International Journal of Production Management and Engineering

Sequential use of blocplan, solver, and particle swarm optimization (PSO) to optimize the double row facility layout

Wildanul Isnaini — 2024-05-08

Facility layout optimization is used to increase company productivity by minimizing waste on transportation, movement, and waiting time. It was mentioned in several previous studies that optimal facility layout can reduce production costs by up to 40%. Because of this importance, many previous researchers have carried out research in the field of Facility Layout. The differences between each Facility Layout research are in the characteristics and criteria being analyzed and the optimization method used. The several approaches used to optimize the layout are constructed algorithm, exact algorithm, and metaheuristic. These three methods have their respective purposes and to the best of our knowledge have not been used sequentially. So, this study aims to find the best layout for the double-row facility problem with aisle width consideration using three sequential methods. There are BLOCPLAN for the constructed algorithm, solver for the exact algorithm, and Particle Swarm Optimization (PSO) for the metaheuristic. The result shows that the use of BLOCPLAN gives a better result of Total Material Handling Cost (TMHC) in PSO. For more machines, PSO has better results than Gurobi Optimization.

Adopting lean product development in new production system introduction process for sustainable operational performance

Md Hasibul Islam — 2024-05-06

This research explores adopting the lean product development (LPD) concept in the new production system introduction process (NPSIP) to achieve both pre-launching and post-launching operational performance considering sustainability aspects. An empirical study was conducted in a multi-national pharmaceutical company, having lean practice for over a decade. Two case projects for launching the new production system were followed in retrospect, and data was collected by interviewing experts. In the case company, evidence were found regarding adoption of soft lean practices in the NPSIP, however, lack of adoption of hard lean practices. Several challenges were identified that hinder achieving both pre-launching and post-launching operational performance, which could be mitigated by adopting LPD practices. This paper contributes to the broad lean literature by expanding its implication within the NPSIP context. Additionally, a set of LPD principles and practices is proposed that could be adopted in the NPSIP context. Adopting the LPD principles and practices in the NPSIP, manufacturing companies can launch a new production system faster, and achieve target sustainable operational performance faster, resulting in additional competitive advantage.

Integrating human-centric simulations in educational production lines: advancing ergonomics for industry 5.0 applications

Aitor Ruiz de la Torre — 2024-05-07

This research in the Industry 5.0 field focuses on a human-centered simulation of the FAS200 SMC educational production line, utilizing Tecnomatix Process Simulate Human software for developing a virtual human environment. A key aspect of this study is the integration of inertial sensors, enhancing the accuracy and depth of ergonomic analysis. These sensors play a pivotal role in capturing precise human movement data, crucial for ergonomic assessments. Adopting a defined working methodology, the study extensively employs the RULA method to evaluate operator postures in the production line. This approach has led to significant ergonomic improvements, evidenced by a 40 percent reduction in the RULA index at each workstation. The integration of inertial sensors has been instrumental in achieving these results, providing detailed insights into human movements and interactions with the production environment. The research transcends traditional ergonomic assessments by incorporating a new human-centered approach, emphasizing the well-being of individuals working alongside machines. This approach, bolstered by the use of inertial sensors, marks a significant advancement in ergonomic studies, aligning with the principles of Industry 5.0. The findings hold substantial potential for application in industrial settings, signaling a shift towards more human-friendly and efficient industrial practices.

Dynamic lot sizing model for retailers with multi suppliers, quantity discounts, and capacity constraints that consider advance demand informations

Rendiyatna Ferdian — 2024-07-26

The Dynamic lot sizing (DLS) model is widely used in production planning, to minimize inventory levels, which basically will minimize production costs. The DLS model tries to eliminate the assumption of a fixed demand level throughout the period used in the Economic Order Quantity (EOQ) model. The characteristics of business processes in online retailers are the basis of this research to develop DLS models. This research develops a DLS model for retailers with multi-supplier cases, quantity discounts, and capacity constraints that consider Advanced Demand Information (ADI). Based on the numerical test results, it appears that ADI has an effect on reducing total production costs in the DLS model. The results of the numerical tests also showed that the model was able to solve the problems of the production planning process for SMEs and retailers who considered ADI.

The evolution of Kaizen in the industry: systematic literature review

Zineb Sahmi — 2024-07-26

The paper discusses the concept of Kaizen, a Japanese philosophy of continuous improvement, and highlights its historical significance and widespread adoption in various industries worldwide. This paper is based on literature review of 98 research articles published related kaizen's evolution, industry application, and limitations during 2000-2022. The study employed a comprehensive search strategy across multiple databases like Scopus, Google Scholar, and others to gather relevant systematic reviews on kaizen. It references established guidelines like PRISMA and it mentions the planned thematic analysis using NVivo software, highlighting its applicability in identifying patterns and themes across diverse data sources. The review showed that Kaizen adoption is a useful tool for organizations looking to achieve continuous performance improvement and sustainability over time.

Synergizing FMEA and PDCA for superior risk management and process improvement in the semiconductor industry: a case study

Ding Hock Hii — 2024-07-26

The semiconductor industry faces the dual challenge of risk assessment and process improvement. This paper introduces a framework that integrates Failure Mode and Effects Analysis (FMEA) and Plan-Do-Check-Act (PDCA) cycle to address these challenges effectively. FMEA serves as the initial step to identify potential risks within the system, followed by applying the PDCA cycle to systematically address and enhance the identified risks. The comparison between the initial Risk Priority Number (RPN) value, determined through FMEA, and the post-RPN in PDCA value gauges the success of the framework. Implementing the system in a semiconductor assembly line yielded a significant 51% improvement in RPN, with additional Lean tools incorporated into PDCA, such as SMART goals, 6M, and multi-voting. This integrated framework amplifies risk management, fosters continuous improvement, optimizes resource utilization, and empowers data-driven decisions, ultimately bolstering organizational growth. However, the study acknowledges limitations such as its single-case focus and potential RPN calculation subjectivity.

Understanding the relationship, trends, and integration challenges between lean manufacturing and industry 4.0. A literature review

Tariq Benslimane — 2024-07-26

This research investigates the synergistic relationship between Lean Manufacturing and Industry 4.0, crucial paradigms in modern industry, through a literature review of 60 scientific articles published from January 2013 to November 2023. The study reveals a tripartite relationship: Industry 4.0 technologies amplify Lean Manufacturing’s efficiency; Lean Manufacturing principles facilitate Industry 4.0 adoption; and their interaction fosters mutual enhancement, indicating a dynamic interplay. The results show three main trends: combining Industry 4.0 technologies, especially the Internet of Things, with Lean Manufacturing principles to make things more efficient and productive; highlighting the important role of Lean Manufacturing and Industry 4.0 in tackling sustainability issues and encouraging eco-friendly practices; and combining Lean principles with Industry 4.0 as a step toward Industry 5.0. Challenges include the need for a cultural transformation to align Lean’s simplicity with Industry 4.0’s complexity, resolve compatibility issues between legacy systems and new technologies, enhance data management and cybersecurity, address skill deficiencies through staff training, and ensure supplier and partner alignment. This research enriches academic and industrial discourse by presenting a novel outlook on the convergence of lean manufacturing and Industry 4.0, highlighting its significance for future works.