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Manufacturing process improvements using value adding process point approach
Mälardalen University, School of Innovation, Design and Engineering.
Mälardalen University, School of Innovation, Design and Engineering.ORCID iD: 0000-0002-0662-539X
2013 (English)Conference paper, Published paper (Refereed)
Abstract [en]

Manufacturing functions need to be capable of constantly developing new manufacturing lines, cells, and pieces of equipment in order to maintain their operational competitiveness. This paper explores a unique approach to analyzing and designing manufacturing processes referred to as the Value Adding Process Point (VAPP) approach. This approach particularly focuses on the points where value is added to materials in manufacturing processes. The approach is mostly used at Japanese companies and it has contributed to developing unique manufacturing lines, cells, and pieces of equipment that tend to be simple, slim, and compact, and require low investment cost. The approach has also contributed to achieving major improvements in different performance measures in manufacturing. However, the approach is rarely known internationally. Moreover, the amount of practical information on how to apply the approach at companies has been limited in the scarce literature on the approach. The purpose of this paper is to introduce the VAPP approach to a broader audience and also to provide practical information on how to apply the approach by describing a case study in which the approach was applied at a Swedish manufacturing company. At the company, the application was made in a manner of experiential learning. In this paper, it is described how the VAPP approach was applied, what outcomes were generated by the application, and how participants in the case study experienced the application of the approach. Discussions are made as to usefulness of the approach and effective use of the approach.

Place, publisher, year, edition, pages
2013.
National Category
Production Engineering, Human Work Science and Ergonomics
Identifiers
URN: urn:nbn:se:mdh:diva-20898OAI: oai:DiVA.org:mdh-20898DiVA: diva2:640562
Conference
22nd Annual conference of The International Association for Management of Technology, IAMOT2013, Porto Alegre, Brazil, April 14-18, 2013
Projects
xpres
Funder
XPRES - Initiative for excellence in production research
Available from: 2013-08-13 Created: 2013-08-13 Last updated: 2013-12-11Bibliographically approved
In thesis
1. Kaikaku in production toward creating unique production systems
Open this publication in new window or tab >>Kaikaku in production toward creating unique production systems
2013 (English)Doctoral thesis, comprehensive summary (Other academic)
Abstract [en]

In the business environment characterized by the severe global competition and the fast-paced changes, production functions of manufacturing companies must have a capacity of undertaking not only incremental improvement, Kaizen, but also large-scale improvement that is of a radial and innovative nature here called “Kaikaku” (Kaikaku is a Japanese word meaning change or reformation).

Moreover, production functions especially those located in high-wage countries must be proficient in radical innovation in production to maintain their competitive advantages. They must to be capable of creating new knowledge and constantly developing and implementing radically new production technologies, processes, and equipment which make their production systems more “unique”. Here, a unique production system means a production system that is valuable for the company’s competition, rare in the industry, difficult for competitors to imitate, and difficult for them to substitute.

Kaikaku is not a new phenomenon in the industry, and much research has been done on how to manage large-scale changes in Kaikaku. However, the previous research has rarely focused on the relation of Kaikaku and creating unique production systems. Kaikaku can be an effective means to create such systems. The objective of the research presented in the doctoral thesis is to propose how to plan and implement Kaikaku so that it contributes to creating unique production systems. To fulfil the objective, five empirical studies were conducted. In the empirical studies, data were collected through literature review, interviews, participant-observation, and action research. Japanese and Swedish manufacturing companies were studied.

General conclusions of the research are summarized as follows. In order to achieve Kaikaku so that it contributes to realizing unique production systems, the intent and commitment to realize such systems must be present at the strategic level of the organization. Organization structures and resources need to be prepared to support the mentioned kind of Kaikaku. A process of Kaikaku can be a less linear and systematic but more cyclic and emergent process which can be seen as a series of unfolding smaller improvement or development projects that are undertaken during Kaikaku to achieve overall objectives. In each projects exploration and organizational learning are facilitated. The research has also found a specific direction of how to develop a production system in order to make the system more unique. Finally, in the research, a design method that is helpful to create unique production lines, cells, and equipment has been found and studied

Place, publisher, year, edition, pages
Mälardalens Högskola, 2013
Series
Mälardalen University Press Dissertations, ISSN 1651-4238 ; 143
National Category
Production Engineering, Human Work Science and Ergonomics
Research subject
Innovation and Design
Identifiers
urn:nbn:se:mdh:diva-20901 (URN)978-91-7485-116-8 (ISBN)
Public defence
2013-09-27, Filen, Eskilstuna, 10:00 (English)
Opponent
Supervisors
Projects
Kaikaku
Funder
XPRES - Initiative for excellence in production research
Available from: 2013-08-14 Created: 2013-08-14 Last updated: 2013-12-06Bibliographically approved

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