A review of frameworks, methods and models for the evaluation and engineering of factory life cycles

Dér, Antal; Hingst, Lennart; Nyhuis, Peter; Herrmann, Christoph

doi:10.1016/j.aime.2022.100083

Cited by 13 publications

(12 citation statements)

References 1 publication

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“…Shorter product lifecycles require production systems to be adapted repeatedly (Nåfors et al, 2017;Löffler, 2011). The overlapping life cycles of products, production technologies and production equipment also lead to a more complex factory planning process (Dér et al, 2022). As the factory planning becomes increasingly complex there is a need for digitalisation like a virtual representation of a factory to increase the competitiveness (Schönsleben et al, 2017;Stark, 2022).…”

Section: Challenges Of Data-driven Factory Planningmentioning

confidence: 99%

Towards the digital factory twin – design guide for creating a 3D factory model

Disselkamp,

Grothe,

Lick

et al. 2024

Proc. Des. Soc.

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Shorter product lifecycles are also leading to even shorter planning times for the development of production systems. In most companies, the restructuring is carried out within a few weeks during the annual holidays. Digital tools such as simulations or the digital twin are used to avoid delaying the restructuring during this time. However, the introduction of a 3D model of the factory is often the first point of failure for many companies. This article proposes a six-step process model that enables the transition from 2D to 3D design. The process model was evaluated in a research project.

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Section: Challenges Of Data-driven Factory Planningmentioning

confidence: 99%

Towards the digital factory twin – design guide for creating a 3D factory model

Disselkamp,

Grothe,

Lick

et al. 2024

Proc. Des. Soc.

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“…Zero impact factories apply effective and systemic management of compliance [57] and environmental organization [58]. Factory development processes apply life-cycle thinking in planning processes [59]. The production processes enable zero emissions due to effective processes and technologies [31], and cyber-physical production systems support operational processes in using energy and resources in a transparent and optimal manner [60].…”

Section: Identification Of Strategic Elements For Sustainability Tran...mentioning

confidence: 99%

Implementing Zero Impact Factories in Volkswagen’s Global Automotive Manufacturing System: A Discussion of Opportunities and Challenges from Integrating Current Science into Strategic Management

Gebler,

Warsen,

Meininghaus

et al. 2024

Sustainability

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The current exceeding of six out of nine planetary boundaries requires a significant transition of human societies towards absolute sustainability. Industrial manufacturing systems were and still are an important motor for socio-economic development but at the cost of a significant negative impact on the biosphere. Current concepts in absolute sustainability and sustainable manufacturing provide solutions for sustainability transitions in industry, but various methodological, technical and procedural challenges arise during their adaptation in industrial practice. The development and operationalization of a “zero impact factory” strategy by Volkswagen Group has identified various implementational challenges, which are discussed in this article. First, an overview of motivations for “zero impact” transformations in industry are pointed out. Second, relevant aspects for the strategic management of sustainability transitions in manufacturing companies are highlighted based on a literature analysis. Third, the strategy development process is explained based on a systematic structure, which includes design-thinking principles for sustainability transitions of large technical systems such as factories in global manufacturing systems. Fourth, the developed strategy content is presented, including (1) the strategy vision, (2) the defined quantified “zero impact” goals, (3) a system model and a prototype of a zero impact factory, (4) the developed “Impact Points” and the “Site Checklist” methods (for evaluating the environmental transformation of a factory) and (5) the definition of processes for strategic management during strategy operationalization. Finally, various organizational challenges and opportunities are pointed out, which are considered novel insights from industrial practice and relevant for the science-based strategic management within automotive companies and other global industrial manufacturing organizations, as well for advancing sustainability concepts in applied industrial science.

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“…TPM is a concept that allows production employees to take ownership and responsibility for their equipment (Holgado, Macchi & Evans, 2020;Sahoo, 2019). In the manufacturing setting, TPM aims to enhance equipment performance through a comprehensive preventative maintenance system that spans the whole life of the equipment and involves everyone in all departments and levels (Dér, et al, 2022). It promotes plant maintenance through small-group and volunteer activities.…”

Section: Summary Of Articles In Lm Implementationmentioning

confidence: 99%

“…TPM ultimate goal is to achieve zero operational downtime and zero defects by preventing, rather than addressing, unexpected failures, speed losses, and quality concerns (Rajput & Jayaswal, 2012;Sahoo, 2020). Preventive maintenance is important to keep equipment in order (Dér et al, 2022;Tortorella, Vergara & Ferreira, 2017). TPM comprises preventative and predictive maintenance, a full maintenance system for the equipment life cycle (Nakajima, 1988;Sancha et al, 2020).…”

Section: Summary Of Articles In Lm Implementationmentioning

confidence: 99%

Save it for a rainy day! Lean strategies for cost saving: The role of Lean maturity

Aripin

Nawanir

Hussain

2023

JIEM

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Purpose: This study investigates the effect of lean implementation on production cost reduction and the moderating role of lean manufacturing maturity.Design/methodology/approach: This study employed a cross-sectional survey, of which the samples were drawn using a cluster sampling procedure from 151 middle and top-level management of medium and large manufacturing companies gathered from the Federation of Manufacturers Malaysia (FMM). Data were analyzed using the PLS-SEM approach through SmartPLS4 software.Findings: The result revealed that lean implementation does not leverage production cost reduction as the lean journey requires long-term orientation, which finally leads to valid cost reduction. The moderating role of lean manufacturing maturity was significant and positive in the relationship between lean manufacturing implementation and production cost reduction.Research limitations/implications: Future research should include longitudinal settings as this study is cross-sectional, and future research might put the present model to the test in multiple industries and regions, including a cross-country comparison to improve the generalizability of the findings. Additionally, further studies could extend this study using a mixed-method approach.Practical implications: By offering a holistic perspective, this study expands the existing literature, contributes to knowledge of integrated lean implementation and supports the management in planning their path towards cost-cutting performance.Originality/value: This study answers the inconclusive finding between lean implementation and operational performance in terms of production cost reduction. The study contributes to the body of knowledge and, most importantly, to the practitioners in planning their lean journey.

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A review of frameworks, methods and models for the evaluation and engineering of factory life cycles

Cited by 13 publications

References 1 publication

Towards the digital factory twin – design guide for creating a 3D factory model

Towards the digital factory twin – design guide for creating a 3D factory model

Implementing Zero Impact Factories in Volkswagen’s Global Automotive Manufacturing System: A Discussion of Opportunities and Challenges from Integrating Current Science into Strategic Management

Save it for a rainy day! Lean strategies for cost saving: The role of Lean maturity

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