Review
Engineering, Industrial
Kaustav Kundu, Martin J. Land, Alberto Portioli-Staudacher, Jos A. C. Bokhorst
Summary: This study aims to develop the best Order Review and Release (ORR) method for flow shops. The results show that performance in flow shops can be significantly improved by applying the right combination of workload measures, load balancing, and order dispatching.
FLEXIBLE SERVICES AND MANUFACTURING JOURNAL
(2021)
Article
Chemistry, Multidisciplinary
Paolo Renna
Summary: The reduction in emissions and increasing energy costs drive companies to find solutions to reduce energy consumption in production systems. One proposed approach is shutting down machines in idle state, which does not affect production processes and can be applied in various manufacturing fields. This paper proposes switch-off policies in manufacturing systems under a workload control system, considering queue length and workload evaluation. Simulation models have been developed to test these policies, and the results show that the switch policies significantly reduce on/off activities and ensure lower energy consumption.
APPLIED SCIENCES-BASEL
(2023)
Article
Engineering, Industrial
Andreas Kuhnle, Marvin Carl May, Louis Schaefer, Gisela Lanza
Summary: In the age of Industry 4.0, manufacturing is characterized by high product variety and complex material flows, requiring adaptive production planning systems. This paper investigates methods of explainable reinforcement learning in production control, presenting an approach that combines high prediction accuracy and explainability to generate understandable control strategies. The results are demonstrated on a real-world system from semiconductor manufacturing in a simulated approach.
INTERNATIONAL JOURNAL OF PRODUCTION RESEARCH
(2022)
Article
Engineering, Industrial
Fabiana Dafne Cifone, Alberto Portioli Staudacher
Summary: The integration of traditional lean management and Industry 4.0, known as Lean 4.0, is gaining attention in academia and among practitioners. A study using Bayesian network analysis found that Lean 4.0 enhances company performance regardless of production strategies, but companies with a repetitive strategy see greater improvements. This suggests that the application space of Lean 4.0 may be similar to traditional lean, especially for companies with repetitive operations.
JOURNAL OF MANUFACTURING TECHNOLOGY MANAGEMENT
(2022)
Article
Green & Sustainable Science & Technology
Martin Kurdve, Monica Bellgran
Summary: Utilizing the Green Performance Map as a green lean environmental improvement tool in manufacturing and pharma industry has proven successful in increasing circularity on the shop floor and improving resource efficiency and overall environmental behavior through the integration of the waste hierarchy model.
JOURNAL OF CLEANER PRODUCTION
(2021)
Article
Management
Juliana Keiko Sagawa, Allan Freitas Oliveira, Gasper Music, Martin J. Land, Arthur Sarro Maluf
Summary: Workload control relies on order release and capacity adjustments to regulate manufacturing throughput. Integrated input-output control is rarely studied. A closed-loop integrated model with automatic feedback control is proposed, where order release and capacity decisions are continuous functions of the shop floor state. The model was tested in scenarios of unbalanced work in process and demand fluctuations, showing effective control and cost-saving capacity policies. The proposed approach combines the strengths of closed-loop control models and discrete-event simulation models. Rating: 9/10
EUROPEAN JOURNAL OF OPERATIONAL RESEARCH
(2023)
Article
Engineering, Industrial
Kaustav Kundu, Matteo Rossini, Federica Costa
Summary: This paper examines the advantages of adopting lean techniques in a highly customized environment, specifically in companies using a make-to-order and make-to-stock hybrid strategy. The study shows that implementing workload control, as part of a lean project, in a furniture company can reduce throughput time and improve inventory turnover.
JOURNAL OF MANUFACTURING TECHNOLOGY MANAGEMENT
(2022)
Article
Construction & Building Technology
Dina A. Saad, Mohamed Masoud, Hesham Osman
Summary: A new lean-driven Pull-Batch-based Repetitive Scheduling (PBRS) technique was developed to reduce WIP, time, and cost, utilizing batch- and pull-production lean concepts. It has a built-in multi-objective optimization algorithm and was proven superior in performance through a real case study.
AUTOMATION IN CONSTRUCTION
(2021)
Article
Engineering, Multidisciplinary
Melek Rodoplu, Taha Arbaoui, Alice Yalaoui
Summary: This study introduces new probabilistic constraints and objective functions to address the uncertainty of renewable energy sources in manufacturing industry through probabilistic models, aiming to provide decision-making tools and promote the use of renewable energy sources. Additionally, Mixed Integer Non-Linear Programming models are proposed to integrate the uncertainty of renewable energy sources and tested on a small-size instance for comparison.
APPLIED MATHEMATICAL MODELLING
(2022)
Article
Engineering, Mechanical
Wangming Li, Dong Han, Liang Gao, Xinyu Li, Yang Li
Summary: This paper investigates the integrated production and transportation scheduling problem in hybrid flow shops, proposes an effective solution method, and validates its performance through experiments. The results show that the proposed method is effective.
CHINESE JOURNAL OF MECHANICAL ENGINEERING
(2022)
Article
Engineering, Industrial
Jose Renathoda de Silva Santana, Helio Yochihiro Fuchigami
Summary: This study proposes four mixed integer linear programming (MILP) models to solve the assembly flow shop problem, aiming at minimizing the makespan. The production environment consists of two stages, production and assembly, with the first stage having different machines for manufacturing parts and the second stage for final assembly. The performance measure considered is crucial for industries from various sectors, as it focuses on optimizing production time usage. Statistical analysis using different tools evaluated the performance and efficiency of the mathematical models, with emphasis on performance profiles analysis. Results showed that the mathematical models are efficient, with the position-based model demonstrating the best results for both small and large instances during computational experimentation. All the mathematical models can serve as direct decision-making tools for the production sequencing problem in the studied environment.
INTERNATIONAL JOURNAL OF PRODUCTION RESEARCH
(2023)
Article
Automation & Control Systems
Xiaojun Liu, Chengjin Qiu, Jiahong Shi, Jiasheng Huang, Changbiao Zhu, Zhonghua Ni, Minghao Zhu, Tingyu Liu
Summary: The smart shop floor is the basic unit for intelligent manufacturing, and the digital twin (DT) technology provides model support for shop floor layout, production scheduling, and production simulation. This paper presents a multi-scale, multi-level DT modeling method for production resources, including geometric, physical, behavioral, and rule models. The connection and interaction mechanism is proposed to implement the interaction of different production resources. The feasibility of the method is verified through a micro-assembly shop floor application case, providing guidance for engineers to build reliable and reusable DT models of production resources.
INTERNATIONAL JOURNAL OF ADVANCED MANUFACTURING TECHNOLOGY
(2023)
Article
Mathematics
Varun Tripathi, Somnath Chattopadhyaya, Alok Kumar Mukhopadhyay, Shubham Sharma, Changhe Li, Gianpaolo Di Bona
Summary: The present study aims to develop a methodology for cleaner production management using lean and smart manufacturing in Industry 4.0. The results of two case studies show that the developed methodology can achieve a sustainable production system and problem-solving, while enhancing productivity within limited constraints.
Article
Engineering, Industrial
Nuno O. Fernandes, Matthias Thurer, Mark Stevenson
Summary: This article discusses the importance of workload control and its methods and effects in practical applications. The results of discrete event simulation experiments show that direct workload control can achieve performance levels comparable to other complex methods, and it is more convenient in continuous order release.
INTERNATIONAL JOURNAL OF PRODUCTION RESEARCH
(2022)
Article
Engineering, Industrial
Philipp Neuner, Stefan Haeussler
Summary: An essential task in manufacturing planning and control is to determine when to release orders to the shop floor. This study compares the adapted LUMS-COR model with two approaches from the semiconductor manufacturing literature, showing that the LUMS-COR model yields lower total costs and better performance compared to the other two order release approaches, and is robust across different settings.
INTERNATIONAL JOURNAL OF PRODUCTION RESEARCH
(2021)
Article
Automation & Control Systems
Matteo Rossini, Federica Costa, Guilherme L. Tortorella, Alberto Portioli-Staudacher
INTERNATIONAL JOURNAL OF ADVANCED MANUFACTURING TECHNOLOGY
(2019)
Review
Engineering, Industrial
Kaustav Kundu, Martin J. Land, Alberto Portioli-Staudacher, Jos A. C. Bokhorst
Summary: This study aims to develop the best Order Review and Release (ORR) method for flow shops. The results show that performance in flow shops can be significantly improved by applying the right combination of workload measures, load balancing, and order dispatching.
FLEXIBLE SERVICES AND MANUFACTURING JOURNAL
(2021)
Article
Engineering, Industrial
Fabiana Dafne Cifone, Alberto Portioli Staudacher
Summary: The integration of traditional lean management and Industry 4.0, known as Lean 4.0, is gaining attention in academia and among practitioners. A study using Bayesian network analysis found that Lean 4.0 enhances company performance regardless of production strategies, but companies with a repetitive strategy see greater improvements. This suggests that the application space of Lean 4.0 may be similar to traditional lean, especially for companies with repetitive operations.
JOURNAL OF MANUFACTURING TECHNOLOGY MANAGEMENT
(2022)
Article
Engineering, Industrial
Matteo Rossini, Fabiana Dafne Cifone, Bassel Kassem, Federica Costa, Alberto Portioli-Staudacher
Summary: This paper investigates how manufacturing companies embark upon digital transformation and how being lean might affect it. The findings show the significant role of lean in driving digital transformation, identifying two different digital transformation patterns according to companies' commitment to Lean.
JOURNAL OF MANUFACTURING TECHNOLOGY MANAGEMENT
(2021)
Article
Health Policy & Services
Najla Alemsan, Guilherme Luz Tortorella, Alejandro Francisco Mac Cawley Vergara, Carlos Manuel Taboada Rodriguez, Alberto Portioli Staudacher
Summary: This study proposes a demand forecast model for special nutrition materials and evaluates different inventory management and control systems. Through a case study in a Brazilian public teaching hospital, it is found that implementing the proposed inventory management method can result in savings of up to 33% in stock values.
INTERNATIONAL JOURNAL OF HEALTH PLANNING AND MANAGEMENT
(2022)
Article
Management
Federica Costa, Alberto Portioli-Staudacher
Summary: The paradigm shift towards Industry 4.0 is enhancing human capabilities, with a focus on worker knowledge and labor flexibility. Flexibility in labor is a managerial tool for achieving production and mix flexibility, and for addressing market uncertainty and global competition. Integrating labor flexibility into production planning and control mechanisms can lead to optimized resource allocation and reduced lead times.
OPERATIONS MANAGEMENT RESEARCH
(2021)
Article
Engineering, Industrial
Fabiana Dafne Cifone, Kai Hoberg, Matthias Holweg, Alberto Portioli Staudacher
Summary: Digital technologies, such as advanced analytics, can substantially improve operations by augmenting operational execution and decision-making processes in manufacturing and supply chain management. Identifying digital waste reduction mechanisms provides a structured approach for firms to select the most effective technologies for process improvement activities.
INTERNATIONAL JOURNAL OF PRODUCTION ECONOMICS
(2021)
Article
Engineering, Industrial
Matteo Rossini, Federica Costa, Guilherme Luz Tortorella, Alessia Valvo, Alberto Portioli-Staudacher
Summary: This study empirically tested the association between Lean Automation and operational performance by integrating Lean practices with Industry 4.0 technologies, revealing two core components of Lean Automation: focus on operational stability and streamline optimization. The research also demonstrated a positive correlation between Lean Automation and operational performance, contributing to the understanding of integrating new technologies with Lean Production systems for academics and practitioners.
INTERNATIONAL JOURNAL OF PRODUCTION RESEARCH
(2022)
Article
Engineering, Industrial
Kaustav Kundu, Fabiana Cifone, Federica Costa, Alberto Portioli-Staudacher, Matteo Rossini
Summary: The purpose of this paper is to introduce an original framework for maintenance management plan development, which integrates different World Class Manufacturing (WCM) tools for preventive maintenance. The framework was evaluated through a qualitative study in an Italian company, demonstrating its ease of implementation and acceptance by employees. This study highlights the ability to integrate various WCM-based tools and serves as a starting point for companies new to preventive maintenance.
JOURNAL OF QUALITY IN MAINTENANCE ENGINEERING
(2022)
Proceedings Paper
Computer Science, Information Systems
Federica Costa, Kaustav Kundu, Alberto Portioli-Staudacher
Summary: Traditional market response configurations like MTO and MTS are no longer suitable in today's competitive context, leading companies to transition towards hybrid solutions. Researchers are focusing on flow shop configuration to address bottleneck issues. The choice of control at dispatching level has significant impact on different scenarios and must be carefully considered.
ADVANCES IN PRODUCTION MANAGEMENT SYSTEMS: ARTIFICIAL INTELLIGENCE FOR SUSTAINABLE AND RESILIENT PRODUCTION SYSTEMS, PT V
(2021)
Article
Management
Guilherme Tortorella, Rogerio Miorando, Rodrigo Caiado, Daniel Nascimento, Alberto Portioli Staudacher
Summary: The study found that employee involvement plays a positive mediating role between Industry 4.0 adoption and operational performance improvement in emerging countries' manufacturing sector. The implementation of Industry 4.0 can assist in enhancing employees' continuous improvement awareness and participation.
TOTAL QUALITY MANAGEMENT & BUSINESS EXCELLENCE
(2021)
Article
Business
Guilherme Tortorella, Gopalakrishnan Narayanamurthy, Moacir Godinho Filho, Alberto Portioli Staudacher, Alejandro Francisco Mac Cawley
Summary: The study found that organizations implementing lean services more extensively are more likely to benefit from the impact of COVID-19 on work environments, especially in the case of home office. However, social distancing does not seem to mediate the effects of lean services on quality and delivery performances.
JOURNAL OF SERVICE THEORY AND PRACTICE
(2021)
Article
Management
Guilherme Luz Tortorella, Matteo Rossini, Federica Costa, Alberto Portioli Staudacher, Rapinder Sawhney
Summary: This study investigates the differences in implementation levels of Lean Automation (LA) in manufacturers from emerging and developed economies. It found that the socio-economic context of a company does impact the extent of LA implementation, but with proper management, high levels of implementation are still achievable. Additionally, company characteristics that contribute to higher LA levels may vary between emerging and developed economies, highlighting the importance of understanding the socio-economic specificities of different contexts.
TOTAL QUALITY MANAGEMENT & BUSINESS EXCELLENCE
(2021)
Article
Engineering, Industrial
Alberto Portioli-Staudacher, Federica Costa, Matthias Thurer
INTERNATIONAL JOURNAL OF INDUSTRIAL ENGINEERING COMPUTATIONS
(2020)
Article
Operations Research & Management Science
Federica Costa, Leonardo Lispi, Alberto Portioli Staudacher, Matteo Rossini, Kaustav Kundu, Fabiana Dafne Cifone
OPERATIONS RESEARCH PERSPECTIVES
(2019)