This paper provides a literature review on zero defect manufacturing based on the content analysis performed for 280 research articles published from 1987 to 2018 in a variety of academic journals ...and conference proceedings. The review summarises the state-of-the-art, highlights shortcomings and further directions in research. Accordingly, we investigated how zero defect manufacturing was implemented and evaluated the main research patterns in the sample by analysing key factors. Based on the extensive review of the zero defect manufacturing literature, we identified and highlighted four distinctive strategies based on overarching themes for zero defect manufacturing, i.e. detection, repair, prediction, and prevention. Evaluation of current research and descriptive analysis highlighted six major shortcomings of current research in zero defect manufacturing: (i) focus on a single strategy instead of a holistic approach for global optima; (ii) certain industries are under-researched; (iii) full potential of industry-academia collaboration is not achieved; (iv) not enough focus on the beginning of manufacturing lifecycle; (v) cost-benefit comparative analysis is not evident; (vi) standard and clear definition of terms are missing. Finally, we presented four further directions in which an advance of the topic would stimulate scholarly and practical needs: (i) shift from local to global solutions; (ii) investigate pros and cons; (iii) role of people and human activities in manufacturing; (iv) new business models for zero defect manufacturing.
The literature on energy management in manufacturing is rapidly growing. Since the literature is also quite fragmented, we believe that the time has come to delve into current knowledge in the ...research field to provide directions for policy makers and guidance for future research. To achieve this, we present a detailed analysis of the research literature on energy management in manufacturing, now encompassing 365 articles published from 1995 to 2015 in a variety of academic journals. Six main lines of research related to energy management appear in the area of the study: (i) drivers and barriers, (ii) information and communication technologies, (iii) strategic paradigms, (iv) supporting tools and methods, (v) manufacturing process paradigms, and (vi) manufacturing performances in the trade-off. Thus, a framework is derived inductively based on a comprehensive and systematic analysis of the literature to describe the dynamic process of energy management in manufacturing. The review and the proposed framework might be useful for both academicians and practitioners, as the study raises central theoretical and managerial questions as well as providing suggestions for further research on this important yet complex topic.
•We present a detailed analysis of the research literature on energy management in manufacturing.•The analysis encompasses 365 articles published from 1995 to 2015 in a variety of academic journals.•Six main lines of research related to energy management emerge in this area of study.•A framework is derived inductively to describe the dynamic process of energy management in manufacturing.•The framework could be of use in guiding future research on this important yet complex topic.
The paper investigates the effects of production scheduling policies aimed towards improving productive and environmental performances in a job shop system. A green genetic algorithm allows the ...assessment of multi-objective problems related to sustainability. Two main considerations have emerged from the application of the algorithm. First, the algorithm is able to achieve a semi-optimal makespan similar to that obtained by the best of other methods but with a significantly lower total energy consumption. Second, the study demonstrated that the worthless energy consumption can be reduced significantly by employing complex energy-efficient machine behaviour policies.
•The paper aims at introducing the way toward eco-factories of the future.•A focus group study is conducted with 22 European experts.•We highlight research directions and solutions for eco-factories ...in the next 20 years.•Human participants in a manufacturing system can foster change toward eco-factories.•Firm-intern characteristics determine successful transition and competitiveness.
The integration of environmental sustainability and eco-efficiency has been recognized as a means to foster economic and environmental performance, increase competitiveness and use it as a lever to spur innovation. Besides integrating green technologies in the manufacturing system, putting environmental goals on the company agenda, and pursuing green norms and directives, the question is: quo vadis eco-factory? Based on a focus group study with 22 European experts and high-level representatives from industry, policy-makers and academia, we raised the question of what might be the research directions and solutions for eco-factories in the next 20years. Our two major findings suggest that (i) research should more focus on the opportunities that human participants in a manufacturing system can foster change toward eco-factories and that (ii) firm-intern characteristics like enabling environmental capability, organization and structure will likely determine upon successful transition and increased competitiveness.
Quality is a key aspect in the era of Industry 4.0. Zero-defect manufacturing (ZDM) as the latest quality assurance approach. It can be implemented in two different approaches: the product-oriented ...and the process-oriented ZDM. It is important to know how and when to consider adopting one approach over the other. To achieve that there is the need for analyzing the differences of the two ZDM approaches. However, the current literature lacks a detailed analysis and comparison of these two approaches to ZDM implementation. Earlier studies on the topic have adopted one of these approaches over the other without evaluating how it fits with specific cases. The literature of the last decade indicates a movement towards product-oriented approaches, but it has not shown proof why product oriented was used over process oriented. Guided by these gaps, this research work creates a model for quantifying the effects of the implementation of both the product-oriented and process-oriented ZDM approaches. The proposed model considers all the critical parameters that affect the problem and serves as an assisting tool to engineers during the design or re-configure manufacturing systems, for choosing the most efficient ZDM approach for their specific cases. The robustness of the model was analyzed using the design of experiments method. The results from both the designed experiments and an industrial use case illustrate that in most cases, product-oriented ZDM performs better than the process-oriented approach. Nevertheless, in our analysis, we also highlight strong interactions between some factors that make the selection between product-oriented and process-oriented ZDM difficult and complex.
The successful development and deployment of adequate sustainable manufacturing strategies are still open issues and of utmost interest for research and practice. Guided by this particular challenge, ...we investigate the significance of organisational change management for sustainable competitiveness in manufacturing. By using six case studies from the Lombardia region in Italy and basing our research on the theoretical constructs of competitive aggressiveness and organisational change, we discover four archetypes of companies that show an increasing sustainable competitiveness with an increasing formalism and persistence in organisational change. Our findings suggest that change management practices are conditional hypothesis for creating competitive advantage through sustainability, and implementation gaps do hinder companies in realising the full potential. The study offers guidance to stakeholders, on how change management actions may potentially affect company performance in the manufacturing sector, as well as providing direction on the impact improved planning and leadership instances can have on the sustainability performance.
The approach to achieving zero defects by using Industry 4.0 technologies is what constitutes Zero Defect Manufacturing (ZDM). However, its implementation is not a simple task since it requires ...careful design and new methods. The current literature on zero defect manufacturing lacks methods, tools, and guidelines for a successful shift toward ZDM implementation in manufacturing facilities aligned with the recent advancements in enabling technologies as well as data-driven approaches and models. In this paper, we propose a step-by-step practical implementation guide for achieving zero defects in modern manufacturing facilities. While considering the links with various ZDM strategies, this guide can be applied to both new and existing production systems. The proposed method has been tested with an industrial example that concerns the manufacturing of an electronics board in the case of a European semiconductors manufacturer. We demonstrated, using this industrial example, that the multi-criteria approach that has been proposed may effectively evaluate the potential risk of defects for each stage of manufacturing and the extent to which ZDM adoption is required.
In the competitive market of manufacturing, quality is a criterion of primary importance in order to win market share. Quality improvement must be coupled with performance point of view. Lean ...Manufacturing, Six Sigma, Lean Six Sigma, Total Quality Management, Theory of Constraints, and their combination are philosophies dedicated to this goal. This study is a literature review on the implementation of these philosophies to improve quality of processes and products in a system, and also covers the commonalities and differences with Zero Defect Manufacturing (ZDM) philosophy. In this study, 45 articles have been analyzed. These articles have been selected by a research on several scientific libraries with specific keywords. The methodology is based on a list of information extracted from each paper. The data searched are on the tool selections, critical factors of implementations and the benefits obtained from them. Based on the review and analysis of the literature and practices, we provide the top 10 main components of the tools used for quality improvement, enabling factors, benefits, and barriers to implementation. Moreover, we present and discuss categorization of quality improvement methods and the way toward ZDM. The need of standardized toolkits for different levels of maturity in quality management systems and a better education have been enlightened. Thanks to technological improvement in information flow management, ZDM seems close to be achieved even though some new risks and wastes have to be taken care of within the implementation.
To provide direction and advice for future research on Industry 4.0 maintenance, we conducted a comprehensive analysis of 344 eligible journal papers published between 2013 and 2022. Our systematic ...literature review identifies key trends in advanced maintenance techniques and the consolidation of traditional maintenance concepts, which are driven by the increasing adoption of Industry 4.0 technologies and the need to optimize manufacturing systems' performance and reliability. In light of our findings, we highlight the importance of addressing sustainability factors, human aspects, and the implementation of environmental KPIs in future research. Building upon these insights, we introduce the Maintenance 5.0 framework, which emphasizes the integration of human-centered and AI-driven strategies for achieving efficient and sustainable maintenance in Zero-Defect Manufacturing (ZDM) systems. We propose a novel framework that links traditional and advanced maintenance policies for small and medium-sized enterprises (SMEs) to facilitate the adoption of Industry 4.0 technologies in the maintenance field. This work underscores the need for future research to bridge the gap between these policies, enabling a seamless transition for SMEs towards Industry 4.0 maintenance practices, while fostering sustainable and socially responsible operations.
•Investigate key factors of current research on Industry 4.0 maintenance.•Provide a comprehensive and systematic review method for the state-of-the-art analysis.•Provide an overview and classification of the literature on Industry 4.0 maintenance.•Design a framework to map the important constructs in Industry 4.0.•Set the research agenda for future work and directions in the domain of maintenance.
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