•Disruptions require a rapid supply chain reconfiguration to maintain viability.•Viability like resilience requires a comprehensive comparison of reconfigurations.•Process capability analysis has ...been adapted to a Supply Chain Resilience Analysis.•Relevant metrics have been merged into a Supply Chain Resilience Index.•Approach has been successfully validated for an automotive network.
Unpredictable disruptions of the supply chain, as they have been caused by the Covid-19 pandemic, require a rapid adaptation of the supply chain, i.e., the reconfiguration of processes and structures to re-establish resilience and maintain viability. Promising reconfigurations need to be identified and assessed regarding anticipatable supply chain performance and costs. Nevertheless, a comprehensive comparison of all potential reconfigurations is difficult as several objectives need to be aligned. To support a rapid preselection of the most promising ones, this paper presents the novel approach of a Supply Chain Resilience Analysis (SCRA), which allows to quantitatively evaluate the effectiveness and efficiency of supply chain reconfigurations under disruption to ensure long-term recovery. Key concept of the SCRA is the combination of all relevant metrics into a single Supply Chain Resilience Index (SCRI) that builds upon an adapted process capability index (PCI). The PCI is usually applied in quality management of production processes to assess if a process adheres to specified limits of quality characteristics. In combination with a digital twin of the supply chain, the SCRA methodology can be applied for an automatic pre-selection of supply chain reconfigurations. For verification and validation of the developed methodology and its index, the presented methodology has been applied in a use case of an automotive supply chain.
While six sigma quality has long been achieved in other industries, it is rarely seen in the pharmaceutical sector. However, consumers and patients deserve six sigma quality pharmaceuticals with ...minimal risks of shortages or recalls. We propose that the future of pharmaceutical quality is six sigma, meaning that no more than 3.4 defects occur per million opportunities. We discuss the path to get there, including economic drivers, performance-based regulation, Quality by Design, advanced manufacturing technologies, and continuous improvement and operational excellence. This article outlines an ambitious goal and is intended to be thought-provoking in spite of the challenging path to get there. This goal is envisioned because it is in the best interest of patients and consumers and is realizable with continued advances and investments in science and technology. The fundamental destination of pharmaceutical quality has been long envisioned: a maximally efficient, agile, flexible pharmaceutical manufacturing sector that reliably produces high quality drugs without extensive regulatory oversight.
Purpose: The central purpose of the study is to model the process capability of drift-inherent manufacturing processes by testing the efficacy of a novel approach that filters trend from raw process ...data before applying statistical process control tools. A secondary aim was to ascertain the intrinsic capability of the process following the filtering. Design/Methodology/Approach: Specifically, the study focused on processes in a nail-wire drawing and tested a method for analysing data from naturally-drifting processes that involves filtering trends from data before applying appropriate tools to verify the state of statistical control and capability of the process. The physical foundation for this work is based on data collected from a nail-wire drawing process A total of 250 data points were gathered over 50 days in two successive instances of 125 points, each spanning 25 days. Data were checked for normality followed by mathematical conditioning to filter out the wear trend before analysis by normal statistical process capability and control chart procedures. Findings: Results show that the proposed method is effective for tracking hidden effects in steadily drifting processes such as those associated with wear. After filtering, the data is found to fall within product specifications, though robust statistical control was still required through appropriate measures. Research Limitation: To investigate the intrinsic nature of the process outside of the process, material wear is assumed to be the sole source of the inherent drift. In processes where several sources of inherent drift are present, this may pose a problem. Additionally, the study focused on just one plant; however, data from other similar plants will be needed to buttress the findings and widen the scope of applicability of the findings. Practical implication: The competitive pressures of today’s marketplace are increasingly forcing companies to place premium emphasis on product quality while aiming at the lowest costs possible. The study recommends continuous and sustained efforts to reduce variation in manufacturing processes to brighten firms’ competitive survival. Social implication: The study will bring new knowledge to metal product manufacturers that can help them deliver high-quality products and value for money to consumers. Originality / Value: New insights afforded by the study’s approach include revelations of otherwise hidden measurement errors as well as undersized finishing-die. Any other out-of-control occurrences can then be more easily tracked and identified and root-cause analysis applied to eliminate them. This is a practical study that seeks to develop an innovative way to monitor the quality of processes whose tracking is made difficult by inherent drift. The easy-to-adopt methodology can be implemented by metal product manufacturers grappling with drift-inherent processes.
Process capability analysis is the main tool of statistical process control. It is used for the ongoing monitoring of product compliance with imposed requirements. The main objective and novelty of ...the study were to determine the capability indices for a precision milling process of AZ91D magnesium alloy. Machining was performed in terms of variable technological parameters and using end mills with protective TiAlN and TiB
coatings intended for the machining of light metal alloys. The Pp and Ppk process capability indices were determined based on the measurements of the dimensional accuracy of the shaped components that were taken on a machining centre with a workpiece touch probe. Obtained results demonstrated that the type of tool coating and variable machining conditions had a significant impact on the machining effect. The selection of appropriate machining conditions enabled a terrific level of capability to be achieved at a tolerance of 12 µm, several times lower than under unfavourable conditions where the tolerance was up to 120 µm. Improvements in process capability are mainly achieved by adjusting the cutting speed and feed per tooth. It was also shown that process estimation based on improperly selected capability indices might lead to an overestimation of the actual process capability.
Today, hybrid manufacturing technology has drawn significant interests from both academia and industry due to the capability to make products in a more efficient and productive way. Although there is ...no specific consensus on the definition of the term 'hybrid processes', researchers have explored a number of approaches to combine different manufacturing processes with the similar objectives of improving surface integrity, increasing material removal rate, reducing tool wear, reducing production time and extending application areas. Thus, hybrid processes open up new opportunities and applications for manufacturing various components which are not able to be produced economically by processes on their own. This review paper starts with the classification of current manufacturing processes based on processes being defined as additive, subtractive, transformative, joining and dividing. Definitions of hybrid processes from other researchers in the literature are then introduced. The major part of this paper reviews existing hybrid processes reported over the past two decades. Finally, this paper attempts to propose possible definitions of hybrid processes along with the authors' classification, followed by discussion of their developments, limitations and future research needs.
In the face of increased competition and globalization, supply chain management has become a crucial aspect of securing competitive advantage. Within this, the quality offered by suppliers is vital. ...Thus, in this paper, we develop a model to select the best supplier based on process quality from the perspective of the buyer. We first employ the process capability index
, which can provide an exact measure of process yield, to evaluate the process quality of suppliers. However,
must be estimated from preliminary samples or obtained subsamples. This increases uncertainty and can lead to miscalculation. To ensure the reliability of assessment, we derive the lower confidence limit of
to serve as a standard of process quality assessment and construct a process capability analysis chart to select the best supplier. The chart also provides recommendations for process improvement to serve as a reference for suppliers with poor performance. Finally, we present two real-world case studies to demonstrate the practical applicability of the proposed method.
The need for improved productivity without sacrificing quality, which is in line the prime target of many manufacturing industries. The aim of this study is to investigate the causes of production ...variation: a case study of the rail manufacturing industry, South Africa. In this study, the six-sigma Define, Measure, Analyse, Improve and Control (DMAIC) phases were applied to enhance the process capability (long term) in the production of bolster compression springs in the main line of bogie secondary suspension system. In every phase of DMAIC method, a combination of both qualitative and quantitative techniques was utilized. First, process capability index Cpk of the current process was computed which was found less than 1. The results obtained indicated that the process capability index values were found to be 1 after the improvement phase. Hence, significant improvement was achieved in the area of reduction in process variation and product quality after taking corrective actions. From outcomes of the study, it can be concluded that process performance of a train manufacturing plant can be improved significantly by implementing six-sigma DMAIC methodology. The novelty of this study lies in the fact that the implementation of the six-sigma DMAIC phases to enhance the process capability (long term) and minimise variations in the production of bolster compression springs has not be sufficiently highlighted by the existing literature.
This article summarizes experimental, theoretical, and computational assessments performed to understand the effect of filling and suck-back cycle factors on fluid behaviors that increase the ...propensity for filling needle clogging. Product drying under ambient conditions decreased considerably when the liquid front was altered from a droplet or meniscus at the needle tip to a point approximately 5 mm inside the needle. Minimizing the variation in size of product droplet formed after the fill cycle is critical to achieve a uniform meniscus height after the suck-back cycle. Several factors were found to contribute to droplet size variability, including filling and suck-back pump speed, suck-back volume, and product temperature. Filling trials and the computational fluid dynamics simulations showed that product meniscus stability during the suck-back cycle can be improved by reducing the suck-back flow rate. The computational fluid dynamics simulations also showed that a decrease in contact angle had the greatest effect in reducing meniscus stability. As the number of filling line stoppages increases, the product buildup at the needle increases. The interaction between stoppages and the number of dispenses between stoppages was established to minimize product buildup at the filling needle. Improved suck-back control was shown to improve process capability of large-scale batches.
Capability indices are the most common tools in process capability analysis, measuring how much the product meets the costumer expectations. One type of capability indices are loss-based indices that ...consider the cost of the difference between the product characteristic and its target value. In this work, we apply an asymmetric loss function to construct a new loss-based capability index for non-normal processes allowing a more customized way of considering the costs in capability analysis. The performance of the proposed capability index is studied by simulation results. Three real examples are given to show the utilization of the proposed index.
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