Gobetto, Marco (2014) Operations Management in Automotive Industries. Springer Science+Business Media Dordrecht.
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1 Historical Outlines and Industrial Strategies for Automotive Industries .............................. 1 1.1 Historical Outlines in the Automotive Industry . . . . . . . . . . . . . 1 1.2 Strategic Planning of Production Activities. . . . . . . . . . . . . . . . 13 1.3 Process Integration and ‘‘Make or Buy’’ Decision-Making . . . . . 16 1.3.1 Items (m) for the Decision to ‘‘Make’’ . . . . . . . . . . . . . 17 1.3.2 Items (b) for the Decision to ‘‘Buy’’ . . . . . . . . . . . . . . . 18 1.3.3 Items (c) for the Decision for ‘‘Co-Makership’’ . . . . . . . 18 1.4 Manufacturing Systems Set-Up and Location Criteria . . . . . . . . 19 1.4.1 Equipment Level and the Defining of Technological Solutions. . . . . . . . . . . . . . . . . . . . . . 20 1.5 Overview of Technologies for Materials Applied to the Construction of Vehicles . . . . . . . . . . . . . . . . . . . . . . . . 23 1.6 Sketches for Manufacturing Systems Adopted in Car Manufacturing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 1.7 Systems’ Strategic Prerogatives. . . . . . . . . . . . . . . . . . . . . . . . 42 2 From Project to Product . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45 2.1 Standardization Logic and Project Set-Up. . . . . . . . . . . . . . . . . 45 2.2 Industrialization Process Description . . . . . . . . . . . . . . . . . . . . 48 2.3 Product/Process Information Technology System. . . . . . . . . . . . 52 2.4 Product Composition Analysis . . . . . . . . . . . . . . . . . . . . . . . . 61 2.5 Management of Technical Changes . . . . . . . . . . . . . . . . . . . . . 63 3 Manufacturing Engineering and Equipment Efficiency Evaluation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67 3.1 Manufacturing Engineering Planning and Executive Project . . . . 67 3.1.1 Manufacturing Engineering Plan Study and ‘‘System’’ Preliminary Project . . . . . . . . . . . . . . . . 67 3.1.2 Executive Project . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68 3.2 Production Capacity Setting . . . . . . . . . . . . . . . . . . . . . . . . . . 70 3.3 Working Time Analysis Methodologies . . . . . . . . . . . . . . . . . . 73 3.4 Man–Machine Interaction and Standard Working Time Definition. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76 xiii 3.5 Equipment Utilization Analysis . . . . . . . . . . . . . . . . . . . . . . . . 78 3.6 Introduction of Integrated Production Systems . . . . . . . . . . . . . 80 3.7 Operative Productivity and Flexibility . . . . . . . . . . . . . . . . . . . 81 3.8 Equipment and Machine Loading . . . . . . . . . . . . . . . . . . . . . . 82 3.9 Defining Installed Productive Capacity. . . . . . . . . . . . . . . . . . . 84 4 Work Analysis and Labour Productivity Evaluation Criteria. . . . . 87 4.1 Activity Level and Labour Efficiency . . . . . . . . . . . . . . . . . . . 87 4.1.1 Labour Efficiency Analysis . . . . . . . . . . . . . . . . . . . . . 88 4.2 Manpower Planning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89 4.2.1 Indirect Labour Requirement . . . . . . . . . . . . . . . . . . . . 90 4.2.2 Operative Plan and Staff Balancing: Requirements . . . . . 91 4.3 Working Time Length and Flexibility . . . . . . . . . . . . . . . . . . . 92 4.4 Labour Productivity and Improvement Plans. . . . . . . . . . . . . . . 94 4.5 Input Data for Operative Control. . . . . . . . . . . . . . . . . . . . . . . 99 4.6 Assignment of Tasks and Workload Balance . . . . . . . . . . . . . . 104 4.6.1 Considerations on Work Organization for Assembly Lines or Parallel Workstations . . . . . . . . . . . . . . . . . . . 108 4.7 Motivation and Rewarding of Employees . . . . . . . . . . . . . . . . . 110 5 Manufacturing System Management and Maintenance Criteria . . . 115 5.1 Plant Manufacturing System . . . . . . . . . . . . . . . . . . . . . . . . . . 115 5.2 Reliability and Maintainability of Equipment . . . . . . . . . . . . . . 117 5.3 Maintenance Management . . . . . . . . . . . . . . . . . . . . . . . . . . . 122 5.3.1 Autonomous Maintenance Activities (Simple and Recurrent Interventions: Type A) . . . . . . . . 123 5.3.2 Professional Maintenance Activites (Type B, C and D) . . . . . . . . . . . . . . . . . . . . . . . . . . . 125 5.4 Correlation Between Cost and Maintenance Effectiveness . . . . . 128 5.4.1 Breakdown Maintenance Activity Volume . . . . . . . . . . . 130 5.4.2 Preventive Professional Maintenance Activity Volume . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130 5.4.3 Individual Activity Achievable . . . . . . . . . . . . . . . . . . . 131 5.5 General and Complementary Equipment for Production . . . . . . . 131 5.5.1 General Services Equipment and Energy Consumption Optimization. . . . . . . . . . . . . . . . . . . . . . 131 5.5.2 Co-generation Equipment and Electric Energy Consumption Control Systems . . . . . . . . . . . . . . . . . . . 132 5.5.3 Auxiliary Equipment and Exhaust Material Management . . . . . . . . . . . . . . . . . . . . . . . . . 133 5.6 Tools and Consumables Management. . . . . . . . . . . . . . . . . . . . 134 5.6.1 General Criteria . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134 5.6.2 Tools and Tooling Subject to Quick Usury . . . . . . . . . . 135 5.7 ‘‘Total Productive Maintenance’’ Approach . . . . . . . . . . . . . . . 138 xiv Contents 6 Logistics and Supply Chain Basics for Automotive Application . . . 141 6.1 Historical Evolution of Logistics and Actual Strategies . . . . . . . 141 6.1.1 1925–1975: Logistics as ‘‘Material Management’’ Support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 142 6.1.2 1975–1990: Logistics Oriented to ‘‘Time-to-Market’’ and ‘‘Commercial Network Service’’ . . . . . . . . . . . . . . . 143 6.1.3 Actual period: Logistics as an ‘‘Integrated Process’’ to Support ‘‘Supply Chain Management’’. . . . . . . . . . . . 143 6.2 Logistic Flow in the Supply Chain . . . . . . . . . . . . . . . . . . . . . 144 6.3 Material Handling and Inventory Management Methodologies. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 148 6.4 Production and Delivery Planning . . . . . . . . . . . . . . . . . . . . . . 155 6.5 Logistics Information Technology Systems. . . . . . . . . . . . . . . . 160 6.6 Key Performance Indicators of Logistics . . . . . . . . . . . . . . . . . 163 6.6.1 Finished Product Inventory Indicators and Work in Process . . . . . . . . . . . . . . . . . . . . . . . . . . 163 6.6.2 Process Lead Time and Flow Index . . . . . . . . . . . . . . . 164 6.6.3 Risk Indicators of Inventory Obsolescence . . . . . . . . . . . 165 6.6.4 Order Execution Lead Time . . . . . . . . . . . . . . . . . . . . . 165 6.6.5 Service Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 166 6.7 Just in Time Approach . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 167 7 Global Purchasing Operations . . . . . . . . . . . . . . . . . . . . . . . . . . . 169 7.1 Role of the Purchasing Department . . . . . . . . . . . . . . . . . . . . . 169 7.2 Evolution of Purchasing Policies . . . . . . . . . . . . . . . . . . . . . . . 171 7.3 Purchasing, Marketing and Global Sourcing Policies . . . . . . . . . 174 7.4 Management of Suppliers Network . . . . . . . . . . . . . . . . . . . . . 176 7.5 Order Procedure and Cooperation Agreements . . . . . . . . . . . . . 178 7.6 Supplying Cost and Purchasing Effectiveness Indicators. . . . . . . 179 7.7 ‘‘E-procurement’’ Techniques . . . . . . . . . . . . . . . . . . . . . . . . . 181 8 Quality Management and Continuous Improvement . . . . . . . . . . . 183 8.1 The ‘‘Learning Curve’’ Concept . . . . . . . . . . . . . . . . . . . . . . . 183 8.2 Production Ramp up and Maximum Rate Achievement . . . . . . . 184 8.3 Quality Management in Industrial Processes . . . . . . . . . . . . . . . 187 8.4 Quality and Reliability Assurance Techniques in Product Design Phase. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 190 8.5 Total Quality Management and Continuous Improvement Approach . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 191 Contents xv 9 Value Creation and Final Considerations . . . . . . . . . . . . . . . . . . . 201 Appendix: Production Management Basics. . . . . . . . . . . . . . . . . . . . . 205 About the Author . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 245
| Item Type: | Book |
|---|---|
| Subjects: | H Social Sciences > HD Industries. Land use. Labor > HD28 Management. Industrial Management |
| Depositing User: | Unnamed user with email [email protected] |
| Date Deposited: | 16 May 2023 02:54 |
| Last Modified: | 16 May 2023 02:54 |
| URI: | http://eprint.ulbi.ac.id/id/eprint/1848 |
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