Search results for: manufacturing cost saving
Commenced in January 2007
Frequency: Monthly
Edition: International
Paper Count: 2899

Search results for: manufacturing cost saving

2509 Quality Approaches for Mass-Produced Fashion: A Study in Malaysian Garment Manufacturing

Authors: N. J. M. Yusof, T. Sabir, J. McLoughlin

Abstract:

The garment manufacturing industry involves sequential processes that are subjected to uncontrollable variations. The industry depends on the skill of labour in handling the varieties of fabrics and accessories, machines, as well as complicated sewing operation. Due to these reasons, garment manufacturers have created systems to monitor and to control the quality of the products on a regular basis by conducting quality approaches to minimize variation. With that, the aim of this research has been to ascertain the quality approaches deployed by Malaysian garment manufacturers in three key areas - quality systems and tools; quality control and types of inspection; as well as sampling procedures chosen for garment inspection. Besides, the focus of this research was to distinguish the quality approaches adopted by companies that supplied finished garments to both domestic and international markets. Feedback from each company representative has been obtained via online survey, which comprised of five sections and 44 questions on the organizational profile and the quality approaches employed in the garment industry. As a result, the response rate was 31%. The results revealed that almost all companies have established their own mechanism of process control by conducting a series of quality inspections for daily production, either it was formally set up or otherwise. In addition, quality inspection has been the predominant quality control activity in the garment manufacturing, while the level of complexity of these activities was substantially dictated by the customers. Moreover, AQL-based sampling was utilized by companies dealing with exports, whilst almost all the companies that only concentrated on the domestic market were comfortable using their own sampling procedures for garment inspection. Hence, this research has provided insights into the implementation of a number of quality approaches that were perceived as important and useful in the garment manufacturing sector, which is truly labour-intensive.

Keywords: Garment manufacturing, quality approaches, quality control, inspection, acceptance quality limit (AQL), and sampling.

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2508 Bioclimatic Design, Evaluation of Energy Behavior and Energy-Saving Interventions at the Theagenio Cancer Hospital

Authors: Emmanouel Koumoulas, Aikaterini Rokkou, Marios Moschakis

Abstract:

Theagenio" in Thessaloniki exists and works for three centuries now as a hospital. Since 1975, it has been operating as an Integrated Special Cancer Hospital and since 1985 it has been integrated into the National Health System. "Theagenio" Cancer Hospital is located at the central web of Thessaloniki residential complex and consists of two buildings, the "Symeonidio Research Center", which was completed in 1962 and the Nursing Ward, a project that was later completed in 1975. This paper examines the design of the Hospital Unit according to the requirements of the energy design of buildings. Initially, the energy characteristics of the Hospital are recorded, followed by a detailed presentation of the electromechanical installations. After the existing situation has been captured and with the help of the software TEE-KENAK, different scenarios for the energy upgrading of the buildings have been studied. Proposals for upgrading concern both the shell, e.g. installation of external thermal insulation, replacement of frames, addition of shading systems, etc. as well as electromechanical installations, e.g. use of ceiling fans, improvements in heating and cooling systems, interventions in lighting, etc. The simulation calculates the future energy status of the buildings and presents the economic benefits of the proposed interventions with reference to the environmental profits that arise.

Keywords: Energy consumption in hospitals, energy saving interventions, energy upgrading, hospital facilities.

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2507 CAD Model of Cole Cole Representation for Analyzing Performance of Microstrip Moisture Sensing Applications

Authors: Settapong Malisuwan, Jesada Sivaraks, Wasan Jaiwong, Veerapat Sanpanich

Abstract:

In the past decade, the development of microstrip sensor application has evolved tremendously. Although cut and trial method was adopted to develop microstrip sensing applications in the past, Computer-Aided-Design (CAD) is a more effective as it ensures less time is consumed and cost saving is achieved in developing microstrip sensing applications. Therefore microstrip sensing applications has gained popularity as an effective tool adopted in continuous sensing of moisture content particularly in products that is administered mainly by liquid content. In this research, the Cole-Cole representation of reactive relaxation is applied to assess the performance of the microstrip sensor devices. The microstrip sensor application is an effective tool suitable for sensing the moisture content of dielectric material. Analogous to dielectric relaxation consideration of Cole-Cole diagrams as applied to dielectric materials, a “reactive relaxation concept” concept is introduced to represent the frequency-dependent and moisture content characteristics of microstrip sensor devices.

Keywords: Microstrip, Sensor, Cole-Cole Representation, Moisture content.

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2506 Topographic Mapping of Farmland by Integration of Multiple Sensors on Board Low-Altitude Unmanned Aerial System

Authors: Mengmeng Du, Noboru Noguchi, Hiroshi Okamoto, Noriko Kobayashi

Abstract:

This paper introduced a topographic mapping system with time-saving and simplicity advantages based on integration of Light Detection and Ranging (LiDAR) data and Post Processing Kinematic Global Positioning System (PPK GPS) data. This topographic mapping system used a low-altitude Unmanned Aerial Vehicle (UAV) as a platform to conduct land survey in a low-cost, efficient, and totally autonomous manner. An experiment in a small-scale sugarcane farmland was conducted in Queensland, Australia. Subsequently, we synchronized LiDAR distance measurements that were corrected by using attitude information from gyroscope with PPK GPS coordinates for generation of precision topographic maps, which could be further utilized for such applications like precise land leveling and drainage management. The results indicated that LiDAR distance measurements and PPK GPS altitude reached good accuracy of less than 0.015 m.

Keywords: Land survey, light detection and ranging, post processing kinematic global positioning system, precision agriculture, topographic map, unmanned aerial vehicle.

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2505 Supply Chain Decarbonisation – A Cost-Based Decision Support Model in Slow Steaming Maritime Operations

Authors: Eugene Y. C. Wong, Henry Y. K. Lau, Mardjuki Raman

Abstract:

CO2 emissions from maritime transport operations represent a substantial part of the total greenhouse gas emission. Vessels are designed with better energy efficiency. Minimizing CO2 emission in maritime operations plays an important role in supply chain decarbonisation. This paper reviews the initiatives on slow steaming operations towards the reduction of carbon emission. It investigates the relationship and impact among slow steaming cost reduction, carbon emission reduction, and shipment delay. A scenario-based cost-driven decision support model is developed to facilitate the selection of the optimal slow steaming options, considering the cost on bunker fuel consumption, available speed, carbon emission, and shipment delay. The incorporation of the social cost of cargo is reviewed and suggested. Additional measures on the effect of vessels sizes, routing, and type of fuels towards decarbonisation are discussed.

Keywords: Slow steaming, carbon emission, maritime logistics, sustainability, green supply chain.

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2504 Real-Time Testing of Steel Strip Welds based on Bayesian Decision Theory

Authors: Julio Molleda, Daniel F. García, Juan C. Granda, Francisco J. Suárez

Abstract:

One of the main trouble in a steel strip manufacturing line is the breakage of whatever weld carried out between steel coils, that are used to produce the continuous strip to be processed. A weld breakage results in a several hours stop of the manufacturing line. In this process the damages caused by the breakage must be repaired. After the reparation and in order to go on with the production it will be necessary a restarting process of the line. For minimizing this problem, a human operator must inspect visually and manually each weld in order to avoid its breakage during the manufacturing process. The work presented in this paper is based on the Bayesian decision theory and it presents an approach to detect, on real-time, steel strip defective welds. This approach is based on quantifying the tradeoffs between various classification decisions using probability and the costs that accompany such decisions.

Keywords: Classification, Pattern Recognition, ProbabilisticReasoning, Statistical Data Analysis.

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2503 Cost Benefit Analysis and Adjustments of Corporate Social Responsibility in the Airline Industry

Authors: Roman Asatryan

Abstract:

The decision-making processes in Corporate Social Responsibility (CSR) among firms in the airlines industry borders on the benefits that accrue to firms through those investments. The crux of the matter is how firms can quantify the benefits derived from such investments. This paper analyses the cost benefit adjustment strategies for firms in the airline industry in their CSR strategy adoption and implementation. The paper discusses the CBA model in order to understand the ways airlines can reduce costs and increase returns on CSR, or balance the cost and benefits. The analysis indicates that, economic concepts especially the CBA are useful, though they are not without challenges. This paper concludes that the CBA model gives a basic understanding of the motivations for investing in intangible assets like CSR. It sets the tone for formulating relevant hypothesis in empirical studies in investment in CSR and other intangible assets in business operations.

Keywords: Cost Benefit Analysis, Corporate Social Responsibility, airline industry.

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2502 Improvement of Overall Equipment Effectiveness through Total Productive Maintenance

Authors: S. Fore, L. Zuze

Abstract:

Frequent machine breakdowns, low plant availability and increased overtime are a great threat to a manufacturing plant as they increase operating costs of an industry. The main aim of this study was to improve Overall Equipment Effectiveness (OEE) at a manufacturing company through the implementation of innovative maintenance strategies. A case study approach was used. The paper focuses on improving the maintenance in a manufacturing set up using an innovative maintenance regime mix to improve overall equipment effectiveness. Interviews, reviewing documentation and historical records, direct and participatory observation were used as data collection methods during the research. Usually production is based on the total kilowatt of motors produced per day. The target kilowatt at 91% availability is 75 Kilowatts a day. Reduced demand and lack of raw materials particularly imported items are adversely affecting the manufacturing operations. The company had to reset its targets from the usual figure of 250 Kilowatt per day to mere 75 per day due to lower availability of machines as result of breakdowns as well as lack of raw materials. The price reductions and uncertainties as well as general machine breakdowns further lowered production. Some recommendations were given. For instance, employee empowerment in the company will enhance responsibility and authority to improve and totally eliminate the six big losses. If the maintenance department is to realise its proper function in a progressive, innovative industrial society, then its personnel must be continuously trained to meet current needs as well as future requirements. To make the maintenance planning system effective, it is essential to keep track of all the corrective maintenance jobs and preventive maintenance inspections. For large processing plants these cannot be handled manually. It was therefore recommended that the company implement (Computerised Maintenance Management System) CMMS.

Keywords: Maintenance, Manufacturing, Overall Equipment Effectiveness

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2501 Pay Per Click Attribution: Effects on Direct Search Traffic and Purchases

Authors: Toni Raurich, Joan Llonch-Andreu

Abstract:

This research focused on the relationship between Search Engine Marketing (SEM) and traditional advertising. The dominant assumption is that SEM does not help brand awareness and only does it in session as if it were the cost of manufacturing the product being sold. The study is methodologically developed using an experiment where the effects were determined to analyze the billboard effect. The research allowed the cross-linking of theoretical and empirical knowledge on digital marketing. This paper has validated that, this marketing generates retention as traditional advertising would by measuring brand awareness and its improvements. This changes the way performance and brand campaigns are distributed within marketing departments, effectively rebalancing budgets moving forward.

Keywords: Search engine marketing, click-through ratios, pay-per-click, marketing attribution.

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2500 A Particle Swarm Optimal Control Method for DC Motor by Considering Energy Consumption

Authors: Yingjie Zhang, Ming Li, Ying Zhang, Jing Zhang, Zuolei Hu

Abstract:

In the actual start-up process of DC motors, the DC drive system often faces a conflict between energy consumption and acceleration performance. To resolve the conflict, this paper proposes a comprehensive performance index that energy consumption index is added on the basis of classical control performance index in the DC motor starting process. Taking the comprehensive performance index as the cost function, particle swarm optimization algorithm is designed to optimize the comprehensive performance. Then it conducts simulations on the optimization of the comprehensive performance of the DC motor on condition that the weight coefficient of the energy consumption index should be properly designed. The simulation results show that as the weight of energy consumption increased, the energy efficiency was significantly improved at the expense of a slight sacrifice of fastness indicators with the comprehensive performance index method. The energy efficiency was increased from 63.18% to 68.48% and the response time reduced from 0.2875s to 0.1736s simultaneously compared with traditional proportion integrals differential controller in energy saving.

Keywords: Comprehensive performance index, energy consumption, acceleration performance, particle swarm optimal control.

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2499 An Application of SMED Methodology

Authors: Berna Ulutas

Abstract:

Single Minute Exchange of Dies (SMED) mainly focuses on recognition of internal and external activities. It is concerned particularly with transferring internal activities into external ones in as many numbers as possible, by also minimizing the internal ones. The validity of the method and procedures are verified by an application a Styrofoam manufacturing process where setup times are critical for time reduction. Significant time savings have been achieved with minimum investment. Further, the issues related with employer safety and ergonomics principles during die exchange are noted.

Keywords: Die exchange, internal-external set-up, lean manufacturing, single minute die exchange.

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2498 Prediction-Based Midterm Operation Planning for Energy Management of Exhibition Hall

Authors: Doseong Eom, Jeongmin Kim, Kwang Ryel Ryu

Abstract:

Large exhibition halls require a lot of energy to maintain comfortable atmosphere for the visitors viewing inside. One way of reducing the energy cost is to have thermal energy storage systems installed so that the thermal energy can be stored in the middle of night when the energy price is low and then used later when the price is high. To minimize the overall energy cost, however, we should be able to decide how much energy to save during which time period exactly. If we can foresee future energy load and the corresponding cost, we will be able to make such decisions reasonably. In this paper, we use machine learning technique to obtain models for predicting weather conditions and the number of visitors on hourly basis for the next day. Based on the energy load thus predicted, we build a cost-optimal daily operation plan for the thermal energy storage systems and cooling and heating facilities through simulation-based optimization.

Keywords: Building energy management, machine learning, simulation-based optimization, operation planning.

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2497 Effective Security Method for Wireless LAN using Life-Cycle of Wireless Access Point

Authors: Soon-Tai Park, Haeryong Park, Myoung-sun Noh, Yoo-Jae Won

Abstract:

There are many expand of Wi-Fi zones provided mobile careers and usage of wireless access point at home as increase of usage of wireless internet caused by the use of smart phone. This paper shows wireless local area network status, security threats of WLAN and functionality of major wireless access point in Korea. We propose security countermeasures concerned with life cycle of access point from manufacturing to installation, using and finally disposal. There needed to releasing with configured secure at access point. Because, it is most cost effective resolution than stage of installation or other life cycle of access point.

Keywords: Wireless LAN Security, Wi-Fi Security, Wireless Access Point, Product Life-Cycle

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2496 The Impact of Motivation, Trust, and National Cultural Differences on Knowledge Sharing within the Context of Electronic Mail

Authors: Said Abdullah Al Saifi

Abstract:

The goal of this research is to examine the impact of trust, motivation, and national culture on knowledge sharing within the context of electronic mail. This study is quantitative and survey based. In order to conduct the research, 200 students from a leading university in New Zealand were chosen randomly to participate in a questionnaire survey. Motivation and trust were found to be significantly and positively related to knowledge sharing. The research findings illustrated that face saving, face gaining, and individualism positively moderates the relationship between motivation and knowledge sharing. In addition, collectivism culture negatively moderates the relationship between motivation and knowledge sharing. Moreover, the research findings reveal that face saving, individualism, and collectivism culture positively moderate the relationship between trust and knowledge sharing. In addition, face gaining culture negatively moderates the relationship between trust and knowledge sharing. This study sets out several implications for researchers and practitioners. The study produces an integrative model that shows how attributes of national culture impact knowledge sharing through the use of emails. A better understanding of the relationship between knowledge sharing and trust, motivation, and national culture differences will increase individuals’ ability to make wise choices when sharing knowledge with those from different cultures.

Keywords: Knowledge sharing, motivation, national culture, trust.

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2495 Learning Factory for Changeability

Authors: Dennis Gossmann, Habil Peter Nyhuis

Abstract:

Amongst the consistently fluctuating conditions prevailing today, changeability represents a strategic key factor for a manufacturing company to achieve success on the international markets. In order to cope with turbulences and the increasing level of incalculability, not only the flexible design of production systems but in particular the employee as enabler of change provide the focus here. It is important to enable employees from manufacturing companies to participate actively in change events and in change decisions. To this end, the learning factory has been created, which is intended to serve the development of change-promoting competences and the sensitization of employees for the necessity of changes.

Keywords: Changeability, human resources, learning factory.

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2494 STEP-NC-Compliant Systems for the Manufacturing Environment

Authors: Yusri Yusof

Abstract:

The paper provides a literature review of the STEPNC compliant research around the world. The first part of this paper focuses on projects based on STEP compliance followed by research and development in this area based on machining operations. Review the literature relating to relevant STEP standards and application in the area of turning centers. This research will review the various research work, carried out from the evolution of STEP-NC of the CNC manufacturing activities. The paper concludes with discussion of the applications in this particular area.

Keywords: STEP-NC, CNC, Machining and Turning.

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2493 A Search Algorithm for Solving the Economic Lot Scheduling Problem with Reworks under the Basic Period Approach

Authors: Yu-Jen Chang, Shih-Chieh Chen, Yu-Wei Kuo

Abstract:

In this study, we are interested in the economic lot scheduling problem (ELSP) that considers manufacturing of the serviceable products and remanufacturing of the reworked products. In this paper, we formulate a mathematical model for the ELSP with reworks using the basic period approach. In order to solve this problem, we propose a search algorithm to find the cyclic multiplier ki of each product that can be cyclically produced for every ki basic periods. This research also uses two heuristics to search for the optimal production sequence of all lots and the optimal time length of the basic period so as to minimize the average total cost. This research uses a numerical example to show the effectiveness of our approach.

Keywords: Economic lot, reworks, inventory, basic period.

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2492 Performance Evaluation of Energy Efficient Communication Protocol for Mobile Ad Hoc Networks

Authors: Toshihiko Sasama, Kentaro Kishida, Kazunori Sugahara, Hiroshi Masuyama

Abstract:

A mobile ad hoc network is a network of mobile nodes without any notion of centralized administration. In such a network, each mobile node behaves not only as a host which runs applications but also as a router to forward packets on behalf of others. Clustering has been applied to routing protocols to achieve efficient communications. A CH network expresses the connected relationship among cluster-heads. This paper discusses the methods for constructing a CH network, and produces the following results: (1) The required running costs of 3 traditional methods for constructing a CH network are not so different from each other in the static circumstance, or in the dynamic circumstance. Their running costs in the static circumstance do not differ from their costs in the dynamic circumstance. Meanwhile, although the routing costs required for the above 3 methods are not so different in the static circumstance, the costs are considerably different from each other in the dynamic circumstance. Their routing costs in the static circumstance are also very different from their costs in the dynamic circumstance, and the former is one tenths of the latter. The routing cost in the dynamic circumstance is mostly the cost for re-routing. (2) On the strength of the above results, we discuss new 2 methods regarding whether they are tolerable or not in the dynamic circumstance, that is, whether the times of re-routing are small or not. These new methods are revised methods that are based on the traditional methods. We recommended the method which produces the smallest routing cost in the dynamic circumstance, therefore producing the smallest total cost.

Keywords: cluster, mobile ad hoc network, re-routing cost, simulation

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2491 An Exhaustive Review of Die Sinking Electrical Discharge Machining Process and Scope for Future Research

Authors: M. M. Pawade, S. S. Banwait

Abstract:

Electrical Discharge Machine (EDM) is especially used for the manufacturing of 3-D complex geometry and hard material parts that are extremely difficult-to-machine by conventional machining processes. In this paper authors review the research work carried out in the development of die-sinking EDM within the past decades for the improvement of machining characteristics such as Material Removal Rate, Surface Roughness and Tool Wear Ratio. In this review various techniques reported by EDM researchers for improving the machining characteristics have been categorized as process parameters optimization, multi spark technique, powder mixed EDM, servo control system and pulse discriminating. At the end, flexible machine controller is suggested for Die Sinking EDM to enhance the machining characteristics and to achieve high-level automation. Thus, die sinking EDM can be integrated with Computer Integrated Manufacturing environment as a need of agile manufacturing systems.

Keywords: Electrical Discharge Machine, Flexible Machine Controller, Material Removal Rate, Tool Wear Ratio.

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2490 Predicting Extrusion Process Parameters Using Neural Networks

Authors: Sachin Man Bajimaya, SangChul Park, Gi-Nam Wang

Abstract:

The objective of this paper is to estimate realistic principal extrusion process parameters by means of artificial neural network. Conventionally, finite element analysis is used to derive process parameters. However, the finite element analysis of the extrusion model does not consider the manufacturing process constraints in its modeling. Therefore, the process parameters obtained through such an analysis remains highly theoretical. Alternatively, process development in industrial extrusion is to a great extent based on trial and error and often involves full-size experiments, which are both expensive and time-consuming. The artificial neural network-based estimation of the extrusion process parameters prior to plant execution helps to make the actual extrusion operation more efficient because more realistic parameters may be obtained. And so, it bridges the gap between simulation and real manufacturing execution system. In this work, a suitable neural network is designed which is trained using an appropriate learning algorithm. The network so trained is used to predict the manufacturing process parameters.

Keywords: Artificial Neural Network (ANN), Indirect Extrusion, Finite Element Analysis, MES.

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2489 Speed Optimization Model for Reducing Fuel Consumption Based on Shipping Log Data

Authors: Ayudhia P. Gusti, Semin

Abstract:

It is known that total operating cost of a vessel is dominated by the cost of fuel consumption. How to reduce the fuel cost of ship so that the operational costs of fuel can be minimized is the question that arises. As the basis of these kinds of problem, sailing speed determination is an important factor to be considered by a shipping company. Optimal speed determination will give a significant influence on the route and berth schedule of ships, which also affect vessel operating costs. The purpose of this paper is to clarify some important issues about ship speed optimization. Sailing speed, displacement, sailing time, and specific fuel consumption were obtained from shipping log data to be further analyzed for modeling the speed optimization. The presented speed optimization model is expected to affect the fuel consumption and to reduce the cost of fuel consumption.

Keywords: Maritime transportation, reducing fuel, shipping log data, speed optimization.

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2488 A Study of Classification Models to Predict Drill-Bit Breakage Using Degradation Signals

Authors: Bharatendra Rai

Abstract:

Cutting tools are widely used in manufacturing processes and drilling is the most commonly used machining process. Although drill-bits used in drilling may not be expensive, their breakage can cause damage to expensive work piece being drilled and at the same time has major impact on productivity. Predicting drill-bit breakage, therefore, is important in reducing cost and improving productivity. This study uses twenty features extracted from two degradation signals viz., thrust force and torque. The methodology used involves developing and comparing decision tree, random forest, and multinomial logistic regression models for classifying and predicting drill-bit breakage using degradation signals.

Keywords: Degradation signal, drill-bit breakage, random forest, multinomial logistic regression.

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2487 Cascade Kalman Filter Configuration for Low Cost IMU/GPS Integration in Car Navigation Like Robot

Authors: Othman Maklouf, Abdurazag Ghila, Ahmed Abdulla

Abstract:

This paper introduces a low cost INS/GPS algorithm for land vehicle navigation application. The data fusion process is done with an extended Kalman filter in cascade configuration mode. In order to perform numerical simulations, MATLAB software has been developed. Loosely coupled configuration is considered. The results obtained in this work demonstrate that a low-cost INS/GPS navigation system is partially capable of meeting the performance requirements for land vehicle navigation. The relative effectiveness of the kalman filter implementation in integrated GPS/INS navigation algorithm is highlighted. The paper also provides experimental results; field test using a car is carried out.

Keywords: GPS, INS, IMU, Kalman filter.

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2486 Multi-Objective Multi-Mode Resource-Constrained Project Scheduling Problem by Preemptive Fuzzy Goal Programming

Authors: Phruksaphanrat B.

Abstract:

This research proposes a preemptive fuzzy goal programming model for multi-objective multi-mode resource constrained project scheduling problem. The objectives of the problem are minimization of the total time and the total cost of the project. Objective in a multi-mode resource-constrained project scheduling problem is often a minimization of makespan. However, both time and cost should be considered at the same time with different level of important priorities. Moreover, all elements of cost functions in a project are not included in the conventional cost objective function. Incomplete total project cost causes an error in finding the project scheduling time. In this research, preemptive fuzzy goal programming is presented to solve the multi-objective multi-mode resource constrained project scheduling problem. It can find the compromise solution of the problem. Moreover, it is also flexible in adjusting to find a variety of alternative solutions. 

Keywords: Multi-mode resource constrained project scheduling problem, Fuzzy set, Goal programming, Preemptive fuzzy goal programming.

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2485 Safety Compliance of Substation Earthing Design

Authors: A. Hellany, M.Nagrial, M. Nassereddine, J. Rizk

Abstract:

As new challenges emerge in power electrical workplace safety, it is the responsibility of the systems designer to seek out new approaches and solutions that address them. Design decisions made today will impact cost, safety and serviceability of the installed systems for 40 or 50 years during the useful life for the owner. Studies have shown that this cost is an order of magnitude of 7 to 10 times the installed cost of the power distribution equipment. This paper reviews some aspects of earthing system design in power substation surrounded by residential houses. The electrical potential rise and split factors are discussed and a few recommendations are provided to achieve a safety voltage in the area beyond the boundary of the substation.

Keywords: EPR, Split Factor, Earthing Design

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2484 Oracle JDE Enterprise One ERP Implementation: A Case Study

Authors: Abhimanyu Pati, Krishna Kumar Veluri

Abstract:

The paper intends to bring out a real life experience encountered during actual implementation of a large scale Tier-1 Enterprise Resource Planning (ERP) system in a multi-location, discrete manufacturing organization in India, involved in manufacturing of auto components and aggregates. The business complexities, prior to the implementation of ERP, include multi-product with hierarchical product structures, geographically distributed multiple plant locations with disparate business practices, lack of inter-plant broadband connectivity, existence of disparate legacy applications for different business functions, and non-standardized codifications of products, machines, employees, and accounts apart from others. On the other hand, the manufacturing environment consisted of processes like Assemble-to-Order (ATO), Make-to-Stock (MTS), and Engineer-to-Order (ETO) with a mix of discrete and process operations. The paper has highlighted various business plan areas and concerns, prior to the implementation, with specific focus on strategic issues and objectives. Subsequently, it has dealt with the complete process of ERP implementation, starting from strategic planning, project planning, resource mobilization, and finally, the program execution. The step-by-step process provides a very good learning opportunity about the implementation methodology. At the end, various organizational challenges and lessons emerged, which will act as guidelines and checklist for organizations to successfully align and implement ERP and achieve their business objectives.

Keywords: ERP, ATO, MTS, ETO, discrete manufacturing, strategic planning.

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2483 A Study of Replacement Policies for Warranty Products with Different Failure Rate

Authors: Wen Liang Chang

Abstract:

This paper provides a replacement policy for warranty products with different failure rate from the consumer-s viewpoint. Assume that the product is replaced once within a finite planning horizon, and the failure rate of the second product is lower than the failure rate of the first product. Within warranty period (WP), the failed product is corrected by minimal repair without any cost to the consumers. After WP, the failed product is repaired with a fixed repair cost to the consumers. However, each failure incurs a fixed downtime cost to the consumers over a finite planning horizon. In this paper, we derive the model of the expected total disbursement cost within a finite planning horizon and some properties of the optimal replacement policy under some reasonable conditions are obtained. Finally, numerical examples are given to illustrate the features of the optimal replacement policy under various maintenance costs.

Keywords: Planning horizon, Free-repair warranty, Minimal repair, Replacement.

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2482 Current Status of Industry 4.0 in Material Handling Automation and In-house Logistics

Authors: Orestis Κ. Efthymiou, Stavros T. Ponis

Abstract:

In the last decade, a new industrial revolution seems to be emerging, supported -once again- by the rapid advancements of Information Technology in the areas of Machine-to-Machine (M2M) communication permitting large numbers of intelligent devices, e.g. sensors to communicate with each other and take decisions without any or minimum indirect human intervention. The advent of these technologies have triggered the emergence of a new category of hybrid (cyber-physical) manufacturing systems, combining advanced manufacturing techniques with innovative M2M applications based on the Internet of Things (IoT), under the umbrella term Industry 4.0. Even though the topic of Industry 4.0 has attracted much attention during the last few years, the attempts of providing a systematic literature review of the subject are scarce. In this paper, we present the authors’ initial study of the field with a special focus on the use and applications of Industry 4.0 principles in material handling automations and in-house logistics. Research shows that despite the vivid discussion and attractiveness of the subject, there are still many challenges and issues that have to be addressed before Industry 4.0 becomes standardized and widely applicable.

Keywords: Industry 4.0, internet of things, manufacturing systems, material handling, logistics.

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2481 A Goal Programming Approach for Plastic Recycling System in Thailand

Authors: Wuthichai Wongthatsanekorn

Abstract:

Plastic waste is a big issue in Thailand, but the amount of recycled plastic in Thailand is still low due to the high investment and operating cost. Hence, the rest of plastic waste are burnt to destroy or sent to the landfills. In order to be financial viable, an effective reverse logistics infrastructure is required to support the product recovery activities. However, there is a conflict between reducing the cost and raising environmental protection level. The purpose of this study is to build a goal programming (GP) so that it can be used to help analyze the proper planning of the Thailand-s plastic recycling system that involves multiple objectives. This study considers three objectives; reducing total cost, increasing the amount of plastic recovery, and raising the desired plastic materials in recycling process. The results from two priority structures show that it is necessary to raise the total cost budget in order to achieve targets on amount of recycled plastic and desired plastic materials.

Keywords: Goal Programming, Plastic Recycling, Thailand.

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2480 Cost of Governance in Nigeria: In Whose Interest?

Authors: Francis O. Iyoha, Daniel E. Gberevbie, Charles T. Iruonagbe, Matthew E. Egharevba

Abstract:

Cost of governance in Nigeria has become a challenge to development and concern to practitioners and scholars alike in the field of business and social science research. In the 2010 national budget of NGN4.6 trillion or USD28.75billion for instance, only a pantry sum of NGN1.8trillion or USD11.15billion was earmarked for capital expenditure. Similarly, in 2013, out of a total national budget of NGN4.92trillion or USD30.75billion, only the sum of NGN1.50trllion or USD9.38billion was voted for capital expenditure. Therefore, based on the data sourced from the Nigerian Office of Statistics, Central bank of Nigeria Statistical Bulletin as well as from the United Nations Development Programme, this study examined the causes of high cost of governance in Nigeria. It found out that the high cost of governance in the country is in the interest of the ruling class, arising from their unethical behaviour – corrupt practices and the poor management of public resources. As a result, the study recommends the need to intensify the war against corruption and mismanagement of public resources by government officials as possible solution to overcome the high cost of governance in Nigeria. This could be achieved by strengthening the constitutional powers of the various anti-corruption agencies in the area of arrest, investigation and prosecution of offenders without the interference of the executive arm of government either at the local, state or federal level.

Keywords: Capital expenditure, Cost of governance, recurrent expenditure, unethical behaviour.

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