Fiat was among the first companies to adopt a Post-Fordist system in production after its recovery from the 1970 oil crisis. The large-scale deployment of robotics in the production process of Fiat Company was the most significant move to cope with increased competition and demand. In 1972, the company initiated the adoption of FMS so that it could shift to flexible production methods from the Fordistic inflexible mass production systems. The move was considered as the first step towards discontinuity in management and organization involving the shift in planned goals and replacements of procedures supporting operations supervision. The Robogate technology was developed in-house by Fiat Company and used to create flexibility with enhanced product-mix flexibility. Product-mix flexibility is the conferred ability of an organization to produce different products sequentially using the same lines of production. As indicated, the shift from Fordist mass production systems enables a company to reduce tool specificity Continue reading
Production Management Techniques
Concurrent Engineering Vs Traditional (Sequential) Engineering Methods
Traditionally, products were designed and manufactured following the sequential engineering methods, where people from different departments work one after the other on successive phases of development. This method of production is in a linear format. The different steps are done one after another, with all attention and resources focused on that one task. After it is completed it is left alone and everything is concentrated on the next task. The product is first completely defined by the engineering design department, and then the manufacturing department take over and define the manufacturing process, etc. This was a lengthy process, and often led to a lot of design changes as the prototype testing began, due to production problems, delays or design flaws. This is therefore a slow and costly approach, often leading to a low-quality and less competitive product. Concurrent Engineering, sometimes called Simultaneous Engineering or Integrated Product Development (IPD), can be Continue reading
Concurrent Engineering (CE) – Definition, Approaches and Requirements
Introduction to Concurrent Engineering Concurrent engineering (CE) is a method that is used in the product development process. Concurrent Engineering, sometimes called Simultaneous Engineering or Integrated Product Development (IPD), can be defined as a systematic approach to the integrated, concurrent design of products and their related processes, including manufacture and support. It is different than the traditional approach from the product development in which it uses simultaneous, something that sequential, processes. By finishing the tasks in paralelamente, the product development can be obtained more efficiently and in substantial saving in costs. In the traditional approach finishing all the physical manufacture of a prototype before realizing any test, but In the concurrent engineering it allows to design and multiple analyses to happen at the same time, and at different times, before the real unfolding. This multidisciplinary approach accentuates work in equipment with the use of cross-functional equipment, and allows so that Continue reading
Quick Response Manufacturing (QRM) – Meaning, Principles, Benefits, and Drawbacks
Quick Response Manufacturing (QRM) is a strategy which needs to applied throughout the company and whose primary goal is the reduction of lead-time in each and every operation of the company while simultaneously reducing costs and improving quality. QRM can be defined in two contexts: (i) Externally (Customers point of view): QRM means quickly responding to customer needs by designing and producing goods customized to cater those needs. (ii) Internally, QRM stresses on reducing the lead times throughout the organization, leading to lower inventory, better quality, reduced cost, and greater responsiveness. Quick Response Manufacturing (QRM) uses Manufacturing Critical-path Time (MCT) as the metric for measuring the success of QRM processes. MCT is an extension of the concept of lead-time, which is the time from the receipt of order from the customer till the product is delivered to the customer. There are 2 ways of implementing QRM: one is using large Continue reading
Work Study – Meaning, Importance and Procedure
Work Study forms the basis for work system design. The purpose of work design is to identify the most effective means of achieving necessary functions. Work study aims at improving the existing and proposed ways of doing work and establishing standard times for work performance. Work design involves job design, work measurement and the establishment of time standards and worker compensation. Work Study is encompassed by two techniques -method study and work measurement (time study): Method study is the systematic recording and critical examination of existing and proposed ways of doing work, as a means of developing and applying easier and methods and reducing costs. The main purpose of method study is to eliminate the unnecessary operations and to achieve the best method of performing the operation. Method study is also called methods engineering or work design. Method engineering is used to describe collection of analysis techniques which focus on improving Continue reading
Kaizen – Definition, Meaning, Process, Implementation, Advantages and Disadvantages
What is Kaizen? Japan’s management philosophy has introduced a new creative strategy for competitive success in business, or the so-called “Kaizen” model. The term Kaizen began to receive attention from management experts and scholars around the world when Masaaki Imai published his first book in 1986, “The Key to Japan’s Competitive Success”. Kaizen is a Japanese word with literally mean improvement, taken from words ‘Kai’, which means continuous and ‘zen’ which means improvement. Some translate ‘Kai’ to mean change and ‘zen’ to mean good, or for the better. In the context of Lean manufacturing, kaizen is understood to signify small, incremental, and frequent improvements to a process. Lean philosophy states that the large improvement which just require small amounts of investment and risk. The kaizen main mindset is making process improvements without adding people and space to the process. The more important one is implement the change without spending the Continue reading