Query: PRODUCT CYCLE THEORY FOR MANUFACTURING COMPANY

Candidate papers:

abstract: A semiconductor factory goes through many phases in its life cycle including design, build, various ramps, and many levels of production. Maximizing the profitability and return on investment across this life cycle is a critical component of Intels approach to financial success. We have been applying the concepts of Goldratts Theory of Constraints across the factory life cycle and have realized improved performance in many of these phases, as well as in the integration of the phases. Within Intel Corporation, there are at least three identifiable supply lines (Figure 1) The most obvious from outside the company is the product supply line. This supply line includes planning to schedule production, materials to supply the ingredients manufacturing to produce the products, and logistics to deliver them. This is the supply line that springs into action when you place an order with Intel and find it being delivered a short time later. Another supply line for which Intel is famous is its technology supply line, which has two major branches. One is product design, delivering a stream of ever faster and more capable product designs for manufacturing to build. The other is process design, providing a sequence of ever finer and more capable processes for manufacturing to follow in building products. Together they form the supply line that responds to the insatiable market demand for faster semiconductor devices with higher func tionality. Perhaps the least obvious supply line from outside the company is the capacity supply line. This is the supply line that manages manufacturing resources. It is always trying to supply the most cost effective manufacturing capability synchronized with market demand. This supply line involves at least the selection and layout of equipment (design) construction of buildings (build) startup of production (ramp) and operation (Mfg) of Intel factories. Since managing this capacity supply line is the primary focus of this paper, we discuss how this supply line is driven, how its components work together, and what problems it must overcome. Figure 1: Intel supply lines Clearly the capacity supply line is driven by market demand. More interestingly, it is also driven by advances in process technology. As semiconductor process design moves to finer line widths, new cleaner factories with improved equipment are needed to produce cutting edge products commanding premium prices. This results in older factories being relegated to run products that are no longer at the cutting edge and which the market treats as
author_names: Karl G Kempf
title: Improving Throughput Across the Factory Life Cycle

abstract: Abstract Monitoring changing customer needs and requirements, along with shorterning product development cycle times, are major concerns for manufacturing companies. Factors which influence these concerns are determined often at the front end of New Product Development (NPD) Approaches to requirements capture were investigated from telecommunications, automotive and IT industries. It was found that the automotive company used market research agencies as an ongoing input into the NPD process, while the computing company was attempting to introduce a cross disciplinary approach to both idea capture and requirements capture.
author_names: Rachel Cooper

Andrew B Wootton

Margaret Bruce
title: "Requirements capture" theory and practice
year: 1998

abstract: This paper describes the influence of operator competence on judgement of product quality. Manual repetitive work with short work cycle was studied in a manufacturing company. One goal of the company was that all employees would be able to do most production tasks. Forty six operators participated in a field study of quality control. Based on how many tasks operators could perform, they were classified as high competence or low competence. Operators inspected 30 items, out of which 6 were of poor quality. In average 38% of the good items were rejected and 10% of the poor items were missed. Signal detection theory was used to compare the sensitivity d' and the criterion b for high and low competence operators and for departments 1 and 2. High competence operators had greater sensitivity and produced less false alarms and misses than low competence operators. The results are discussed in terms of efficiency of company policies and lack of operator feedback. In addition some tasks were perceived by operators as more prestigious and desirable to perform than others. This bias affects the desirability to learn and perform new tasks, and quality control may suffer. It is important to train and maintain competence in quality control as well as in task performance. The use of high competence operators can improve the quality in manufacturing considerably. Relevance to industry Employees with high competence who managed many production tasks performed significantly better in quality control and judgement of quality than employees who managed only few tasks.
author_names: Eva Loven

Martin G Helander
title: Effect of operator competence on assessment of quality control in manufacturing
year: 1997

abstract: Industrial companies that carry on innovation and operation must have well organized and capable business systems and processes. Customer needs, market demands, global competition and technological changes drive the companies to be more adaptable, flexible and dynamic. By working in network structures as extended enterprises, the companies face new possibilities and new challenges. Design, manufacturing and delivery of high quality products to competitive prices to the customers are essential for industrial companies. Holistic view of the product life cycle from technology development, via product and business system development and realization, to business operation, is important for sustainable industrial companies. A company with engineering and manufacturing of products in a business context needs to have effective innovation of business system and process. Business innovation encompasses the area from business idea to business operation and includes customer demands and solutions. The main part of business innovation is development of the product platform including product and support structures. Product variants are created and realized by various configurations of products and production systems. The thesis is elucidating that business innovation can be carried out by working in a systematic and structured way and by utilizing engineering design theories and methods. The business models, based on a new theory with a new navigation tool for interactions, are describing which activities should be performed in business innovation with product platform development and product structuring. For companies in business with changes, innovations can create new markets and products. Well managed and innovative companies have good possibilities to be competitive in a tough business environment. The creation of business innovation models has been carried out according to a hermeneutic research method. The research work followed the hermeneutic circle or spiral. The thesis introduces a new dimension to the design area, namely business innovation or engineering, corresponding to business design and development. Business innovation is also a new type of innovation, combining technological, product, process, market and organizational innovations in industrial companies.
author_names: Leif Clausson
title: Business Innovation by utilizing Engineering Design Theory and Methodology
year: 2006

abstract: In today's market, obtaining a variety of products through configuration design has become increasingly common. However, with the development of the market, customers have not only satisfied the company offering a variety of products, and more demands on participating in the process of configuration design by themselves, so that they can obtain fully personalized products. Customer participation leads to the changes of design process, company's management model, etc. Based on the above problem, this thesis takes industrial robot as an example, and studies the management issues related to the customer involved in the design, in order to address the contradiction between product diversification, personalized requirements and the long design cycle and high manufacturing costs. Firstly, Auser customized configuration design pattern is presented. The theory source of user customized configuration design pattern is introduced, and then the related concepts are expounded. The corresponding business mode of user customized configuration design pattern is given, and the key technologies to realize business mode is studied. System dynamics models were established for user customized configuration design business mode and for traditional business mode of industrial robots by Anylogic simulation software. Secondly, the component based theory and method are studied, including the formal description of things, ontology representation, componentization and servitization. On this basis, the componentization description model is established for the product parts. And the model is represented as service component. Next, the formation process and extension method of service component are introduced. An example of industrial robot components modeling is analyzed, includingestablishing industrial robot domain ontology by protege, describing, instantiating and extensing components. Thirdly, the industrial robot user customized configuration design template is constructed, and users can obtain the industrial robot meeting constraints through parameters setting; The kinematics and dynamics analysis on template is taken by Simscape model, and the dynamic parameters is analyzed, and the finite element analysis on template is taken by ANSYS, including statics analysis and modal analysis. The parameters flow process in template is analyzed. Then taking industrial robot user customized configuration design using configuration template as an example, the configuration template is analyzed in application. Fourthly, the internal algorithm of user customized configuration design is researched. Platform based and user leading user customized configuration design process is constructed, and then the internal algorithm to keep the design running smoothly is studied, including the degree of freedom determination, fuzzy demand calculation, and service component configuration and the configuration program evaluation. A case analysis is also taken for the internal algorithm Finally, on the basis of the previous section, the prototype system design of the open design platform is taken. Based on system requirements analysis and system design, the main pages of the platform are designed, and the key functions are introduced
author_names: Jing Li
title: Design of mechatronic products based on user customized configuration an application for industrial robots
year: 2015

abstract: Lean production is a way to promote production and manage the level of manufacturing as well as to enhance competitiveness in a workshop. Welding is one of the key links of the four important technology processes in auto manufacturing. Based on the theory of lean thinking, this paper took the CS (Changhe) Automobile Company as a specific case and analyzed the current situation of its welding workshop with the SWOT matrix. Conclusions are drawn that enhancement of the logistics system of the welding workshop is necessary. Led by the thought of JIT (just in time) and the balancing of lean production, the basic idea of improving the logistics system is discussed here, and the specific programs for improving the workshop logistics system are put forth. By comparing the improved data, the conclusion shows that the logistics cycle times are cut, site areas are saved, product quality is controlled effectively, labor intensity is significantly reduced, and the production balance in the welding workshop is significantly improved. Thus, the improvement of a welding workshop logistics system based on lean thinking contributes to improving vehicle quality, reducing manufacturing costs, and promoting production efficiency.
author_names: Haitao Su

Xiaoyan Jiang

Yan Xue

Libao Li
title: Improvement of a Welding Workshop Logistics System Based on Lean Thinking
year: 2010

abstract: In recent years a growing number of firms have reported dramatic results from an operation's improvement technique called Constraint Management (CM) For example, Ford Motor Company's Electronics division attributes reductions in manufacturing cycle time as high as 89 per cent, 76 per cent fewer product returns, reductions in inventory of 49 per cent and 43 per cent lower freight costs to its implementation of CM. Others such as GM, Grand Rapids Spring and Wire, Valmont/ALS, and Kent Moore Cabinets report similar results. The purpose of this paper is to provide the reader with a basic understanding of Constraint Management, which has also been referred to as synchronized manufacturing; the Drum, Buffer, Rope technique; OPT (Optimized Production Technology) the Theory of Constraints, and to explore its potential impact on logistics managers.
author_names: George C Jackson

James T Low
title: Constraint Management: A Description and Assessment
year: 1993

abstract: Green supply chain management (GSCM) is a modern management model which designs supply chain in ecological method from the view point of product life cycle. In order to optimize the economic performance, environmental and social benefit with high resource efficiency, green supply chain needs close cooperation between sections inside the company and the enterprises, thus integrating environmental management into the supply chain management harmoniously. The theory of green supply chain management is still not systematic but progressive.GSCM can be divided into four research fields: green manufacturing, green purchasing, green logistics, green marketing. Perfecting the environmental law, strengthening the supervising ability of government, cultivating the environmental habit of consumers, advancing the information and environmental protection technology of enterprises will be needed in carrying out GSCM in our country.
author_names: Shen Cheng-lin
title: Summarization of Green Supply Chain Management
year: 2004

abstract: Abstract This paper examines how organizations connect internal and external processes to enable an agile response to continuous change. Drawing on life cycle theory, a hypothetical model is developed regarding the independent and combinative effects of internal and external process connectivity on supply chain agility and the moderating effect of product and supply complexity. The model is tested using hierarchical regression analysis based on survey data from 143 managers at German manufacturing firms. Our findings suggest that internal and external process connectivity have a positive effect on supply chain agility independently and collectively, with complexity having a moderating effect in particular instances. The findings build on prior research regarding the process related enablers of supply chain agility; research that has yet to clearly differentiate between internal and external processes or uses the terms interchangeably. The theoretical contribution of the paper rests on its extension of life cycle theory to the supply chain.
author_names: Samuel Roscoe

Dominik Eckstein

Constantin Blome

Matthias Goellner
title: Determining how internal and external process connectivity affect supply chain agility: a life cycle theory perspective
venue: Production Planning Control
year: 2019

abstract: Abstract Implementing sustainability principles of the circular economy and associated transitions tend to transcend the boundaries of individual businesses. This calls for a shift in traditional sustainability thinking by transitioning from business oriented sub optimisation to collaborative value chain optimisation. This paper proposes a framework to support companies in this transition by visualising the different relations in a morphological matrix to encourage the selection of the most appropriate principles for the specific industry context. The framework is evaluated in an industrial case with multiple stakeholders resulting in a feasible closed material loop.
author_names: Willem Haanstra

Marten E Toxopeus

M R van Gerrevink
title: Product Life Cycle Planning for Sustainable Manufacturing: Translating Theory into Business Opportunities
year: 2017