CERES :: Browsing by Author "Tjahjono, Benny"

Browsing by Author "Tjahjono, Benny"

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Open Access
Achieving manufacturing excellence through the integration of enterprise systems and simulation
(Elsevier, 2016-02-24) Rashid, Asif; Tjahjono, Benny
This paper discusses the significance of the enterprise systems and simulation integration in improving shop floor’s short-term production planning capability. The ultimate objectives are to identify the integration protocols, optimisation parameters and critical design artefacts, thereby identifying key ‘ingredients’ that help in setting out a future research agenda in pursuit of optimum decision-making at the shop floor level. While the integration of enterprise systems and simulation gains a widespread agreement within the existing work, the optimality, scalability and flexibility of the schedules remained unanswered. Furthermore, there seems to be no commonality or pattern as to how many core modules are required to enable such a flexible and scalable integration. Nevertheless, the objective of such integration remains clear, i.e. to achieve an optimum total production time, lead time, cycle time, production release rates and cost. The issues presently faced by existing enterprise systems (ES), if properly addressed, can contribute to the achievement of manufacturing excellence and can help identify the building blocks for the software architectural platform enabling the integration.
Open Access
An advanced decision process for capacity expansion in manufacturing networks
(Cranfield University, 2008-04) Julka, Nirupam; Baines, Tim; Tjahjono, Benny
Manufacturing companies develop multiple production sites for various reasons from cheaper labour to access to local markets. Expansion of capacity in such a manufacturing network is a complex decision and requires consideration of multiple factors. Traditionally, industrial decision makers attempt to minimise the cost of expansion and, usually as an afterthought, consider soft factors like manpower availability and logistics connectivity. This approach has gained acceptance as the research community has focused on developing better mathematical representations of the problem rather than investigate the larger decision process. A review of the literature revealed that all existing processes for multi-site capacity expansion decision fail in this way. Therefore, this research sets out to fulfil the needs of practitioners by developing a more complete process for the capacity expansion decision in multi-site manufacturing networks. The research programme consists of five parts. In the first part an extensive literature review is conducted to identify the state-of-the-art in capacity expansion decision processes. Then, in the second part, a representative process is formed and industrially tested. This generates the specifications for an advanced decision process which addresses the shortcomings of the present body of knowledge and is developed in the third part of the research. In the fourth part the advanced decision process is applied in an industrial setting to validate its effectiveness. Finally, in the fifth part the advanced decision process is refined and illustrated. The outcome of this research is an improved decision making capability. The advanced decision process has been both validated and appreciated by industrial practitioners. Specifically the contribution to knowledge is an advanced decision process for capacity expansion in multi-site manufacturing network.
Open Access
Advances in Manufacturing Technology XXVII: Proceedings of the 11th International Conference on Manufacturing Research (ICMR2013)
(Cranfield University, 2013-09-19) Shehab, Essam; Ball, Peter D.; Tjahjono, Benny
ICMR2013 was organised by Cranfield University on the 19-20 September 2013. The conference focuses on any aspects of product development, manufacturing technology, manufacturing systems, information systems and digital technologies. It provides an excellent avenue for researchers to present state-of-the-art multidisciplinary manufacturing research and exchange ideas. In addition to the four keynote speeches from Airbus and Rolls-Royce and three invited presentations, there are 108 papers in these proceedings. These papers are split into 24 technical sessions. The International Conference on Manufacturing Research is a major event for academics and industrialists engaged in manufacturing research. Held annually in the UK since the late 1970s, the conference is renowned as a friendly and inclusive environment that brings together a broad community of researchers who share a common goal; developing and managing the technologies and operations that are key to sustaining the success of manufacturing businesses. For over two decades, ICMR has been the main manufacturing research conference organised in the UK, successfully bringing researchers, academics and industrialists together to share their knowledge and experiences. Initiated a National Conference by the Consortium of UK University Manufacturing Engineering Heads (COMEH), it became an International Conference in 2003. COMEH is an independent body established in 1978. Its main aim is to promote manufacturing engineering education, training and research. To achieve this, the Consortium maintains a close liaison with government bodies concerned with the training and continuing development of professional engineers, while responding to the appropriate consultative and discussion documents and other initiatives. COMEH is represented on the Engineering Professor’s council (EPC) and it organises and supports national manufacturing engineering education research conferences and symposia.
Open Access
Aligning retail reverse logistics practice with circular economy values: An exploratory framework
(Taylor and Francis, 2018-05-25) Bernon, Michael; Tjahjono, Benny
Although there is a growing body of literature concerning Circular Economy (CE), there is little, in terms of frameworks in the literature, which focuses on embedding CE values in consumer Retail Reverse Logistics (RRL) operations. The aim of this paper is to present a conceptual framework that supports the adoption of CE values within RRL operations. The framework is designed to assist both practitioners and academics in better understanding the key management aspects involved. The methodology adopts a mixed methods approach combining a desk-based research with rich empirical data from interviews with senior management practitioners and academics in the fields of CE and RRL. From this research, it was found that embedding CE values within RRL necessitates the adoption of a multi-faceted approach. The adoption of the framework will have an impact on practitioners by assisting them in moving towards a more restorative and less impactful approach to their RRL practices. The work is considered innovative and novel as this is the first time the empirical results that suggest a multi-dimensional approach embedding CE values in RRL operations are presented.
Open Access
Allocation of quality control stations in multistage manufacturing systems
(Elsevier Science B.V., Amsterdam., 2011-05-31T00:00:00Z) Shetwan, Ali G.; Vitanov, Valentin; Tjahjono, Benny
The allocation of quality control stations (AQCS) in multistage manufacturing systems has been studied extensively over the decades. This paper reviews the existing approaches, models comparison and solution techniques applied in AQCS. The relevance of the models and the effectiveness of the inspection strategies are examined by developing a generalised model. The conducting simulation experiments show that as the number of workstation increases the processing tine to solve the problem increases significantly. This led to the development of a heuristic algorithm with local search. The performance the heuristic was compared with the optimization method based on complete enumeration method (CEM). It was found that the heuristic method can derive an acceptable solution significantly faster than the CEM. The review has shown that the most common techniques used are dynamic programming and non-linear programming. The paper suggests some biologically inspired optimisation algorithms can be of interest for further study. (C) 2011 Elsevier Ltd. All rights reserved.
Open Access
Applying performance measures to support decision-making in supply chain operations: a case of beverage industry
(Taylor and Francis, 2015-08-13) Moreira, Madalena; Tjahjono, Benny
Performance measurement systems (PMS) have commonly been applied to evaluate and reward performances at managerial levels, especially in the context of supply chain management. However, evidence suggests that the effective use of PMS can also positively influence the behaviour and improve performance at an operational level. The motivation is to accomplish organisational goals, namely to increase supply chain flexibility by responding to evermore-varying customer demands in a timely manner. The purpose of the study described in this paper was to develop a conceptual framework that adopts performance measures for ex-ante decision-making at an operational level within the supply chain. To guide the research, five questions were asked and subsequently key gaps have been identified. In an attempt to fill the gaps, a case study at a major global brand beverage company has been carried out, and as a result, a conceptual framework of the PMS has been developed. Overall, the research offers a foundation of the applicability and impact of PMS in the supply chain and provides a framework that attends to some of the potential uses of PMS that so far have not been practically applied. The outcomes from the testing indicate that the initial gaps identified in the literature have been addressed and that the framework is judicious with scope for practical applicability. The framework is deemed worthy of further testing in different operational contexts of the supply chain.
Open Access
Applying performance measures to support informed decision making at an operational level
(Cranfield University Press, 2013-09-19) Moreira, Madalena; Tjahjono, Benny; Julião, Jorge
Performance Measurement Systems (PMS) have commonly been applied to evaluate and reward performances at managerial levels, especially in the context of supply chain management. However, evidence suggests that the effective use of PMS can also positively influence the behaviour and improve performance at an operational level. The purpose of the study described in this paper is to develop a conceptual framework that adopts performance measures for ex-ante decision-making at an operational level within the supply chain. A case study at Coca-Cola Enterprises has been carried out and as a result, a conceptual framework of the PMS has been developed.
Open Access
Capturing the Industrial Requirements of Set-Based Design for the CONGA Framework
(2013-09-19T00:00:00Z) Al-Ashaab, Ahmed; Golob, Matic; Noriega, Paula; Torriani, Filippo; Alvarez, Pedro; Beltran, Ana; Busachi, Alessandro; Ex-Ignotis, Lambert; Rigatti, Carlotta; Sharma, Sanjiv; Shehab, Essam; Ball, Peter; Tjahjono, Benny
The Configuration Optimisation of Next-Generation Aircraft (CONGA) is a proposed framework in a response to industrial need to enhance the aerospace capability in the UK. In order to successfully address this challenge, a need to develop a true multi-disciplinary Set-Based Design (SBD) capability that could deploy new technologies on novel configurations more quickly and with greater confidence was identified. This paper presents the first step towards the development of the SBD capabilities which is to elicit the industrial requirement of the SBD process for the key aerospace industrial partners involved in this CONGA approach.
Open Access
Comparison of the environmental impact of the CRIMSON process with normal sand casting process
(2013-09-02T00:00:00Z) Zeng, Binxu; Salonitis, Konstantinos; Jolly, Mark R.; Shehab, Essam; Ball, Peter D.; Tjahjono, Benny
The CRIMSON process is an alternative process to conventional casting that can be used for small to medium batch sizes. The aim of this process are to improve the casting quality and reduce the energy consumption within light-metal casting industry. Nowadays, the energy efficiency becomes more and more important. This is not only about the cost of the production, but also about the environmental effect. In this paper, the CRIMSON process will be compared with the conventional sand casting process. The Life cycle assessment (LCA) method will be used to assess the environmental impact of both casting processes.
Open Access
A decision model for manufacturing best practice adoption: Linking practices to competitive strategies
(Cranfield University, 2007-10) Lee Gan Kai, William; Baines, Tim; Tjahjono, Benny
This thesis describes research that has developed a decision model for the analytical selection of manufacturing best practices. The competitiveness and growth in the manufacturing sector is critical for Singapore economy. Design and improvement of manufacturing systems is imperative to sustain the competitiveness of manufacturing organisations in the country. It is common for companies to adopt manufacturing best practices in this design process to emulate the success and performance of their counterparts. However, practices should be adapted to the competitive environment and strategy of the company to yield the desired results. Therefore, linkages between best practices and their associated competitive priorities will present useful guidelines for action to help manufacturing organisations achieve superior performance. The research programme has set out to define a decision model for best practice adoption. A broad taxonomy of manufacturing strategies and concepts has been used to identify and cluster a list of popular best practices commonly adopted. The decision framework for best practice adoption process is then formulated and a preliminary decision model constructed. This model is verified through semistructured interviews with industry and academic experts. Validation of model is conducted via case study research on eight manufacturing organisations. Linkages between practices and competitive strategies are then constructed to establish the final decision model. Finally, this decision model is illustrated in the form of a guidebook to help practitioner in the best practice selection process. This research has bridged the fields of manufacturing strategy and best practice research by establishing a comprehensive taxonomy of manufacturing strategies and concepts to classify the popular and commonly adopted best practices. A decision model that links best practices to competitive strategies has been developed to select the most appropriate practices for an environment. Thus, the work presented in this thesis has made a significant and original contribution to knowledge on the provision of analytical decision support for practitioners engaging in the manufacturing best practice adoption process.
Open Access
Decision support method for contracting of non-original equipment manufacturer aero engine maintenance repair and overhaul service providers.
(2017-10) Wibowo, Arie; Tomiyama, Tetsuo; Tjahjono, Benny
Non-Original Equipment Manufacturer (Non-OEM) Maintenance Repair and Overhaul (MRO) service providers of aero-engines are facing challenges resulting from the rapidly changing MRO market. They need to offer innovative service solutions to airlines through, for example, PSS (Product Service Systems) offerings that combine service(s) and products. PSS can be achieved by either servitisation to add service offerings to products or productisation to add tangible products to service offerings. Currently, however, MRO contracts that include PSS offerings have been prepared based on experiences and intuitions. Ideally, these contracts should be designed to bring about a win-win situation for both airlines (as customers) and MRO service providers. This research aims to develop a new robust, scientific method to prepare contracts for decision makers of non-OEM MRO service providers. The research began with studying current general situation of the PSS in the aero-engine MRO market as well as, in particular, of a Non-OEM MRO service provider. From these, this research first identified sufficient key parameters that describe MRO operations with regard to flight operations of customer airline. A computer-based simulation model was built to assess the capacity and capability of the shop floor operations taking flight operations of the customer into consideration using the discrete event simulation. The simulation model was run over a set of systematically and exhaustively created combinations of different types of services and products. This has helped in selecting the most favourable combinations services and products, which can lead to the win-win situation for both the airlines and the MRO service providers.
Open Access
A decision support tool to facilitate the design of cellular manufacturing layouts
(Elsevier, 2007-05) Vitanov, Val; Tjahjono, Benny; Marghalany, I.
This paper presents a decision support tool that can be used by practitioners and industrialists to solve practical cell formation problems. The tool is based on a cell formation algorithm that employs a set of heuristic rules to obtain a quasi-optimal solution from both component routing information and other significant production data. The algorithm has been tested on a number of data sets obtained from the literature. The test results have demonstrated that in many cases the algorithm has produced an exceptional performance in terms of the grouping efficiency, grouping efficacy and quality index measures. The algorithm, to an extent, overcomes common problems in existing cell formation methods such as in dealing with ill-structured matrices and achieving rational cell sizes.
Open Access
A decision-making framework for purchasing product-service systems
(Cranfield University, 2016-01) Alotaibi, Sati Fehaid; Tjahjono, Benny; Al-Ashaab, Ahmed
As technologies become more complex and competition becomes tougher than ever before, manufacturers in the developed world acknowledge the significance of a competitive strategy in increasing sales to their customers. These strategies not only include offering the products, but also offering service contracts and integrated bundles of products and services, where the supplier is responsible for the required engineering services, typically for a relatively long period of time. This is also known as Product-Service Systems (PSS). For many commercial and governmental organisations, purchasing PSS remains challenging. Despite the considerable work that has been conducted to investigate and improve the methodological applications of the concept of PSS from PSS providers’ perspective, purchasing PSS positions the PSS customers halfway between PSS providers’ strategies and the PSS customer traditional strategies. Little effort in the literature describing how to assist PSS customers in the selection and evaluation of the PSS offerings has been observed. Consequently, this research attempts to satisfy the gap in the body of knowledge by proposing a decision-making framework to enable PSS customer to evaluate and select from the various PSS offers. The research began by reviewing the state-of-art of PSS, followed by the identification of the most likely characteristics exhibited by PSS customers. Then, the research investigates the existing PSS frameworks and analyses it to identify its appropriateness for use by PSS customers. The basis of the PSS framework is initially structured on the findings from the literature review, then modified by the result obtained from the field study in Saudi Arabia. The PSS framework is refined through expert feedback. Then, a computerised software tool was developed for the purpose of validation. Finally, the proposed PSS framework is validated by conducting five case studies. The proposed framework can guide purchasing practitioners through a step by step process, from evaluation to selection the most suitable PSS offers, by considering the degree of fitness between the PSS offerings and customer’s characteristics. This research has satisfied the industrial need and filled the gap in the literature, and has made a significant contribution to the knowledge on PSS customers to overcome the challenge of purchasing PSS.
Open Access
Designing contracts for aero-engine MRO service providers: models and simulation
(Elsevier, 2017-03-02) Wibowo, Arie; Tjahjono, Benny; Tomiyama, Tetsuo
The aero-engine Maintenance-Repair-Overhaul (MRO) service provider has begun to adopt the product-service system (PSS) offering in order to maintain their competitiveness. Such total solution approach combines an availability-based service contract with product offerings (e.g., leasing). The current MRO service provider's contract design method is inadequate to support this offering. Miscalculation often occurs, because many of the decisions are often based on intuitions and experiences, resulting in lower quality, higher cost and longer turnaround time for the maintenance. This paper proposes an enhanced contract design method that is more scientific through the simulation modelling. The models incorporate both customers’ requirements and the shop floor's operational availability. The paper provides discussion on how the results of the simulation of the models can be used to support decision making and the design of availability based contracts.
Open Access
Development of a strategic supply chain positioning methodology for SMEs in Singapore
(Cranfield University, 2007-10) Lim Yan Guan, Roland; Baines, Tim; Tjahjono, Benny
The Small and Medium Enterprises (SMEs) in Singapore face particular challenges from increasing competition from manufacturers in China, India and other East Asian countries. For these SMEs, survival and growth depend critically on defining their own competitive space among other companies in the manufacturing supply chains. Unfortunately there is little previous research on Strategic Supply Chain Positioning (SSCP) with most current frameworks and methodologies being developed from the perspective of the larger multinational companies (MNCs). Therefore this research has set out to develop a practical and robust SSCP methodology to support strategic decision making in SMEs in Singapore. The research programme began with a review of the existing methodologies and selecting the most promising methodology for further evaluation. Testing of this methodology was then carried out through four industrial case studies. Based on the results of the evaluation, the methodology was refined and a pilot SSCP methodology for SMEs was developed. Further testing was then carried out with another four case studies to identify particular characteristics for further improvement. The final SSCP methodology was then developed as a computerised software tool and presented in Chapter 9 of this thesis. The research has created a strategic supply chain positioning methodology that provides practical and procedural aid for strategic supply chain positioning efforts for SMEs in Singapore. This methodology guides the practitioner through a series of well-defined steps necessary to define the desired strategic positioning of the company in the supply chain. Such a methodology has been lacking in previous research and, hence, is the main contribution to knowledge in this thesis.
Open Access
e-Knowledge: an approach to fostering manufacturing know-how at the shop floor
(Production and Operations Management Society, 2001) Tjahjono, Benny; Bin, Wu
This paper presents an application of the web technology in promoting knowledge management at the shop floor, known as e-knowledge. The system is expected to promote sharing and reusing various levels of manufacturing information from assembly cell to testing area, and from documentation to training. The implementation of such a system has been made possible by utilising the web-programming environment. To investigate how the e-knowledge works, a case study involving a major cellular telecommunication industry is presented.
Open Access
Enhancing regional produce as green products for the Global Market: An exploratory study in a Portuguese region
(IGI Global, 2017-07-31) Gaspar, Marcelo C.; Julião, Jorge; Tjahjono, Benny
This study focuses on exploring the sustainability characteristics of the regional produce, which comes from the Beiras region of Portugal to support new differentiation claims and forecast its effect on a global mass-market. Considering a Multiple Helix approach, this study aims to examine the role and perception of local academia in relation to this new premise to enhance the dynamic and competitive positioning of such regional produce. To this end, several in-depth interviews were conducted with local researchers and decision-makers, allowing the significance and potential of the proposed green claims to be discussed. Several insights into the subject were developed and new directives were presented. Nonetheless, complementary research may still be necessary to assess the remaining multiple helix actors of the local ecosystem in order to identify and develop the most promising strategies to effectively promote local endogenous produce to a global market.
Open Access
Enterprise systems’ life cycle in pursuit of resilient smart factory for emerging aircraft industry: a synthesis of Critical Success Factors’(CSFs), theory, knowledge gaps, and implications
(Taylor & Francis, 2017-01-31) Rashid, Asif; Masood, Tariq; Erkoyuncu, John Ahmet; Tjahjono, Benny; Khan, N.; Shami, M.
The research aims to investigate business value critical success factors (CSFs) of enterprise systems (ES) through their life cycle in pursuit of resilient smart factory for emerging aircraft industry. This article provides an extensive literature analysis of past 22 years based on conscientious criteria of authors: (i) who have published strategic content relevant to CSFs, (ii) received more than 300 citations and (iii) concurrently published two or more papers relevant to ES CSFs. The most cited strategic CSFs were termed as classical CSFs. The 22 CSFs were identified, validated and synthesised for better understanding of success across life cycle by aircraft industry experts. The top 10 empirically verified CSFs have numerous differences with past generic classical CSFs. This article canvases real insights of two distinct views: process and variance approaches of the ES CSFs. The process approach, which is a neglected research area, facilitates the researchers for identification of ES life cycle process coupled with a view of resource deployment when it is needed the most. While the variance approach facilitates practitioners and researchers in finding out which resource (CSF) is relatively more important. The significant findings for ES life cycle can help the practitioners and researchers to make rational decisions throughout the ES life cycle.
Open Access
Environmental impact assessment of the manufacturing of a commercial aircraft
(2013-09-02T00:00:00Z) Kolios, Athanasios J.; Howe, Stuart; Asproulis, Nikolaos; Salonitis, Konstantinos; Shehab, Essam; Ball, Peter D.; Tjahjono, Benny
This paper documents the methodology and presents the results of a comprehensive LCA study of an Airbus A320 commercial airliner to determine the relative environmental impact of its manufacturing phase. The study was conducted in accordance with ISO 14040/44 using SimaPro LCA software, the EcoInvent inventory database and Eco-Indicator 99 weighting method, which allows the analysis to be outputted in a single score representing a number of damage models including damage to human health, ecosystem quality or resource depletion. Results indicate CFRP wings to have the most significant contribution to the overall environmental impact as a proportion to mass.
Open Access
Evaluation of a manufacturing task support system using the Task Technology Fit Model
(Production and Operations Management Society, 2001) Tjahjono, Benny; Fakun, D.; Greenough, Richard M.; Kay, John M.
This paper presents an exploratory study of a Task Support System (TSS) supporting manufacturing task operations. The study investigated the degree to which a TSS, in use in a company, actually supports the task of the shop floor personnel. The approach has been to adopt the Task-Technology Fit (TTF) instrument to measure the degree of fitness between the TSS and the associated task. The analysis gives an indication of the state of the TSS and the potential improvements that can be made. The study also shows that the instrument can be used as a foundation for the development of a hypermedia TSS and a benchmarking tool for a TSS.