Applying Lean and MES toward Smart Manufacturing - Application of a Thai Automotive Company

Chinglung Chang

Abstract


Lean, manufacturing execution systems (MES), and Smart manufacturing are of different disciplines. The objective of this study is to explore the integrated application of these three disciplines. This study conducts a field observation and interview of a selected car wheel frame manufacturer in Thailand to generate five applications. The extended technology acceptance model (TAM2) and overall equipment effectiveness (OEE) are applied to verify the effectiveness of the case company. This study’s results show that MES facilitates production transparency and increases the firm’s ability to focus on value-added activities. Employees can predict potential issues and proactively eliminate them. Improved transparency also enhances employee ownership, enabling employees to independently problem solve and implement improvements before an issue arises.


Keywords


extended Technology Acceptance Model; Lean production; MES; Smart manufacturing

Full Text:

PDF

References


American National Standards Institute. 2005. ANSI/ISA-95 Enterprise-Control System Integration Part 3: Activity Models of Manufacturing Operations Management. International Society of Automation.

Bittencourt, V. L., Alves, A. C., & Leão, C. P. 2020. “Industry 4.0 triggered by Lean Thinking: insights from a systematic literature review”. International Journal of Production Research, Ahead-of-Print, 1-5.

Choi, B. and B. Kim. 2002. “MES (Manufacturing Execution System) Architecture for FMS Compatible to ERP (Enterprise Planning System).” International Journal of Computer Integrated Manufacturing 15 (3): 274–284.

Davis, J., T. Edgar, J. Porter, J. Bernaden, and M. Sarli. 2012. “Smart Manufacturing, Manufacturing Intelligence and Demand-Dynamic Performance.” Computers and Chemical Engineering 47: 145–156.

Deif, A. M. 2012. “Dynamic Analysis of a Lean Cell under Uncertainty.” International Journal of Production Research 50 (4): 1127–1139.

Ehret, O., and P. Cooke. 2010. “Conceptualising Aerospace Outsourcing: Airbus UK and the Lean Supply Approach.” International Journal of Technology Management 50 (3/4): 300–317.

Fang, Ji, G. Q. Huang, and Z. Li. 2013. “Event-Driven Multi-Agent Ubiquitous Manufacturing Execution Platform for Shop Floor Work-In-Progress Management.” International Journal of Production Research 51 (4): 1168–1185.

Filhoa, M. G., G. M. D. Gangaa, and A. Gunasekaranb. 2016. “Lean Manufacturing in Brazilian Small and Medium Enterprises: Implementation and Effect on Performance.” International Journal of Production Research 54 (24): 7523–7545.

Gattiker, T. 2007. “Enterprise Resource Planning (ERP) Systems and the Manufacturing–Marketing Interface: An Information Processing Theory View.” International Journal of Production Research 44 (17): 2895–2917.

Hodge, G. L., K. Goforth Ross, J. A. Joines, and K. Thoney. 2011. “Adapting Lean Manufacturing Principles to the Textile Industry.” Production Planning and Control 22 (3): 237–247.

Houyou, A. M., H.-P. Huth, H. Tresk. 2012. “Agile Manufacturing: General Challenges and an Iot@Work perspective.” 2012 IEEE 17th Conference on Emerging Technologies & Factory Automation (ETFA): 1–7.

Huang, G., Y. F. Zhang, and P. Jiang. 2008. “RFID-Based Wireless Manufacturing for Real-Time Management of Job Shop WIP Inventories.” International Journal of Advanced Manufacturing Technology 23 (4): 469–477.

Imai, M. 2012. Gemba Kaizen: A Common Sense Approach to Continuous Improvement Strategy. 2nd ed. New York: McGrawHill Professional.

Islam, M. and A. Karim. 2011. “Manufacturing Practices and Performance: Comparison Among Small-Medium and Large Industries.” International Journal of Quality and Reliability Management 28 (1): 43–61.

Karim, M. A., A. J. R. Smith, S. K. Halgamuge, and M. M. Islam. 2008. “A Comparative Study of Manufacturing Practices and Performance Variables.” International Journal of Production Economics 112 (2): 841–859.

Leea, S. M., S. G. Hongb, P. Katerattanakulc, and N. R. Kimb. 2012. “Successful Implementations of MES in Korean Manufacturing SMEs: An Empirical Study.” International Journal of Production Research 50 (7): 1942–1954.

Legris, P., J. Ingham, and P. Collerette. 2003. “Why Do People Use Information Technology? A Critical Review of the Technology Acceptance Model.” Information and Management 40 (3): 191–204.

Lu, J.-C., and T. Yang. 2015. “Implementing Lean Standard Work to Solve a Low Work-In-Process Buffer Problem in a Highly Automated Manufacturing Environment.” International Journal of Production Research 53 (8): 2285–2305.

Martinez-Olvera, C. 2009. “Reference Model of the Manufacturing Execution Activity in Make-To-Order Environments.” International Journal of Production Research 47 (6): 1635–1659.

McClellan, M. 1997. Applying Manufacturing Execution Systems. Florida: St. Lucie Press.

MESA International. 1994. MES Functionalities and MRP to MES Data Flow Possibilities. Pittsburgh: MESA International.

Mesut, Y., and A. Elif. 2007. “Production Smoothing in Just-In-Time Manufacturing Systems: A Review of the Models and Solution Approaches.” International Journal of Production Research 45 (16): 3579–3597.

Mullin, R. 1998. “Inching Its Way To ‘Plug and Play’.” Chemical Week 160 (20).

Nakamura, T., L. J. B. Vlacic, and Y. Ogiwara. 1996. “Multiattribute-based CIE/CIM Implementation Decision Model.” Computer Integrated Manufacturing Systems 9 (2): 73–89.

Ohno, T. 1988. Toyota Production System: Beyond Large-Scale Production. New York: Productivity Press.

Pakdila, F., and K. M. Leonard. 2017. “Implementing and Sustaining Lean Processes: The Dilemma of Societal Culture Effects.” International Journal of Production Research 55 (3): 700–717.

Pherson, T. 2006. “Overall Equipment Effectiveness and Real-Time Visual Management Critical Lean Tools.” Intelligent Manufacturing Solutions June 2006: 1-18.

Rocha-Lona, L., J. A. Garza-Reyes, and V. Kumar. 2013. Building Quality Management Systems: Selecting the Right Methods and Tools. Boca Raton, FL: Productivity Press, CRC Press, Taylor & Francis.

Sahoo, A. K., N. K. Singh, R. Shankar, and M. K. Tiwari. 2008. “Lean Philosophy: Implementation in a Forging Industry.” The International Journal of Advanced Manufacturing Technology 36: 451–462.

Schuh, G., R. Anderl, J. Gausemeier, M. T. Hompel, and W. Wahlster. eds. 2017. Industrie 4.0 Maturity Index: Managing the Digital Transformation of Companies. Utz, Herbert.

Shahin, M., Chen, F. F., Bouzary, H., & Krishnaiyer, K. 2020. “Integration of Lean practices and Industry 4.0 technologies: Smart manufacturing for next-generation enterprises”. The International Journal of Advanced Manufacturing Technology, 107(5–6), 2927–2936.

Shipp, S. S. 2012. “Emerging Global Trends in Advanced Manufacturing.” Emerging Global Trends in Advanced Manufacturing. Institute for Defense Analysis. Retrieved April 2016.

Shrouf, F., J. Ordieres, and G. Miragliotta. 2014. “Smart Factories in Industry 4.0: A Review of the Concept and of Energy Management Approached in Production Based on the Internet of Things Paradigm.” 2014 IEEE International Conference on Industrial Engineering and Engineering Management: 697–701.

Steege, P. 1996. “Overall Equipment Effectiveness in Resist Processing Equipment.” In IEEE/SEMI 1996 Advanced Semiconductor Manufacturing Conference and Workshop. Theme-Innovative Approaches to Growth in the Semiconductor Industry. ASMC 96 Proceedings. IEEE: 76–79.

Strauss, A., and J. M. Corbin. 1990. Basics of Qualitative Research: Grounded Theory Procedures and Techniques. Sage Publications, Inc.

Sullivan, W. G., T. N. McDonald, and E. M. Van Aken. 2002. “Equipment Replacement Decisions and Lean Manufacturing.” Robotics and Computer-Integrated Manufacturing 18 (3–4): 255–265.

Tortorella, G., Sawhney, R., Jurburg, D., de Paula, I. C., Tlapa, D., & Thurer, M. 2020. “Towards the proposition of a Lean Automation framework”. Journal of Manufacturing Technology Management 51(8): 2145-2156.

Womack, J., Jones, D. T., and Roos, D. 1990. “The Machine That Changed the World: The Story of Lean Production”. Rawson Associates.

Yang, T., C.-H. Hsieh, B.-Y. Cheng. 2011. “Lean-Pull Strategy in a Re-Entrant Manufacturing Environment.” International Journal of Production Research 49 (6): 1511–1529.

Yin, R. K. 2003. “Application Research: Design and Methods.” Sage Publications, Inc., California, USA.


Refbacks

  • There are currently no refbacks.


_________________________________________________________

Licença Creative Commons
This journal is licenced under a Creative Commons LicenseCreative Commons - Atribuição-CompartilhaIgual 4.0 Internacional.

Contact: lean@contato.ufsc.br
Tel: +554837217062

EPS - Departamento de Engenharia de Produção e Sistemas

CTC - Centro Tecnológico

UFSC - Universidade Federal de Santa Catarina

Caixa Postal 476 - Campus Universitário - Trindade