Integration of Data-Driven Process Re-Engineering and Process Interdependence for Manufacturing Optimization Supported by Smart Structured Data

Khan, Ashikul Alam; Butt, Javaid; Mebrahtu, Habtom; Shirvani, Hassan; Sanaei, Alireza; Alam, Mohammad Jahangir

doi:10.3390/designs3030044

Cited by 6 publications

(17 citation statements)

References 30 publications

(88 reference statements)

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“…Concepts such as lean manufacturing, six sigma, and total quality management are popular in the manufacturing sector [76]. In that context, the work done by Khan et al [77] explored the capabilities of WITNESS Horizon to simulate a valve manufacturing facility and implemented Khan-Hassan-Butt (KHB) process re-engineering methodology for its optimization. They showed an increase of 20% in production output as a result of their proposed methodology that can identify process interdependencies and can be used with structured, as well as semi-structured, data.…”

Section: Simulationmentioning

confidence: 99%

A Strategic Roadmap for the Manufacturing Industry to Implement Industry 4.0

Butt

2020

Designs

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Industry 4.0 (also referred to as digitization of manufacturing) is characterized by cyber physical systems, automation, and data exchange. It is no longer a future trend and is being employed worldwide by manufacturing organizations, to gain benefits of improved performance, reduced inefficiencies, and lower costs, while improving flexibility. However, the implementation of Industry 4.0 enabling technologies is a difficult task and becomes even more challenging without any standardized approach. The barriers include, but are not limited to, lack of knowledge, inability to realistically quantify the return on investment, and lack of a skilled workforce. This study presents a systematic and content-centric literature review of Industry 4.0 enabling technologies, to highlight their impact on the manufacturing industry. It also provides a strategic roadmap for the implementation of Industry 4.0, based on lean six sigma approaches. The basis of the roadmap is the design for six sigma approach for the development of a new process chain, followed by a continuous improvement plan. The reason for choosing lean six sigma is to provide manufacturers with a sense of familiarity, as they have been employing these principles for removing waste and reducing variability. Major reasons for the rejection of Industry 4.0 implementation methodologies by manufactures are fear of the unknown and resistance to change, whereas the use of lean six sigma can mitigate them. The strategic roadmap presented in this paper can offer a holistic view of phases that manufacturers should undertake and the challenges they might face in their journey toward Industry 4.0 transition.

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Section: Simulationmentioning

confidence: 99%

A Strategic Roadmap for the Manufacturing Industry to Implement Industry 4.0

Butt

2020

Designs

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“…In recent years, much work has been done to study factors that influence the implementation and performance of the BPR [3]. The Hammer and Champy's BPR methodology (Business system diamond), Davenport's and Short's Methodology, process analysis and design methods (PADM) framework, and Jacobson's methodology (objective-oriented methodology of BPR) explain the core process and objective of BPR [4][5][6][7][8][9][10][11][12][13][14][15][16][17][18][19][20]. Hammer and Champy describe the reengineering objective as "achieving dramatic improvements by redesigning the fundamental business process" [21].…”

Section: Introductionmentioning

confidence: 99%

“…PADM framework identifies the goal of the reengineering process and technical boundaries as the most critical task to be accomplished. It provides a framework to reduce complexity, nonvalue adding steps, and improve control of variances between business functions [4][5][6]. Jacobson's objective-oriented method identifies the object orientation of a company in terms of products, processes, and services [4,22].…”

Section: Introductionmentioning

confidence: 99%

“…The tactical dependencies of BPR arise during the implementation phase and could either increase the efficiency or create obstacles [4,5]. Different methodologies of BPR reveal that some degrees of dependency exist in every step and substep of a reengineering process [1,[30][31][32][33][34][35][36][37][38].…”

Section: Introductionmentioning

confidence: 99%

“…In the manufacturing process, the dependence issues can be termed as process interdependence (PI). They are cross-functional and have a significant impact on organizational performance and productivity [4,5,30]. Based on the structure of the organization and manufacturing process, the tactical dependencies issues can be formed in three different types, i.e., pooled interdependencies, sequential interdependencies, and reciprocal interdependencies [5,11].…”

Section: Introductionmentioning

confidence: 99%

See 2 more Smart Citations

Analyzing the Effects of Tactical Dependence for Business Process Reengineering and Optimization

Khan

Butt

Mebrahtu

et al. 2020

Designs

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Implementing business and manufacturing process reengineering is challenging and poses major issues. The dependence issues between process functions during the implementation phase are the main reason for the high failure rate of process reengineering. The incompetence in identifying the dependence makes existing business process reengineering approaches static for modern business and manufacturing process structures. This paper has implemented a new process reengineering approach called the Khan–Hassan–Butt (KHB) methodology that incorporates the process interdependence algorithm to identify the dependence issues. The KHB method is a hybrid process reengineering approach to identify dependence issues before implementing changes; thus significantly reducing the failure rate of implementing business process reengineering. The KHB method has been implemented in a Bangladesh fabric manufacturing facility. The mapping and verification of the process have been completed using the WITNESS Horizon 22.5 simulation package. The case study has investigated the fabric production process and identified the dependence issues between each function and suggested changes to optimize the process. The outcome has shown significant improvement in production output and process efficiency.

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Business Process Redesign: A Systematic Review of Evaluation Approaches

Tsakalidis,

Vergidis

2023

Decis. Mak. Appl. Manag. Eng.

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The continuous and systematic redesign of key business processes is very important for businesses and organizations that seek to achieve cost savings and efficiency enhancements. Selecting the most impactful processes and ensuring a successful redesign initiative remains an important topic that motivated the authors to conduct a Systematic Literature Review (SLR) on Business Process Redesign (BPR) Evaluation methodologies by applying an established eight-step SLR guide. The review sheds light on the current state of research and highlights the research gap by considering two dimensions of BPR artifacts: (a) the type of evaluation and (b) the generalizability of the existing approaches. The findings indicate that there is a lack of systematic methodologies in literature that properly evaluate the redesign capacity of models prior to implementation. Additionally, the existing methodologies do not cumulatively evaluate the quality characteristics that are necessary for BPR implementation or the applicability of BPR heuristics, and do not bear the generalizability to be readily used in a more general context. This paper aims to provide researchers with the necessary context and motivation to bridge this gap and further systematize BPR methodologies that can preselect the most suitable business processes for redesign.

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Integration of Data-Driven Process Re-Engineering and Process Interdependence for Manufacturing Optimization Supported by Smart Structured Data

Cited by 6 publications

References 30 publications

A Strategic Roadmap for the Manufacturing Industry to Implement Industry 4.0

A Strategic Roadmap for the Manufacturing Industry to Implement Industry 4.0

Analyzing the Effects of Tactical Dependence for Business Process Reengineering and Optimization

Business Process Redesign: A Systematic Review of Evaluation Approaches

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