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This paper presents a novel lean tool called Project Time Deployment (PTD) whose objectives are to classify, analyse, and eliminate losses in order to reduce production lead time in Engineer-to-Order (ETO) environments. By combining two already known approaches, i.e. the Manufacturing Critical-path Time and the Manufacturing Cost Deployment, PTD identifies the critical losses affecting the project, focusing on the business processes where causal losses occur, and providing opportunities for greater efficiency and effectiveness by reducing or even eliminating them. In ETO projects, the lead time and respecting deadlines are of paramount importance and they are often threatened by several different losses that are difficult to compare. Companies thus need a tool to identify the losses and the tasks where they occur, quantifying them in terms of a single dimension: the time. PTD was designed using a methodology based on four steps: analysis of current solutions, concept design and prototype, proof of concept and validation, and definition of future researches. It was also validated in an industrial implementation concerning an Engineering, Procurement & Construction company operating in the steel industry, and led to an approximate 24% reduction in lead time. [ABSTRACT FROM AUTHOR]

Quick response strategy (QRS) has been widely adopted in a supply chain where members collect timely market information for better forecasting, and then respond promptly to the market changes by adjusting initial inventory decision. After adopting the QRS, sustainability issues such as greenhouse gas emission and energy waste may be more serious as production lead time is shorter. In this study, due to this dilemma, we develop a two-stage quick response supply chain with cleaner technology, where the manufacturer determines the cleaner technology investment and afterwards the retailer decides the ordering quantity. Based on Bayesian theory, we depict an information updating process for the QRS with cleaner technology. First, we find that the inventory service level significantly affects both manufacturer’s and retailer’s performance under the QRS with cleaner technology. Moreover, our analytical results indicate that the performance of centralised supply chain system is always better than the decentralised one. As a result, we propose two supply chain contracts, minimum ordering quantity (MOQ) and MOQ with buyback (MOQ-BB) to achieve supply chain coordination. Comparing with the MOQ, the MOQ-BB is more flexible to allow better allocation of the ‘additional’ expected profit between the channel members through the buyback price negotiation. [ABSTRACT FROM AUTHOR]

The main goal of this research is to identify whether companies that have implemented the Quick Response Manufacturing (QRM) approach have full knowledge of the QRM principles or have merely applied the elements (principles and tools) that have a close relationship with Lean Manufacturing. Based on a review of the literature regarding the QRM principles, an exploratory survey was conducted for over 20 manufacturing companies from Brazil, Europe and the USA that operate in an Engineer or Make to Order environment system and explicitly have conducted QRM journeys. The results of the present study show that (i) the surveyed companies have difficulty knowing and applying some of the exclusive elements of this approach, even if they started implementing QRM several years ago; (ii) the surveyed companies’ knowledge degree over QRM exclusive elements is apparently higher among US-based companies due to better trained employees and better dissemination and awareness of the QRM exclusive elements; and (iii) a mentality based on productivity, low costs and due date delivery was identified as the main barrier for companies to achieve a higher knowledge degree regarding QRM. [ABSTRACT FROM PUBLISHER]

The manufacturing industry is having an issue regarding the quality of the company's planning to produce efficient performance throughout the year. The improvement needs to be carried out to give customers considerable satisfaction regarding the quality of the products and the delivery time. As the manufacturing industry evolves throughout the decades, the demands are becoming more challenging: faster delivery and better quality of products. The markets will interrupt a good supply chain of a company. The Quick Response Manufacturing (QRM) approach significantly benefits companies whose focus is on lead time reduction. This study aims to reduce the lead time and to improve the supply chain of a selected automotive production line by using Witness software simulation. The improvement also sought to implement the Just-In-Time (JIT) inventory management method. The data collected from company X is simulated to get the percentage of idle, blocked, and overall process time. By using the data from the selected line, the improvement of the overall process time is 27.5%, meaning that the company is ready to implement the JIT inventory management method. [ABSTRACT FROM AUTHOR]

In competitive and uncertain business environments, manufacturing firms face various challenges requiring quick response, customisation and cost effectiveness to sustain competitive advantage. This paper proposes a segment set-based approach for the part input sequencing problem of flexible manufacturing systems (FMSs). The segment set theorems are built for the development of the segment set-based approach for the problem. A numerical study is done using simulation, and validated through statistical analyses. Our approach results in the significant performance improvement of the FMSs. Managerial implications are discussed. Further research is also provided. [ABSTRACT FROM AUTHOR]

To remain competitive in today's increasingly dynamic and complex environments, manufacturing enterprises must build resilience to respond to changes quickly. As such, lean production has provided firms with an alternative to "fat and lazy" mass production. In addition, Quick Response Manufacturing has been presented as a credible supplement to lean production, specifically in High Mix, Low Volume environments. Drawing on practical insights from two case studies, we present a Quick-Scan method as an initial step towards creating resilient and responsive value chain strategies. The approach combines manufacturing critical-path time mapping from Quick Response Manufacturing with Gemba-based discovery and learning from Lean - to find, face, and frame real problems, and thereafter form solutions together with managers and front-line personnel. The method has been adopted in both cases as a means of revitalizing operations with the intention of enabling more effective delivery of customer-specific products. [ABSTRACT FROM AUTHOR]

The market of consumer goods requires nowadays quick response to customer needs. As a consequence, this is transferred to the time restrictions that the semi-finished product manufacturer must meet. Therefore the cost of manufacturing cannot determine how production processes are designed, and the main evaluation function of manufacturing processes is the response time to customers' orders. One of the ideas for implementing this idea is the QRM (Quick Response Manufacturing) production organization system. The purpose of the research undertaken by the authors was to develop an innovative solution in the field of production structure, allowing for the implementation of the QRM concept in a Contract Manufacturer, which realizes its tasks according to engineering-to-order (ETO) system in conditions defined as High Mix, Low Volume, High Complexity. The object of the research was to select appropriate methods for grouping products assuming that certain operations will be carried out in traditional but well-organized technological and/or linear cells. The research was carried out in one of the largest producers of sheet metal components in Europe. Pre-completed groupings for data obtained from the company had indicated that -- among the classical methods -- the best results had been given by the following methods: King's Algorithm (otherwise called: Binary Ordering, Rank Order Clustering), k-means, and Kohonen's neural networks. The results of the tests and preliminary simulations based on the data from the company proved that the implementation of the QRM concept does not have to be associated with the absolute formation of multi-purpose cells. It turned out that the effect of reducing the response time to customer needs can be obtained by using hybrid structures that combine solutions characteristic of cellular systems with traditional systems such as a technological, linear, or mixed structure. However, this requires the application of technological solutions with the highest level of organization. [ABSTRACT FROM AUTHOR]

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The Quick Response Management (QRM) has as its main goal lead time reduction in companies that offer a wide range of products. With the evolution of production paradigms and considering the current context in which organizations operate, the necessity of competition based on time is growing increasingly. Due to this, and in order to minimize them, this research focused on investigating the main causes of these long lead times in a company active in the chemical sector. The research started with a bibliographic review about the subject of QRM; the second part of the study consisted of field research and the use of a computer simulation application (MPX.) Results from the research show the effectiveness of applying concepts from QRM for lead time reduction, whereby a reduction of around 50% in lead time was possible. This paper outlines contributions to the theories about the subject and collaborates to disseminate this issue, which is relatively scarce in Brazil, more broadly.

POLCA (i.e. Paired-cell Overlapping Loops of Cards with Authorization) is a card-based production control approach developed to support the adoption of Quick Response Manufacturing. POLCA's control mechanism is unique since it combines a card-based element (the paired cell overlapping loops of cards) with a higher-level Material Requirements Planning system for release authorization. POLCA has been applied in practice and evaluated in research, but the loops of cards element (POLC) has been adopted without the authorization element (A). In response, we use simulation to evaluate the effect of POLCA's authorization element. We show that this element has a direct detrimental effect on percentage tardy and mean tardiness performance. While the literature argues that the authorization element should be an integral part of POLCA, our results suggest the opposite. This has important implications for research and practice. Instead of using POLCA with its authorization element, it is preferable to combine POLC—the card-based element—with a shop floor dispatching rule. [ABSTRACT FROM AUTHOR]

Copyright of Gestao & Producao is the property of Gestao & Producao and its content may not be copied or emailed to multiple sites or posted to a listserv without the copyright holder's express written permission. However, users may print, download, or email articles for individual use. This abstract may be abridged. No warranty is given about the accuracy of the copy. Users should refer to the original published version of the material for the full abstract. (Copyright applies to all Abstracts.)

This article is devoted to research of such concept of the organization of production, as Quick Response Manufacturing or Quick-response production, at the center which, time of implementation of the order is put. Today domestic producers are compelled to function in new conditions, competing with a great number of players of the global market, as a result the emphasis on timely implementation of orders and a tendency of reduction of time of production will allow to reach competitive advantages. Fundamental aspects of Quick Response Manufacturing within functioning of the enterprise of branch are considered, and also the essential lack of this concept is revealed.The purpose / objectives. The purpose of article is research of the economic contents of the concept of the organization of production Quick Response Manufacturing and area of its use at the modern industrial enterprises. Article tasks: to investigate economic contents of the concept of Quick Response Manufacturing, to reveal its features and scopes in the modern industry.Methods. A methodical basis of this article are comparative methods of the analysis.Results. The economic contents of the concept of Quick Response Manufacturing are investigated. Four main key aspects which are the cornerstone of this concept are investigated: time force, organizational structure of the enterprise, system dynamics and possibilities of its application in scales of all enterprise. Components of positive work of system dynamics of the industrial enterprise are revealed, the trend of critical process of production is built. Considering that modern conditions demand from the enterprises to react, adapt quickly for the changing conditions, the factor of time plays an important role. Therefore the concept of QRM has rather perspective character, focusing attention on time of implementation of the order, in that communication that this parameter is one of key both for the enterprise, and for increase of its competitiveness.Conclusions and Relevance. It is necessary to expand practical use of instruments of controlling in activity of the industrial enterprises as they allow to increase management efficiency as a result of the accounting of opportunities and threats of environment and current state of the enterprise, its strong and weaknesses. Practical application of results of this work will allow to improve procedures of functioning of the industrial enterprises taking into account current economic and social trends.

Copyright of Revista Producao Online is the property of Associacao Brasileira de Engenharia de Producao and its content may not be copied or emailed to multiple sites or posted to a listserv without the copyright holder's express written permission. However, users may print, download, or email articles for individual use. This abstract may be abridged. No warranty is given about the accuracy of the copy. Users should refer to the original published version of the material for the full abstract. (Copyright applies to all Abstracts.)

This article compares the Quick Response Manufacturing and Time-Based Competition methodologies and identifies their similarities and differences. This investigation deepens our understanding in terms of Quick Response Manufacturing pursuing a theoretical framework for applications in Brazilian companies. Data was collected from publications aimed at presenting and discussing the tactics and approaches of the methodologies. Similarity and difference classification tables are presented. The results reveal that 67% of all approaches compared were classified as analogous and 19% were not analogous. In addition, 14% of approaches presented the non-existence of similarities.

Copyright of Exacta is the property of Exacta - Engenharia de Producao and its content may not be copied or emailed to multiple sites or posted to a listserv without the copyright holder's express written permission. However, users may print, download, or email articles for individual use. This abstract may be abridged. No warranty is given about the accuracy of the copy. Users should refer to the original published version of the material for the full abstract. (Copyright applies to all Abstracts.)

This article compares the Quick Response Manufacturing and Time-Based Competition methodologies and identifies their similarities and differences. This investigation deepens our understanding in terms of Quick Response Manufacturing pursuing a theoretical framework for applications in Brazilian companies. Data was collected from publications aimed at presenting and discussing the tactics and approaches of the methodologies. Similarity and difference classification tables are presented. The results reveal that 67% of all approaches compared were classified as analogous and 19% were not analogous. In addition, 14% of approaches presented the non-existence of similarities. [ABSTRACT FROM AUTHOR]

Operations management researchers have largely studied and analysed lean manufacturing (LM) for its capacity for productivity improvement in industry. Even so, this approach has found several difficulties in dealing with all production types, especially in high-variety and low-volume production. Managers have complemented other approaches to LM to resolve those issues, but there is little research considering quick response manufacturing (QRM). This research shows how QRM can complement LM in a make-to-order environment. Two cases were analysed, where both approaches were used in a complementary way. Data were collected throughout interviews, document analyses and observation. As the main result, we show that QRM complements LM by means of incorporating concepts of system dynamics, exclusively focusing on lead time reduction and the continuous monitoring of utilisation levels. [ABSTRACT FROM AUTHOR]

High capital and labor costs, coupled with high rates of technological and competitive change, present challenges for manufacturers in developed countries, often spurring them to offshore production to low cost sources. However, the electronics industry provides an exception to this trend, where dynamic, high cost conditions have given rise to a new production system – seru – a cellular assembly approach. Seru evolved as an alternative to lean systems approaches, manifesting important differentiated system design choices that appear to offer promise for manufacturing in dynamic, high-cost markets. This paper reports the results of in-depth, longitudinal case studies of two electronics giants who have implemented seru. The case studies describe seru's fundamental extensions to, and departures from, lean production, agile production, and group technology-based cellular manufacturing. We explain how Sony and Canon have applied seru to improve productivity, quality, and flexibility in ways that have enabled them to remain competitive. In addition, our findings elaborate the theory of swift, even flow, with implications for future research of trade-offs related to production efficiency, responsiveness, and competitiveness in high-cost, technologically dynamic markets. [ABSTRACT FROM AUTHOR]

O Quick Response Manufacturing (QRM) é uma abordagem de gestão alternativa à Manufatura Enxuta, que objetiva alcançar a redução do lead time em ambientes com alta variedade de produtos. O objetivo da presente pesquisa é apresentar a proposta de implementação de alguns conceitos e ferramentas do QRM para redução do lead time em uma empresa de materiais de escrita. Basicamente a proposta seguiu os passos básicos de um projeto QRM, chegando à conclusão de que o longo lead time no setor estudado da empresa é ocasionado por quatro principais causas: (i) alocação de recursos em função dos tamanhos de pedidos; (ii) longo set up; (iii) quebra de máquinas; e (iv) tamanhos de lotes grandes. Seis cenários baseados em princípios e técnicas do QRM foram propostos e avaliados por meio de simulação, usando-se a tecnologia RMT (Rapid Modelling Technique). Os resultados esperados indicam que a empresa estudada pode obter uma redução de, aproximadamente, 68% no nível de WIP e de, aproximadamente, 74% no lead time médio, caso implemente a proposta sugerida. O presente trabalho contribui para aumentar a divulgação do paradigma QRM na academia e prática gerencial brasileira.Quick Response Manufacturing (QRM) is a production management approach aiming at reducing lead time in environments with high product variety. The main goal of this research is to present a proposal for the implementation of some QRM concepts and tools for lead time reduction in a company which manufactures school supplies. The proposal followed the basic QRM project steps, concluding that four main reasons explained the long lead time found in the company: (i) allocation of resources made according to order sizes, (ii) set up time, (iii) machine failures, and (iv) large lot sizes. Six scenarios, based on QRM principles and techniques, were proposed and evaluated using Rapid Modelling Technology (RMT). The expected results indicate that the studied company can achieve a reduction of approximately 68% in the WIP level and 74% in the average lead time. This study contributes to spread out the QRM paradigm among researchers and managerial practice in Brazil.

The current paper aims at treating a fundamental problem which is the large volume of operating data associated with increasing the variety, high competition and production according to (Quick Response Manufacturing ) system .Thus, the current study focuses on link the Generic Bill of Material file (GBOM) and Generic Product Structure file (GPS) to creating ( BOMO) Approach as the main requirement for applying (QRM) system, because this approach contributes, to a high extent, in reducing deadlines of production by achieving the simultaneous timing in performing processes . In order to fulfill the aims of the current study, a database is designed by using (Oracle ), then applied practically to a real product(a three–drawer desk). The results are exhibited within the framework of (BOMO) through the integration between (BOMO) and the (Routing) of the product .

Copyright of Exacta is the property of Exacta - Engenharia de Producao and its content may not be copied or emailed to multiple sites or posted to a listserv without the copyright holder's express written permission. However, users may print, download, or email articles for individual use. This abstract may be abridged. No warranty is given about the accuracy of the copy. Users should refer to the original published version of the material for the full abstract. (Copyright applies to all Abstracts.)

Copyright of Revista Producao Online is the property of Associacao Brasileira de Engenharia de Producao and its content may not be copied or emailed to multiple sites or posted to a listserv without the copyright holder's express written permission. However, users may print, download, or email articles for individual use. This abstract may be abridged. No warranty is given about the accuracy of the copy. Users should refer to the original published version of the material for the full abstract. (Copyright applies to all Abstracts.)

Copyright of Revista Producao Online is the property of Associacao Brasileira de Engenharia de Producao and its content may not be copied or emailed to multiple sites or posted to a listserv without the copyright holder's express written permission. However, users may print, download, or email articles for individual use. This abstract may be abridged. No warranty is given about the accuracy of the copy. Users should refer to the original published version of the material for the full abstract. (Copyright applies to all Abstracts.)

This paper presents a complete review of the literature regarding lead time reduction within the context of time-based competition (TBC) and quick response manufacturing (QRM) paradigms. From the review, a classification system has been proposed. From this study, gaps in the literature could be identified as follows: (1) lack of quantitative studies showing the benefits of TBC/QRM and the use of empirical studies (especially action research) about these paradigms; (2) some principles and tools of both paradigms are rarely studied, for example, principles related to utilization levels, lot size, and performance measures focused on time; and (3) the application of principles and tools of the TBC/QRM in practice are scarce. These gaps represent opportunity for future research in the area. This paper is also valuable for managers in practice once it concludes that the essential aspect of the paradigm TBC/QRM is the focus on lead time reduction and not on tools and methods. A direct consequence of this finding is that to develop and use performance measures of lead time reduction is critical within the TBC/QRM. [ABSTRACT FROM AUTHOR]

Virtual Cellular Manufacturing System is a new type of cellular system that emerged as a promising alternative for designing cells in real time. The problem is complex and time consuming NP-hard problem in its nature. This study was conducted to design virtual cells that maximizes similarity index and minimizes lead time. A mathematical model and an effective solution procedure were proposed. Several randomly generated data sets were used along a case study to test the performance of the proposed approach. The effects of inherent parameters of virtual systems were investigated and compared by using particular performance measures. [ABSTRACT FROM AUTHOR]