Strategies and Techniques for Quality and Flexibility

129 Pages·2018·2.202 MB·English

by  Miryam Barad (auth.)

SPRINGER BRIEFS IN
APPLIED SCIENCES AND TECHNOLOGY
Miryam Barad
Strategies and
Techniques for
Quality and
Flexibility
123
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Miryam Barad
Strategies and Techniques
for Quality and Flexibility
123
Miryam Barad
Department ofIndustrial Engineering, The
IbyandAladar Fleishman Faculty of
Engineering
TelAviv University
TelAviv
Israel
ISSN 2191-530X ISSN 2191-5318 (electronic)
SpringerBriefs inApplied SciencesandTechnology
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https://doi.org/10.1007/978-3-319-68400-0
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Preface
IthasbeenalongtimesinceIfirstthoughtofwritingabook.Itoldmyfriendsthat
when I retire I would write a book. They laughed and said that academic people
working at universities, who really want to write a book, do not wait until their
retirement.Idonotwriteeasily.Ittakesmealongtimetowriteapaper,butIenjoy
doingit.Ontheotherhand,writingabookisacomplexandbigwork,soIdecided
to wait until my retirement. However, upon my retirement from Tel Aviv
UniversitytheRectorofacollegeaskedmetojointheacademicstaffasHeadofthe
IndustrialEngineeringandManagementDepartmentinordertoenablethestudents
to get an academic degree similar to that of universities, i.e., Bachelor of Science
(B.Sc.). Therefore, again the book had to wait.
Theideaofwritingabookcamebacktomeafterafewmoreyears.Theeditorof
an important professional journal asked me, as member of its editorial board, to
write a paper for a special volume commemorating 50 years of the journal first
issue.
He mentioned that I was free to select any topic for the paper, eventually
expressingmyspecificexperiencerelatedtothetopic.Iselected‘Flexibility’asthe
topic to write about. The paper title became Flexibility development—a personal
retrospective. It integrated several of my published papers emphasizing my per-
sonal views and experience on the topic.
Since the publication of this paper, the road toward writing the book became
cleartome.AsthepapersIhadpublisheddealtwithmanytopics,Istartedtowrite
building blocks for the book, in terms of papers integrating my main research
topics. The book had to provide the relationships between them.
At the beginning of the 1980s, Quality started to become an important topic in
industry. That was before Quality Management or Total Quality Management
emergedasvitalstrategies.Atthatperiod,Istartedmyresearchonquality-oriented
organizations through a survey, investigating Quality Assurance Systems in Israeli
industries. I selected a particular industrial area, Electric and Electronics industry
because this area made use of the highest developed technologies, sensitive to
v
vi Preface
quality aspects. Hence, it seemed the most promising area for the development of
quality-oriented organizations and for application of quality methods. However,
even in that area, we found out that managers were not aware enough of the
economic opportunities of quality systems. They acted toward their development
because of the pressure exerted upon them by strong buyers.
Since that period, I continued intermittently to study and research this topic
using various techniques such as Design of Experiments and later on Quality
Function Deployment. I also published invited chapters on Total Quality
Management in several encyclopedias.
In the meantime, a more exciting topic emerged, Flexibility. For many years,
flexibilityhasbeenmymaintopicofresearch.Itisacomplexandchallengingtopic
with never-ending research possibilities. It is important in the human body, and
according to recent research works, it seems that it is important in the brain per-
formance as well. In manufacturing and other man-made systems such as infor-
mation, logistics, or supply chains, there is consensus that flexibility means
adaptations to changes.
The early approaches to flexibility research were associated with Flexible
Manufacturing Systems (FMSs). These early approaches to flexibility had a
bottom-upstructurerelatedtoamanufacturinghierarchy,i.e.,frombasicflexibility
types, such as ‘machine flexibility,’ to system flexibility such as ‘volume flexibil-
ity,’ or ‘mix flexibility.’ My first research on flexibilityused a bottom-up structure
describedintwopaperspublishedattheendof1980s.BothpapersusedPetrinets
to model flexibility in manufacturing systems. By the end of the 1990s, the
importance of flexibility got its main recognition from a strategic perspective.
Accordingly, my next research projects were devoted to flexibility-oriented
strategies, through a top-down approach. Many of these projects used Quality
Function Deployment.
Chapter Organization and Topical Coverage
The book has two parts and six chapters.
PartIisaboutstrategies.ItisanoverviewonQualityandFlexibilityaslinkedto
my professional development and comprises three chapters.
Chapter1hasonesectionthatincludessomegeneralDefinitionsofStrategyand
its importance. Chapter 2 describes Quality-oriented Strategies and contains seven
sections. Chapter 3 describes Flexibility-oriented Strategies and comprises six
sections.
Part II is about techniques. It describes several of my published papers that
apply multipurpose techniques for assessing quality and flexibility and contains
three chapters as well.
Preface vii
Chapter 4 is about Design of Experiments (DOE) and has five sections.
Chapter5describesPetriNetsandcontainssixsections.Chapter6isaboutQuality
Function Deployment (QFD) and contains six sections as well.
At the end of each chapter, there is a list of references.
Tel Aviv, Israel Miryam Barad
Contents
Part I Strategies
1 Definitions of Strategies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
References . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
2 Quality-oriented Strategies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
2.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
2.2 Quality Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
2.3 Quality Development in the US (Before the Quality Revolution
in the Mid-1980s). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
2.4 Quality Organization in Japan . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
2.4.1 Implementation of the American Quality Methods. . . . . . . 10
2.4.2 The Integrated Japanese Quality System . . . . . . . . . . . . . . 11
2.5 TotalQualityStrategiesAftertheQualityRevolution—Universal
Views . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
2.5.1 USA—Malcolm Baldridge National Quality Award
(MBNQA). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
2.5.2 Europe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
2.5.3 Australia . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
2.5.4 Cultural/Geographical Styles—East Versus West
(China Versus Australia) . . . . . . . . . . . . . . . . . . . . . . . . . 18
2.6 Quality Management Theories and Practices—Usage Aspects . . . . 22
2.6.1 Logistics Versus Manufacturing . . . . . . . . . . . . . . . . . . . . 22
2.6.2 Contribution of QM Tools and Practices to Project
Management Performance . . . . . . . . . . . . . . . . . . . . . . . . 24
2.7 Soft Versus Hard Quality Management Practices . . . . . . . . . . . . . 27
References . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
ix
x Contents
3 Flexibility-oriented Strategies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
3.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
3.2 Flexibility in Manufacturing Systems. . . . . . . . . . . . . . . . . . . . . . 33
3.2.1 Flexible Manufacturing Systems (FMSs). . . . . . . . . . . . . . 33
3.2.2 Classifications of Flexibility in Manufacturing Systems . . . 35
3.2.3 Flexibility Types and Measures (Dimensions/Metrics) . . . . 36
3.3 Flexibility in Logistic Systems . . . . . . . . . . . . . . . . . . . . . . . . . . 42
3.4 Flexibility of Generic Objects . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
3.4.1 Clouds Representation . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
3.4.2 Flexibility Aspects and Analysis of Several Generic
Objects . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
3.4.3 Context Perspective—Information, Manufacturing
(or Service). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
3.5 Flexibility in Supply Chains . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
3.6 Strategic Flexibility. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
References . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
Part II Techniques
4 Design of Experiments (DOE). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
4.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
4.1.1 Guidelines. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
4.1.2 Fisher’s Basic DOE Principles . . . . . . . . . . . . . . . . . . . . . 62
4.1.3 Factorial Experiments . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
4.2 Impact of Flexibility Factors in Flexible Manufacturing
Systems—A Fractional Factorial Design of a Simulation
Experiment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
4.2.1 The Selected Factors (Independent Variables), Their
Levels and the Simulation Design. . . . . . . . . . . . . . . . . . . 64
4.2.2 Response (Dependent Variable) . . . . . . . . . . . . . . . . . . . . 66
4.2.3 Simulation Analysis. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
4.2.4 Some Results . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
4.2.5 Concluding Remarks . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
4.3 Prior Research Is the Key to Fractional Factorial
Design—A Fractional Factorial Design
of a Physical Experiment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
4.3.1 The Selected Factors (Independent Variables)
and Their Levels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
4.3.2 Response (Dependent Variable) . . . . . . . . . . . . . . . . . . . . 69
4.3.3 Choice of the Design. . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
4.3.4 Analysis of the First Data Set. . . . . . . . . . . . . . . . . . . . . . 71
4.3.5 Analysis of the Second Data Set and Some Concluding
Remarks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71