Advances in Manufacturing Technology XXVI

Advances in Manufacturing Technology XXVI Volume 1

Tenth International Conference on Manufacturing Research Incorporating the 27

th

National Conference on Manufacturing Research

Manufacturing technology and operations to sustain business success

Edited by T. S. Baines, B. T. Clegg and D. K. Harrison

Advances in Manufacturing Technology – XXVI Proceedings of the 10thInternational Conference on Manufacturing Research (ICMR2012) 11th – 13th September 2012

Edited By Tim Baines and Ben Clegg, Aston University, UK & David Harrison, Glasgow Caledonian University, UK

First Published 2012

ISBN 9781905866601

i

FOREWORD The International Conference on Manufacturing Research is a major event for academics and industrialists engaged in manufacturing research. Held annually in the UK since the late 1970s, the conference is renowned as a friendly and inclusive environment that brings together a broad community of researchers who share a common goal; developing and managing the technologies and operations that are key to sustaining the success of manufacturing businesses. This year, ICMR 2012 has taken place on the 11-13 September 2012 at Aston University.

For over two decades ICMR has been the main manufacturing research conference organised in the UK. Initiated as a National Conference by the Consortium of UK University Manufacturing Engineering Heads (COMEH) it became an International Conference in 2003. COMEH is an independent body established in 1978. Its main aim is to promote manufacturing engineering education, training and research. To achieve this, the Consortium maintains a close liaison with government bodies concerned with the training and continuing development of professional engineers, while responding to appropriate consultative and discussion documents and other initiatives. COMEH is represented on the Engineering Professor’s Council (EPC) and it organises and supports national manufacturing engineering education research conferences and symposia. The host universities for NCMR have been:

1985 Nottingham

1994 Loughborough

1986 Napier

1995 De Montfort

1987 Nottingham

1996 Bath

1988 Sheffield

1997 Glasgow Caledonian

1989 Huddersfield

1998 Derby

1990 - None

1999 Bath

1991 Hatfield

2000 East London

1992 Central England

2001 Cardiff

1993 Bath

2002 Leeds Metropolitan

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In 2002 the conference was accorded the title International (ICMR) to reflect the current trends in manufacturing engineering and to promote the exchange of research and engineering application experiences internationally. The ICMR, has since its introduction, incorporated the NCMR. The 10th international conference, ICMR 2012, incorporates the 27th NCMR. The host universities for ICMR have been:

2003 Strathclyde

2008 Brunel University

2004 Sheffield Hallam

2009 Warwick University

2005 Cranfield

2010 Durham University

2006 Liverpool John Moores

2011 Glasgow Caledonian

2007 De Montfort University

2012 Aston University

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ACKNOWLEDGEMENTS On behalf of the conference chairs we would like to thank COMEH for inviting Aston Business School to host the 10thInternational Conference on Manufacturing Research.We would also like to thank all of the overseas and local contributing authors and delegates for the high quality ofpapers submitted and the wide range of topics addressed. We look forward to ICMR2012 being asinformative and enjoyable as previous NCMR and ICMR conferences and that opportunities forinteraction and exchange of ideas are taken by delegates.Academic aspects of the conference, particularly the refereeing of papers, have been undertaken bymembers of the following committees:

Conference Chairs Tim Baines, Ben Clegg & David Harrison

Local organising committee at Aston University Maria Podsiadly and Bhomali Grover (Conference secretariat) Pavel Albores Christopher Brewster Grace Bruce Prasanta Dey William Ho Patrick Keen

Louise Knight Ming Lim John Morley Breno Nunes Chris Owen

COMEH Advisory Committee Linda Newnes (Chair) University of Bath Keith Case (Deputy Chair), Loughborough University Peter Ball, Cranfield University James Gao, Greenwich University Diane Mynors, Wolverhampton University

Essam Shehab, Cranfield University Mozafar Saadat, University of Birmingham David Stockton, De Montfort University Yi Qin, Strathclyde University

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Scientific Committee Azmawani Abd Rahman, University Putra Pavel Albores, Aston Business School Peter Ball, Cranfield University David Bennett, University of South Australia Christopher Brewster, Aston University Keith Case, Loughborough University Walid Cheffi, Rouen Business School Kai Cheng, Brunel University Wai Ming Cheung, Northumbria University Alan Crispin, Manchester Met. University Marc Desmulliez, Herriot Watt University Prasanta Dey, Aston University John Erkoyuncu, Cranfield University Sarah Fletcher, Cranfield University James Gao, Greenwich University Jose Garza Reyes, Derby University Rick Greenough, De Montfort University Angappa Gunasekaran, Uni. of Massachusetts George Haritos, Hertfordshire University Christian Hicks, Newcastle Uni. Business School William Ho, Aston University Bernard Hon, Liverpool University Ian Jennions, Cranfield University Louise Knight, Aston University Hermann Kühnle, Institute of Ergonomics Ashraf Labib, University of Portsmouth Jay Lee, University of Cincinnati Fiona Lettice, Norwich Business School

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Howard Lightfoot, Aston University Ming Lim, Aston University Jill MacBryde, Strathclyde University Diane Mynors, University of Wolverhampton Linda Newnes, University of Bath Sai Nudurupat, Manchester Met. University Breno Nunes, Aston University Chris Owen, Aston University Ivana Partridge, Cranfield University David Petty, Manchester Met. University Paul Maropoulos, University of Bath Yi Qin, Strathclyde University Louis Redding, Cranfield University Mozafar Saadat, Birmingham University Essam Shehab, Cranfield University Palie Smart, Cranfield University David Stockton, De Montfort University James Stone, Aston University Mike Sweeney, Cranfield University Daizhong Su, Nottingham Trent University Janusz Szpytko, University of Krakow Ashutosh Tiwari, Cranfield University Benny Tjahjono, Cranfield University Kumar Vikas, Dublin City University Mats Winroth, Chalmers Uni. of Technology Mianhong Wu, University of Derby Zhengxu Zhao, Shijiazhuang Tiedao Institute Erping Zhou, University of Bolton

This publication is copyright under the Berne Convention and the International CopyrightConvention. All rights reserved. Apart from any fair dealing for the purpose of private study, research,criticism or review, as permitted under the Copyright, Designs and Patents Act, 1998, no part of thispublication may be reproduced, stored in or introduced into a retrieval system, or transmitted, in anyform or by any means (Electronic, digital, mechanical, photocopying, recording or otherwise circulatein any form of binding or cover other than in which it is published and without similar conditionincluding this condition being imposed on the subsequent publisher. Unlicensed multiple copying of the contents of this publication is illegal. Enquiries should be addressed to the publishers: Aston Business School Aston University Aston Triangle Birmingham B4 7ET © Aston Business School

ISBN 9781905866601 Glasgow Caledonian University Printed in Great Britain The publishers are not responsible for any statement made in this publication. Data, discussion andconclusions developed by authors are for information only and are not intended for use withoutindependent substantiating investigation on the part of potential users. Opinions expressed are thoseof authors and are not necessarily those of Aston University.

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In Memoriam

1953 -2011 These proceedings are dedicated to the memory of Professor Val Vitanov, Durham University. Born in Sofia, Bulgaria in 1953, Val Vitanov graduated as MEng in Electrical engineering and later completed an MSc in Applied mathematics and Informatics. His doctoral studies were with the Electro-Technical University of St.Petersburg. In 1988, following a period in the Bulgarian army, he first visited the UK as a Visiting Scholar at Staffordshire Polytechnic, and this subsequently led to positions at Portsmouth and Cranfield Universities. In 2009 he took the position of Professor of Design, Manufacture and Management in the School of Engineering at Durham University. Professor Vitanov was well known for his research on product design and technology optimization, production and operations management, and simulation and statistical process control. He supervised a broad range of projects commissioned in different branches of industry, long-term and multiple project relationships with international companies including, Airbus, Rolls Royce, BAE Systems, GEC Marconi Defence Systems, BMW, Ford, Nissan, EATON Corporation, and Peugeot. Professor Vitanov was a Fellow of the IET and an active member of six international bodies from the UK, USA, and Europe. Val was an active contributor to ICMR, the manufacturing community in the UK, and a dear friend to the COMEH committee and the organisers of this year’s conference. He was admired in many ways, not least for his successful transition from a lecturer in Bulgaria, to a full Professor at one of the premier institutions in the UK. His commitment and sacrifices were staggering. In 2010 Val successfully hosted the 8th ICMR conference at Durham. In early 2011 he was diagnosed with cancer and died shortly after. He is survived by his wife Tanya and son Ivan.

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ICMR Conference – Contents

Volume 1 Track 1: Management, Production Systems and Optimisation 1 2 3 4 5 6 7 8

9

10 11 12

13 14 15 16 17 18 19 20 21 22

An optimization methodology for the investments on maintenance personnel within an industrial environment. J. Khalil Application of image processing concept for identifying product line defects (case study: shiraz vegetable oil company). V. Zarif and A. Khatami Ranking of project risks based on the PMBOK standard by fuzzy DEMATEL. S.M. Ali Khatami Firouzabadi and A.V. Nikjoo Capabilities and competence management in Small and Medium Enterprises. A. Munir, M. Lim and L. Knight An artificial immune system scheduling tool for production scheduling in the capital goods industry. W. Xie, C. Hicks and P. Pongcharoen A Methodology for Purchasing Cost and Risk Reduction. A. Tiwari, C. Turner and K. Younis Industry platform strategies for market expansion. C-L. Tsai Applying classifications to measure and achieve manufacturing system fitness, performance and best practice. J. Baldwin, C. Rose-Anderssen, F. Boettinger, I. Németh, I. Brencsics and K. Kodua Cladistic classification and rapid layout design of manufacturing systems. I. Németh, J.S. Baldwin, J. Püspöki, C. Haraszko, C. Rose-Anderssen and K. Ridgway Characterisation of uncertainties in costing for availability contracts. S. Narayana Improving maintenance and tooling organisation in a manufacturing environment. P. Lindsey Supplier Competitive Advantage in Inter-firm Business Relationships: Is Keiretsu Really a Source of Competitive Advantage for Japanese Automotive Suppliers? T. Kato and B. Nunes Optimizing biomass supply portfolios. J. Scott, W. Ho and P. Dey QFD-based manufacturing strategy development in an uncertain environment. P.Singh, M. Lim and D. Love Decentralized Bilevel Model for Shared Inventory with emergency and back orders. F. Ben Abdelaziz and S. Mejri Business Performance Monitoring: beyond financial indicators. D. Kumar Hurreeram, A. Ruggoo, D. Callychum and K. Soobhug Supplier development literature review. M. Ahmed and L. Hendry Investigating Types of Variability on Food Flow Processing Systems. A. Noorwali, R. Khalil and D. Stockton The evaluation and identification of agility capabilities of sapco’s suppliers. A.K. Firouzabadi and S.S. Chelengar Reliability analysis of trunk road network maintenance: A study of category 1 defects. E. Orugbo, B. Alkali, A. Desilva and D. Harrison The benefits of PLC integration into current manufacture of PTFE compression moulded rod and tube products. S. Murray, M.J. Roudsari and G. Haritos. Human system analysis for productivity indicators using virtual engineering simulation modelling. U. Ghani, R. Monfared, R. Harrison and I. Ghani 8

2 8 14 20 26 32 38 43

49

55 61 67

73 80 86 92 98 104 109 115 121 127

23 24

Machine utilisation and breakdown modelling for measuring productivity using virtual engineering simulation modelling. U. Ghani, R. Monfared and R. Harrison Resource-Efficient Planning in Production through Flexibility Measurements. S. Rogalski, H. Wicaksono and J. Ovtcharova

133 139

Track 2: Information Systems and Digital Technology 25 26 27 28

29 30 31

32

Formal assembly reference ontology for assembly systems compatibility assessment. M. Imran, B. Young and Z. Usman The user perspective on the Quality Information Framework. P.Saunders, N. Orchard, P. Maropoulos and A. Graves Managing ERP capabilities and collaborative enterprise reference grid for ERP information systems. Y. Wan and B. Clegg Towards a dynamically generated Product Configurator that reflects the available Manufacturing Capability. A. LanKuan Yip, A.P. Jagadeesan, Y. Qin and J. Corney Advances and Trends in Cloud-based PHM for Predictive Manufacturing Systems. J. Lee, S. Yang, E. Lapira, H. An Kao and N. Yen Do manufacturing firms need informality in ERP post-implementation? Y. Wang, A. Greasley and P. Albores Developing interdisciplinary specifications for the design and implementation of IT scheduling decision support systems: An SME case study. C. Dimopoulos, J. Cegarra and G. Gavriel The integration of quality management in information systems. C. Rosique, D. Petty, A. Labib, I. Faraj and D. Harrison

146 152 158 164

170 176 182

188

Track 3: Human Centred Manufacturing 33 34

35

36 37

38 39 40

Assessing the impact of job involvement and commitment on organizational productivity. K. Amazyed and A. Olabi Developing true cooperation between human operators and robots in assembly work systems; A proxemics study of behaviour, workload and comfort. M. Walton, S. Fletcher and P. Webb Using ergonomic job design principles to reduce injuries and increase productivity in a commercial lighting manufacturing facility: A case study. J. Kapellusch and A. Garg Indigenous Methods – Keys to Success for Global Supply Networks: The Ethiopian Case. I.Z. Muhammed and H. Kuehnle Impact of multimodal feedback on vr training for manufacturing manual work. A. Langley, S. Sharples, M. Dcruz, H. Patel, A.R. Lecuona and M. Poyade Ergonomic cycle time: a proposed metric for designing safe jobs while maximizing productivity. J. Kapellusch, J. Kapellusch and A. Garg An Exploratory Study to Identify Impacts of Confined Space Working in Modern Manufacturing. M.I.R. Albarracin and S.R. Fletcher Human stress-centred behaviours study related to small and medium enterprises – A Malaysian perspective. S.T.S. Shazali, M. Rosli and A. Yassin 9

195 201

207

213 219

225 231 237

41 42

Addressing human variability and work performance through an inclusive design method. A. Hussain, K. Case, S. Summerskill and R. Marshall The welfare supervisor: lessons for the modern day from improvements of conditions for female munitions workers during the great war. W. Osborne and K. Case

243 249

Track 4: Cost Engineering 43 44

45 46 47 48

Recycling cost modelling methodology of carbon fibre composites. E. Shehab, G. Al-Anazi and A. Wasim Cost modelling to support lean product and process development: current industrial practices and requirements. A. Wasim, E. Shehab, H. Abdalla and A. AlAshaab Integrating a scientific approach to cost engineering into an industry design process. L. Newnes, M. Saravi and K. Morton Estimating through-life in-service costs for long-life high-value assets in the water industry. H. Cornwell and L. Newnes An investigation into the stages of Identifying and Collecting Data in the Cost Modelling Process. Y.D. Arvelo, D. Stockton and R. Khalil Factory set-up cost estimation tool for SMEs. M.A. Sarkandi, P. Baguley and A. Tiwari

256 262

268 274 280 285

Track 5: Doctoral Track 49 50 51 52 53 54 55 56 57 58 59

The obstacles of Saudi Arabian organisational culture to implement Total Quality Management (TQM). M. Alnaeem and M. Lim Reengineering manufacturing businesses – characterising and defining future growth in the UK. P. Byard, A. Thomas, M. Evans and G. White New perspectives on open innovation: the role of relative proximity on open innovation implementation in UK high-tech SMEs. D. Weiss Using BS 6143 to help identify lean and six sigma. R. Orme, B. Clegg, C. Rees and M. Titchen Using grounded theory method for theory generation in information systems and manufacturing management research. Y. Wan and B. Clegg Product lifecycle management in medium sized companies – A university research approach. H. Holz, B. Temple, W. Rimkus and D.K. Harrison A web based application to enhance medical data visualisation. S. Alfalah, D. Harrison, V. Charissis and D. Evans Servitization - Complex engineering service availability – is a paradigm shift in the business model and service enterprise required? N. Barnett, G. Parry and M. Saad Distributed agile software development challenges: a systematic map. A. Alqahtani, J.D. Moore, D.K. Harrison and B. Wood Evaluating the value of installed base information in preventive maintenance. M. Arhippainen, M. Finne and J. Holmström Investigation of emerging technologies in luxury brands e-commerce. S. Altarteer, V. Charissis and D. Harrison 1

292 298 304 311 317 323 329 335 342 348 354

60 61

62

The characterisation of an IT system to reduce the gap between information technology and medical education. J. Falah, D. Harrison, B. Wood and D. Evans A methodology for analysis supply management capabilities and operations performance of UK manufacturing SMEs. J. Ofori-Amanfo, L. HuacchoHuatuco and T.F. Burgess Determination of wood strength properties through standard test procedures. A. Naylor, P. Hackney and N. Perera

360 366

372

Track 6: Product Service Systems and Servitization 63 64 65 66 67 68 69

70 71

PSS decision-making framework from the customers’ viewpoint. S. Alotaibi and B. Tjahjono The servitization of product based organisations: A holistic framework. S. Nudurupati, N. Yip and D. Lascelles Product-service system in the Egyptian manufacturing sector: Issues and challenges. M. Elnadi, E. Shehab and J. Peppard Challenges and Opportunities in Through-life Engineering Services: A survey of Manufacturing Organisations. L. Redding, N. Morar and A. Tiwari Component Lifecycle modelling to predict remanufactured part availability. I. ShingFan, J. Heng and J. Bayer Leadership in high-value services for manufacturers: an exploration of the impact to facilities practices. T. Baines and H. Lightfoot Leadership in high-value service for manufacturers: information and communication technologies and the delivery of advanced services. T. Baines and H. Lightfoot Leadership in high-value services for manufacturers: people and the delivery of advanced services. T. Baines and H. Lightfoot Leadership in high-value services for manufacturers: advanced services and their impact on vertical integration. T. Baines and H. Lightfoot

379 385 391 397 407 413 417

422 430

Volume 2 Track 7: Product Design and Development 72 73 74 75 76

Design and development of an excavator mounted dust suppression system. W. Cheung and K. Wallace Reuse of process domain knowledge for better aircraft manufacturing. C. Liu, J.B. Wang and Y.B. Fan An ontology framework for developing gas turbine design systems for the aerospace industry. I. Sanya, E. Shehab, B. Haque and R. Boyce Systems architecture frameworks in aerospace industry: challenges and future research directions. M. Darwich, E. Shehab and B. Haque Design and Development of a new and novel vehicle roof top ladder clamping system. F. Rehman, M. Rae, R. Benham and E. Miller

11

438 444 450 456 462

77 78 79

80 81 82 83

Development of a 1:1 scale true perception virtual reality system for design review in automotive industry. F. Shao, T.J. Robotham and B. Hon Collaborating with Suppliers in the New Product Development Process: The Small Firm Perspective. V. Hanna. Improving the quality of the cost estimate by enhancing optimisation between performance and cost at the early design stages. M. Saravi, L. Newnes and A. Mileham Multiscale simulation of a rod-shaped microstructure with notches in static and cycling loadings. Q. Bai, Y. Liang, K. Cheng and H. Pen Enhancing autonomy in the formation of holonic manufacturing networks. G. Jules, M. Saadat and N. Li Development of a GA-optimized manufacturing network using holonic multi-agent approach. N. Li, M. Saadat and G. Jules Optimization of the deposition and annealing of CuAlMo thin film resistors. M. Birkett

468 474 480

486 492 498 504

Track 8: Advanced Manufacturing Processes and Technologies 84 85 86 87 88 89 90 91 92 93 94 95 96 97 98

A study of workpiece roundness profile frequency components in cylindrical plunge grinding. S.Y. Goh and A.D.L. Batako Grinding Wheel Wear in Vibration Assisted Grinding of Steel. A.D.L. Batako, V. Tsiakoumis, S. Grigor’ev and V. Kuzin A New Generation of Ceramic Cutting Tools. V.V. Kuzin, S.N. Grigor’ev, D.R. Burton and A.D.L. Batako Material removal in polishing processes – finite element simulation and experiment. M. Speich, R. Börret, W. Rimkus and D. Harrison Optimal Selection of Machine Parameters in Tension Levelling of Sheet Metals. I. Roberts, D. Mynors, C. Wang, P. Adams, K. Land and P. Unwin Efficient Grinding Processes: An energy efficiency point of view. K. Salonitis A comparison of the failure modes of PMMA and polypropylene test pieces cut using different manufacturing methods. R. Benham and F. Rehman Principles and Generic Patterns for Networked Manufacturing. H. Keuhnle and A. Leuder A Strategic Evaluation of Implementation of Flexible Manufacturing Systems in a Home application company. A.K. Firoozabadi and A. Kehtari Accuracy and performance characteristics of electrochemical micromaching. H. ElHofy Integration of “automated” quality assurance procedures for flexible and reconfigurable FMS and FMC. G. Haritos Introducing the rapid prototyping technology in the engineering degrees – an experience at Estsetúbal / IPS. J. Simoes and T. Coole Abrasive Flow Machining: R&D Strategy & Challenges in Industrial Applications. M. Howard, K. Cheng and G. Mollart Separation of waviness and roughness using phase correction filter. V. Lakshminarayanan and R. Murali Evaluation of handsaw tooth performance through the development of a controlled cutting test rig. A. Naylor, P. Hackney and N. Perera 12

511 517 523 529 535 541 547 553 559 565 571 577 583 589 594

Track 9: Modelling and Simulation 99 100 101 102 103

104 105 106 107

Aero-acoustical Detection of the Frequency of the wake flow of a Cylinder. C. Maier, M. Macdonald, W. Pannert, D. Harrison and W. Waidmann A Simulation Study of the Shift System at a Police Control Room. A. Greasley, C. Smith and T. Taylor CFD simulation of cavitation in diesel injectors. M. Fuchs, M. Macdonald and W. Waidmann Understanding how discrete event simulation can support decision making in manufacturing systems. S.P. Hernandez-Rodriguez and B. Tjahjono Effect of Process Parameters on Residual Stresses in Laser Melting of Multiple Ti6Al-4V Powder Layers. I. Roberts, C. Wang, D. Mynors, M. Stanford and K. Kibble Analysing interactions among variables in automobile supply chain: an ISM-based approach. R. V and R. Shankar Holonic supply chain: a symbiosis of family-based manufacturing and inventory control policy system. N. Dev, R. Shankar and P. Dey Towards understanding of human behaviour in crowded spaces using video observation analysis. K. Case and S. Mohammaddan Availability modelling techniques review of high value systems. A.M.C. Prieto, P. Baguley and R. Roy

601 607 608 613 619

625 631 637 643

Track 10: Global Manufacturing 108 The Strategic Management of Manufacturing Networks. M. Sweeney, M. Szwejczewski and A. Cousens 109 International technology transfer and development of capabilities in Chinese stateowned manufacturing enterprises: Lessons from 20 years of case research. K. Vaidya, M. Hall, J. He, X. Gao and D. Bennett 110 The Global Plant Location Decision. C. Owen and S. Baker 111 Developing an A3 thinking methodology to enhance the production process. N. Mohd-Saad, M. Flores, I. Alammari and A. Al-Ashaab

650 656

662 668

Track 11: Sustainability 112 Bottom up or top down? Identifying the best approach to achieving manufacturing and economic performance in SMEs. M. Evans, A. Thomas, P. Byard and R. Mason-Jones 113 Design of a test workpiece for energy efficiency assessment of CNC milling machines. B. Afsharizand and K. Cheng 114 Energy efficiency and sustainability in the car-based mobility: the case of the electric vehicle EDITHA. M. Heinicke, G. Wagenhaus, M. Schünemann and K. Kuhlmann 115 Modelling energy in buildings and production systems: The impact of model granularity and model granularity and quality on output. C. Turner, P. Ball, A. Dave, M. Oates and V. Murray 13

675

681 687

693

116 Barriers to energy reduction in manufacturing. P. Lunt and P. Ball 117 Strategies for sustaining manufacturing competitiveness: Case studies of Australian firms. C. Soosay, B. Nunes, D. Bennett, J. Jabar, A. Sohal and M. Winroth 118 Choice and improvement of a multi supplier network for the use of a landscaping waste and alternative energy generation in biogas plants. M. Heinicke and G. Wagenhaus

699 705

711

Track 12: Enterprise Information and Knowledge Management 119 An investigation into the potential use of social media technologies to improve the product development functions within the aerospace and defence industry. R. Evans, J. Gao, N. Martin and C. Simmonds 120 Adoption of Open Source and Conventional ERP Solutions for Small and Medium Enterprises in Manufacturing. M. Nezami, W. Cheung and S. Mansi 121 Developing effective knowledge transfer in manufacturing companies: A case study in industry/academic collaboration. A. Thomas, M. Francis, W. Chappell, K. Williams and C. Lee 122 A Collaboration Framework for Product Development in the Extended Enterprises. S.M. Hasan, S. Shah and J. Gao 123 A framework for effective supplier integration in Global Automotive product development projects. T. Saunders, S. Shah and J. Gao 124 Is ‘knowledge is power’ syndrome in the design team? L. Zaglago, C. Chapman and H. Shah 125 An approach to transforming manufacturing information into knowledge for reuse. Y. Fan, C. Liu and J. Wang 126 Knowledge Management Approach to Improve Energy Efficiency in SmallMedium Enterprises: A case in stainless steel manufacturer. H. Wicaksono, S. Rogalski and J. Ovtcharova 127 Capability development in Chinese manufacturing: A quasi-biotic perspective of knowledge evolution. J. He, W. Lyu and K. Vaidya 128 Virtual commissioning for PLC simulation. M. Ko, D.S. Chang and S.C. Park

718

724 730

736 742 748 754 760

766 772

Track 13: Green Supply Chain 129 A hierarchical fuzzy TOPSIS approach to assess improvement areas when implementing green supply chain practices. X. Wang and H.K. Chan 130 Green strategies and initiatives in the UK transport network and logistics industry. F. Sai, M.K. Lim and G. Rahib 131 Logistical framework for last mile relief distribution in humanitarian supply chain: A case study. P. Roy, P. Albores and C. Brewster 132 Developing carbon footprint criteria for supplier selection in green supply chain management. R. Khodaverdi and A. Khatami 133 Greening the Irish Food Market Supply-Chain through Minimal Carbon Emission: An Integrated Multi-Objective Location-Routing Approach. S. Validi, A. Bhattacharya and P.J. Byrne 14

779 785 793 799 805

134 Green Supply Chain Performance Measurement using Balanced Scorecard in the Manufacturing Industry. W. Cheffi and P.K. Dey 135 A new approach to environmental and societal supply chain demands. P.E. Dossou and P. Mitchell

811 818

Track 14: Lean Six Sigma 136 Sustainable six sigma – An organisational learning perspective. A. Thomas, E. Plant, P. Byard and M. Evans 137 Applying lean management, industrial engineering and automation technology methods for the improvement of a testing process. S. Withers, J.A. Garza-Reyes, H. Soriano-Meier and I. Oraifige 138 Adoption of Lean Manufacturing Processes in Developing Countries: A Case study of Gasland Nigeria Limited. S. Burtonshaw-Gunn, D. Oluwaseun-Apo, H. Soriano-Meier, J.A. Garza-Reyes and V. Kumar 139 The evaluation of Lean in healthcare using qualitative and quantitative methods. C. Hicks, A. Small, T. McGovern, E. Lugsden, N. Steen, P. Whitty, D. Hunter, J. Erskine and M. Eccles 140 Towards the strategic adoption of lean in aviation maintenance repair and overhaul industry: An empirical study into the industry’s lean status. P. Ayeni, P. Ball and T. Baines

15

825 831

837

843

849

Investigating Types of Variability on Food Flow Processing Systems Ammar Noorwali Centre of Advanced Manufacturing Process and Mechatronics De Montfort University Leicester, LE1 9BH, UK [email protected]

Riham Khalil Centre of Advanced Manufacturing Process and Mechatronics De Montfort University Leicester, LE1 9BH, UK [email protected]

David Stockton Centre of Advanced Manufacturing Process and Mechatronics De Montfort University Leicester, LE1 9BH, UK [email protected] ABSTRACT Food processing industry worldwide and specifically in the UK and the Middle East has a high competition and that requires increase efficiency and reduces waste. This paper will illustrate the mixed types of variability that may occur within food processing system i.e. food production line. In addition, food characteristics also can help in understanding constraints and factors that have effect or can act as cause of this variability. Therefore, the research has used process mapping as a first step to understand the different activities in the food processing system and develop a simulation model as a mirroring tool to carry the different process improvements Keywords: Food, Processing, System, Variability, Flow, Simulation Modeling

1 INTRODUCTION According to (Akkerman and van Donk, 2009), The competition is increasing in food industry and the factories have to handle short due dates imposed by high market pressure. Food processing is mostly consisting of processing and packing The entire food industry has become more market-driven, providing products that meet consumer demand. Consumers want more convenient, ready-to-eat, value-added products that focus attention on food safety areas and to monitor and check each step along the process to make sure the product is safe and the process is in control i.e. instead of relying on the end product when it's too late to correct the problem and understanding the different processes that may occur in the manufacturing food processing i.e. workcentres , buffers, processing time, operators. 2

TYPES OF FOOD MANUFACTURING SYSTEM

They are based on basic types of manufacturing system as (Khalil, 2005) mentioned : • • • •

Batch Production; high range of products /low to medium demand level, were small batch size or one item can be produced within a process orientated facility lay out. Job shop production; high range of products / very low demand level, were different sizes of batches can be produced within a process orientated facility lay out. Continues processing; low range of products / very high demand level, were one product is produced through continues product oriented facility layout. Flow production; low range of products / medium to high demand level, were small numbers of product types or large batches of one product are produced through a product oriented facility layout.

Those types can be applied in food flow processing, the research here will investigate factors may affect in each type that cause variability increasing.

104

Noorwali, Khalil, Stockton

3

GENERIC CHARACTERISTICS OF FOOD PROCESSING

According to (van Donk, 2001); (Van Wezel et al., 2006) ; (Soman et al., 2004); (Corti et al., 2006) food processing system has the following features: i.

ii.

iii.

iv.

v.

vi.

4

Product Features; the nature and basis of raw material frequently entail an uncertain supply, quality, and price due to variable yield of farmers. The uncertain supply and quality of raw materials may cause lack of synchronisation between processes. For instance lack or bad quality of raw materials may reduce the quantity of products. Process features; there are long (sequence-dependent) set-up times between different product mix. Therefore, that might be variable between different process and may affect with process stability and fulfilment of customer order. In addition, there are some products have slightly similar process features. Thus, sometimes there is mixing between these products in the production will lead in creating non-value added activities i.e. wastes. Poor capacity planning; in food processing systems that associated with uncertainty and unstable customer demand, it is difficult to estimate capacity requirements far enough into the future to fulfil market requirements. Capacity plans should be implemented carefully to avoid unpleasant surprises. Customer due date; is one of the most significant characteristic of food flow processing system as the product should be available in market shelf as it need it in the planned time. Therefore, a rigid order release plan and dispatching control are essential. The release plan certifies that the order is not released too early or too late, while the dispatching control aims to accelerate late orders to achieve on time delivery for instance in food processing. As (Corti et al., 2006) mentioned that a heuristic algorithm “called Heuristic Delivery Due Date Algorithm, HDDDA”. That allows decision makers to find consistent due date, which is essential for food products, for each item with consideration of the actual outstanding capability of the bottleneck resources. Customer order; as mentioned above that long set-up times may affect with customer order fulfilment. In addition, weather change may affect with the last minute order, as if it’s hot the customer may intend to order more fresh salad than in cold weather. Limited shelf life ; a shelf-life products may limits the probabilities of applying built-up inventories in order to satisfy customers orders and limit intermediate stocks probabilities. DIFFERENT LEVELS OF VARIABILITY IN FOOD PROCESSING INDUSTRY AND MTS-MTO

According to (Hopp and Spearman, 2001), (Germain et al., 2008), (Khalil, 2005) the variability in food processing lies in three main categories in machine, people and method i.e the manufacturing food processing. While, (Akkerman and van Donk, 2009); (Das and Abdel-Malek, 2003); (Germain et al., 2008); (Van Wezel et al., 2006); (van der Vorst et al., 2000); (Nelson et al., 2009); (Fransoo and Wouters, 2000); (Zorzini et al., 2008); (Corti et al., 2006) identified a brief list of types of variability that may affect the food processing system : a. Correlation between products; correlation happen when there are two or more products that have similar process time, routing, and stocks, it is likely to have interruption between processes. That result in increasing wastes in time and product. b. Change in customer demand; that may increase setup time and material waste. c. Machines breakdown; breakdown can be divided as: i. Short stoppages; that can happen accidently . ii. Long stoppages; that can be planned by schedule maintenance. However, sometimes long stoppage may happen due to machine breakdown. d. Changeover time; there are many reasons that cause of variability in change over time: • Inaccurate forecasting. 105


• Uncertain demand. • Additional customer order. e. Weather change; as mention in section 3 weather changes may cause of fluctuation of demand in fresh food products such as fresh salad. f. Uncertain Due date; the due date issue may consider as internal within production planning activities and that can be reflected in raw materials. In addition, it can be consider as external within receiving orders and shipping products and that can reflect in finish goods. Therefore, the characteristics may help in identify the source of uncertainty that affect with line efficiency. The research here may consider each characteristic and predict the variables that may happen and then connect these variables with the model results to identify the variables for each bottleneck areas. 5

CURRENT RESEARCH

The paper here tried to examine different ways that can help in measuring the mixed types of variability. Initially, the first step was to develop a process map that can help in understanding in details the different activities that are carried in every process. Production line of National Biscuits and Confectionary Company (NBCC) in Saudi Arabia was chosen. The factory has 15 production lines that producing about 60 products of biscuits, wafers, chips, and popcorn. The experiment was held in NBCC in one of biscuit production lines. The figures are based on commissioning of 20 shifts (shift =12 hours) with producing 5 different types of biscuit. The model will include three steps in developing the research methodology. The steps are developing process mapping as shown in figure 1 that will help in understanding the tasks undertaken in each process and define value and none-value activities. Then, creating and running simulation model for help to measure the level of variability in each workstation. As (Ardon-Finch J.P. et al., 2008) mentioned that the simulation system is applicable because its flexible in term of modelling flow lines length and allowing number of variables in order to contribute over all variability for individual workstations. The efficiency level is clearly shown in table 1 and figure 2.

Work station Avg Time (min) Efficiency% Flour/Sugar silo 20 97 Dough mixing 13 98 Dough cutter 2 99 Dough laminator 5 99 Cutter roller 2 99 Baking 5 95 Cooling conveyor 5 93 Packing machine 1 0.1 88 Packing machine 2 0.1 89 Packaging 1 0.02 92 Packaging 2 0.02 92 Table1. Biscuit line simulation model figures

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Recycle % 0 0 1 1 1 3 5 8 9 6 6

Scrap% 3 2 0 0 0 2 2 4 2 2 2


Figure 1: Biscuit line process mapping

Figure 2: biscuit production line efficiency

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6 CONCLUSION The paper defined the characteristics of food processing system. That leaded paper to highlight some types of variability in food processing system. Thus, after highlighted the factors might affect with food processing, the initial model was implemented for biscuit production line as a case study in order explain how we can identify bottleneck areas and find out what factor may affected for each area. The model includes three steps lean tool process mapping and simulation model. Table 1 clearly shows that some areas are considerable as high uncertainty areas such as baking, cooling, packing, and packaging areas. Thus, the paper needs to focus more in these areas and investigate the level of variability. The future work might use some of artificial intelligence techniques in order to reduce level of variability in each working area. REFERENCES AKKERMAN, R. & VAN DONK, D. P. (2009) Product mix variability with correlated demand in twostage food manufacturing with intermediate storage. International Journal of Production Economics, 121, 313-322. ARDON-FINCH J.P., STOCKTON D & KHALIL, R. (2008) Walk cycle design for flexible manpower lines. International Journal of Computer Integrated Manufacturing, 46, 29272943. CORTI, D., POZZETTI, A. & ZORZINI, M. (2006) A capacity-driven approach to establish reliable due dates in a MTO environment. International Journal of Production Economics, 104, 536554. DAS, S. K. & ABDEL-MALEK, L. (2003) Modeling the flexibility of order quantities and lead-times in supply chains. International Journal of Production Economics, 85, 171-181. FRANSOO, J. & WOUTERS, M. (2000) Measuring the bullwhip effect in the supply chain. Supply Chain Management: An International Journal, 5, 78-89. GERMAIN, R., CLAYCOMB, C. & DRÖGE, C. (2008) Supply chain variability, organizational structure, and performance: The moderating effect of demand unpredictability. Journal of Operations Management, 26, 557-570. HOPP, W. & SPEARMAN, M. (2001) Factory Physics, New York, Irwin/McGraw-Hill Press. KHALIL, R. (2005) Predicating the effect of variability on the efficiency of flow processing system. Lean Engineering Leicester De Montfort University NELSON, R., KOKIC, P., CRIMP, S., MEINKE, H. & HOWDEN, S. M. (2009) The vulnerability of Australian rural communities to climate variability and change: Part I--Conceptualising and measuring vulnerability. Environmental Science & Policy, 13, 8-17. SOMAN, C. A., VAN DONK, D. P. & GAALMAN, G. (2004) Combined make-to-order and maketo-stock in a food production system. International Journal of Production Economics, 90, 223235. VAN DER VORST, J. G. A. J., BEULENS, A. J. M. & VAN BEEK, P. (2000) Modelling and simulating multi-echelon food systems. European Journal of Operational Research, 122, 354-366. VAN DONK, D. P. (2001) Make to stock or make to order: The decoupling point in the food processing industries. International Journal of Production Economics, 69, 297-306. VAN WEZEL, W., VAN DONK, D. & GAALMAN, G. (2006) The planning flexibility bottleneck in food processing industries. Journal of Operations Management, 24, 287-300. ZORZINI, M., CORTI, D. & POZZETTI, A. (2008) Due date (DD) quotation and capacity planning in make-to-order companies: Results from an empirical analysis. International Journal of Production Economics, 112, 919-933.

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Advances in Manufacturing Technology XXVI This volume comprises the complete proceedings of the 10th International Conference on Manufacturing Research held at the University of Aston in September 2012. This is the latest in a series of research meetings that were first convened in 1985. Edited by Tim Baines, Ben David Clegg Harrison and and David Ben Harrison Clegg, and endorsed by the Consortium of Manufacturing Engineering Heads, this book represents leading edge, state-of-the-art research in the area of systems, production and manufacturing engineering and management. This volume will be of interest to practising systems, industrial and manufacturing engineers and researchers who share an interest in and commitment to the development and implementation of new knowledge, new ideas and new thinking in manufacturing.

ISBN 9781905866601