besides, smooth implementation of green quality standards also ensures that the supply chain achieves sustainable development goals, enabling associated enterprises to fulfil their societal responsibilities, protect the environment an...

Abstract: The purpose of this article is to investigate how the manufacturing process, the shop type and the data quality, i.e. the shop floor characteristics, influence the use of advanced planning and scheduling (APS) systems in production activity and control (PAC). The methodology implemented is a multiple case study at three case companies. Each company has different shop floor characteristics, but all use a scheduling module in an APS system, which supports production scheduling. A theoretical framework is developed suggesting how APS system are used in the PAC activities, and which major aspect to consider. The case analysis shows that the scheduling module in APS system, foremost supports sequencing and dispatching. In particular, the shop type is influenced by the decision of how often the APS runs and what freedom is given to the shop floor. The manufacturing process influences how the dispatch list is created. Contrary to the literature presuming that APS systems are most suitable in job shop processes, it is found that the manufacturing process is not a crucial factor when deciding whether APS systems are an appropriate investment. It is found that the level of data quality needed in the APS system depends to a large extent on how the dispatch list is used. For example, is the dispatch list used as a guideline, not a regulation, the need for accurate data in the module is reduced. This article extends the previous literature concerning APS systems by analysing how APS systems influence PAC as a whole and increase the understanding of the challenges of using APS systems in PAC.

Abstract: Many authors have highlighted gaps at the interfaces between supply chains (SCs) and demand chains. Generally, the latter tends primarily to be ‘agile’ by maximising effectiveness and responsiveness while the former tends to be ‘lean’ by maximising efficiency. When, in the SC, disruptions (that lead to stock-out situations) occur after customer orders have been accepted, managers are faced with the problem of maximising customer satisfaction while taking into consideration the conflicting objectives of the supply and demand sides of the order fulfilment process. This article proposes a cross-functional multi-criteria decision-making (advanced available-to-promise) tool that provides different strategic options from which a solution can be chosen. It also proposes a performance measurement system to support the decision-making and improvement process. The results of some experimental tests show that the model enables to make strategic decisions on the degree of flexibility required to achieve the desired l...

Abstract: Many issues are presently contributing to a greater attention to sustainability. Among them, we can consider the growing cost of energy, the pollution generated by industrial, transportation and ci...

Abstract: A well-crafted manufacturing strategy enables a company to develop its key competitive capabilities (quality, delivery, flexibility and cost efficiency) and enhance its competitiveness in the marketplace. To date, three models have been proposed to guide companies on the development and improvement of these capabilities. These are the trade-off, cumulative and integrative models. Our study focuses on the popular cumulative model proposed by Ferdows and De Meyer (1990). The cumulative model not only suggests that firms can simultaneously compete on all four capabilities, but also defines how this can be done by following a specific pattern of capability improvements. There has been a wide debate in the literature on the validity and applicability of the cumulative model. We tested the cumulative model using data from 218 manufacturing firms in five Asia-Pacific countries (Hong Kong, Singapore, Taiwan, Korea and Australia). We found evidence in support of the model, though this support was not emphatic. Our...

Abstract: Logistics plays a key role for industries since it reveals a critical function designed and managed to pursue economic goals. A large amount of literature is available, providing models which can be used to minimise logistic costs. However, models usually neglect externalities, i.e. social and environmental costs that have to be considered in the framework of sustainable manufacturing. In this article, the authors propose an inventory model to support decision making in means of transport selection and order lot sizing (sustainable order quantity) which minimise both logistic and environmental costs. Dependency of logistic and environmental costs is shaped as functions of the ‘loss factor’, a parameter adopted to classify means of transport based on loss in transport energy. Time and cost constraints as well as the actual means of transport availability reduce the domain of theoretical solutions and limit the set of feasible ones. When there are no feasible solutions, three different strategies are identi...

Abstract: In this article, we present a case study in a complex and diversified multinational steel company using a deterministic formulation for a capacitated location problem based on a model discussed in the literature. The objective is to determine the quantity and location of distribution centres needed to serve a customer base within specified service levels. A large amount of data about the existing distribution network is gathered and modelled. A decision support system based on mixed-integer programming was used to solve the problem. One of the main contributions of this article concerns the manipulation of a large real database to extract enough information to obtain an acceptable model to solve a complex problem of a steel industry based on adaptations and improvements of a model offered in the literature.

Abstract: The primary aim of this article is to examine the impact of management's approach on the effectiveness of service quality operations. Drawing upon semi-structured interviews with multiple managerial actors at different hierarchical levels and archival sources, the findings suggest two alternative paths of management's approach regarding service quality. One of the paths distils customer confidence, aims to fulfil customer requirements as well as the strategic and potential intentions within the organisation. The other represents more of a short-term approach for managing service quality, which only demonstrates some aspects of customer satisfaction at the time when the customer interacts with the service provider. In the latter, as our evidence showed, the service provider could fail to build customer loyalty and face customer boycott. The findings highlight a fundamental need for management across different hierarchical levels to adjust their approach to encompass the entirety of service quality operatio...