Framework of automated value stream mapping for lean production under the Industry 4.0 paradigm

For efficient use of value stream mapping(VSM)for multi-varieties and small batch production in a data-rich environment enabled by Industry 4.0 technologies,a systematic framework of VSM to rejuvenate traditional lean tools is proposed.It addresses the issue that traditional VSM requires intensive on-site investigation and replies on experience,which hinders decisionmaking efficiency in dynamic and complex environments.The proposed framework follows the data-information-knowledge hierarchy model,and demonstrates how data can be collected in a production workshop,processed into information,and then interpreted into knowledge.In this paper,the necessity and limitations of VSM in automated root cause analysis are first discussed,with a literature review on lean production tools,especially VSM and VSM-based decision making in Industry 4.0.An implementation case of a furniture manufacturer in China is presented,where decision tree algorithm was used for automated root cause analysis.The results indicate that automated VSM can make good use of production data to cater for multi-varieties and small batch production with timely on-site waste identification and analysis.The proposed framework is also suggested as a guideline to renew other lean tools for reliable and efficient decision-making.

Lean Product Development Process with Design Verification Stages in the Value Stream of Automotive Industry

In the automotive industry, lean projects and innovation creation come to life by being updated under the control of systematic interdisciplinary process flows. The lean product development process that changes the shell, defined under the light of the variables created by the competitive conditions, is today measured by the value flow efficiency and the global market spread of the final product. Consequently, the lean product development approach, which aims to identify and purify all the wastes that do none value or create value to the system or cause burdens in the new product development process, is shaped by step-by-step approvals in the flow. In the main automotive industry company practices within the scope of the research (3 national, 3 international), the beginning of the concept of lean in design is to define and optimize the steps in the product development process under the value stream map. Therefore, the product function for which the customer has paid for, the function of the new product or the physical structure used to meet the needs in question, the comfort, life, experience, innovations of the scope that constitute the new product concept are planned and verified and implemented in the simplified automotive design stages at the beginning of the lean product development process. In this research, initial automotive design objectives and stages are at the focal point of the innovation and added value creation brought by the concept of “lean” approach. The research is modelled on the determination of steps that do not create added value together with the points where the flow circuits’ or stems, the process is devalued, the interdisciplinary holistic studies intensify, the information and delay begin and end in the sequential and simultaneous design validation step transition stages, which are examined under the lean approach. As a visual and virtual tool that enables the elaboration of nominal values such as the total duration of the design verification stages and the influence of interdisciplinary stakeholders or the test level of the product design with the new product added, it reveals the value flow or losses. Hence research;from innovation creation and new product design steps, which constitute the initial stages of the lean product development process, to design verification analysis, the efficiency of the automotive company processes within the scope of the research has been measured by comparing using lean automotive design techniques, methods and concepts.

Autonomous Vehicle Design in Lean Product Development Processes for Value Stream Map

The global automotive industry is giving a difficult and common test in order to create advanced life models in the near future plans or scenarios that include current autonomous vehicle technologies. Therefore, the main purpose of the research is to comparatively evaluate the impact of autonomous vehicle technologies, which are newly included in the automotive manufacturing industry under sustainable competition, on lean product development processes, value acquisition and preservation, in different organizational structures in the approach. Although mergers or brand acquisitions in the global automotive industry create joint R & D (Research Development) or joint new P & D (Product Development) process structures for the development of autonomous vehicle technologies, heavy competition continues in the market. These new processes create different needs for the merger and partnership of the renewed traffic infrastructures under national and international regulations, and for the implementation of the new autonomous life model. Firm and brand marriages, mergers or acquisitions in today’s automotive industry have ensured the high diffusion of lean product development processes under the stream of value creation or preservation carried out specific to the company under competition. Brand mergers in automotive industry companies struggling to survive under high competition create new work disciplines, professions, and engineering flow steps in lean product development processes. However, lean product development processes driven by technological innovation under simplification have resulted in the integration of parts and systems within the autonomous vehicle design structure, as well as creating new interdisciplinary value streams or different stakeholders. Therefore, the research revealed the significant effects of lean product development processes on the value stream in the automotive industry, on the mixed and lean product development process structure formed by new or existing vehicle systems (conventional vehicle) under the penetration of each existing and new discipline. This research compares the efficient operation steps of the process stakeholders in the autonomous vehicle design parts or systems containing innovation and new technology together with the value stream in the lean product development process, and the new process stakeholder’s business-oriented global and local automotive industry companies. New autonomous vehicle technologies, together with their unique software, hardware and development analysis, have been involved in the lean product development process with their interdisciplinary studies or expertise. Therefore, the study firstly focused on the technologies in environmental use together with the new basic features of autonomous vehicles, and then examined in depth the new or existing disciplines and interdisciplinary basic structure that these innovations affect under the value stream in the lean product development process. In addition, micro-level results and recommendations were shared, shedding light on how autonomous vehicle levels will create changes in the new product development process.

Evaluation of Lean Product Development Stages of Autonomous Vehicle Technologies with AHP Method

The potential innovation and emerging workforce created by autonomous vehicle technologies, which have just entered the lean product development disciplines, play an important role in the development or change of the automotive manufacturing industry. Therefore, the intensity of work and the innovation practices brought by the technologies in question at each step of very different and interdisciplinary studies deeply affect the new and lean product development steps. Comparatively measuring the operating weight of new autonomous vehicle technologies in different company structures in these lean product development steps has important consequences for the development and change of the automotive industry under heavy global competition. On the other hand, it is difficult to measure the innovation input or the use of new autonomous technology under the AHP mathematical model of each part that constitutes the whole of the lean product development process, but it also creates the future predictions of the sector. The Analytical Hierarchy Process (AHP), which is one of the multi-purpose decision-making methods, was used to determine the most intense value creation, the design and development phase where there is innovation input, or the lean product development discipline throughout the whole process. The AHP method was preferred for the comparative analysis and synthesis of different applications or similar approaches in the automotive manufacturing industry companies (global and local) and lean product development processes in the field study of the research, under qualitative data. Under the AHP mathematical model created in the research, it was aimed to measure interdisciplinary clusters with a focus on new technology and to identify similarities or differences under alternative applications created by different company structures and to compare them systematically and evaluate them mathematically. In the study, the AHP mathematical model was used to compare lean product development processes and the use of new autonomous vehicle technologies, and the Expert Choice program was preferred in the application of the method.

中小企业MRP的标准化应用分析

Order-oriented production is the main production method of some small and mediumsized enterprises(SMEs),which not only indicates that customer demand becomes the vane of enterprise production,but also puts high demands on the flexibility of production.Material requirements planning(MRP)is a modern enterprise management method based on basic databill of materials(BOM).For order-driven SMEs,MRP not only helps enterprises to complete material delivery in a timely manner,but also provides flexibility to meet customer needs.Standardization and MRP complement each other in enterprise operation,and they are effective in solving problems such as untimely material supply,undetermined procurement timing,and supply chain system jams.By studying the standardization application of MRP in enterprises,the article not only optimizes the standardization management system of enterprises,but also contributes to the high-quality development of SMEs.

Autonomous Vehicle Technologies Effects the Automotive Concept Design Stages with AHP Method

In the automotive concept design stages, functionally positioning the newly introduced autonomous technologies or remodelling the vehicle accordingly and evaluating the steps or determining the workload together with the collaboration intensity in the current flow is the initial step for the entire process efficiency. Therefore, the main purpose of the research is to reveal the effects of the autonomous technologies, which are newly included in the automotive concept design stages in automotive manufacturing industry companies that continue their lives under heavy competition conditions, according to the order of importance. The objective of this research is to both increase the efficiency of automotive concept design stages and to determine the measurement of the effects of new autonomous vehicle technologies in practice. Under the AHP method used in the research, the automotive concept design stages constitute the alternatives in the order of importance of the working structure, as well as the application variables of autonomous vehicle technologies, the criteria of the mathematical model. In addition, the research method modelled in the study, under the AHP mathematical model, reveals the performances or order of importance of the automotive concept design stages under autonomous technologies. Therefore, the resulting process performances constitute important inputs for efficiency and optimization studies under different research approaches. When the results of the study are examined, due to the high level of influence on the new vehicle concept design performance in automotive industry companies, the adaptation or application steps of autonomous vehicle technologies create new needs in the whole process. The determination of innovation creation clusters in the design process steps or the selection of the density of new technology adaptation in the stages and the order of importance provide a competitive advantage along with optimization in the basic functions of the automotive industry companies. However, the determination of new workload clusters in the mentioned automotive concept design process steps or the effect of autonomous technologies in the design stages, selection, transfer from theory to practice, multiple conflicting criteria and uncertain parameters create a very complex situation. For all these reasons, the Analytical Hierarchy Process (AHP), which is one of the widely used multi-criteria decision-making tools, is considered as a suitable approach for creating such order of importance and solving problems. In this study, an AHP mathematical model was created that determines the workload clusters created by autonomous vehicle technology applications that have just begun to guide the automotive concept design process, which is the main function of automotive manufacturing industry companies. Therefore, in line with the innovations, changes and adequacy criteria created by the current automotive concept design stages in the new autonomous vehicle technology adaptation, a stage order of importance has been selected.

New Autonomous Vehicle Technologies Effect on Automotive Concept Design Stages

New road transportation systems solutions create significant changes in existing automotive manufacturing industry products and technologies, from design to use. The conveniences within the framework of new approaches brought by autonomous vehicle technologies primarily make individuals transition from driver duty to passenger and high-comfort alternative travel technologies. Therefore, the research: defining the path followed by the autonomous vehicle technologies, which lead to the development of the said new life model and automotive products within the future fiction, in the stages of designing new concept vehicles in practice or measuring the effect on the processes constitute important values for the future prediction of this sector. In addition, the research has focused on the effects of interdisciplinary studies at the automotive concept design stages, which are at the beginning of today’s lean and new product development process, where innovation goals or technologies emerge with more concrete needs. New autonomous vehicle technologies and the main purpose of revealing the interdisciplinary studies created by new disciplines in the current automotive concept design stages make significant contributions to the optimization of the lean product development process and value creation. For this reason, the automotive manufacturing industry, which is on the eve of a major transformation with the said new autonomous vehicle technologies;determining the needs or sustainable position in the flow of digital perception and orientation systems;determining value creation criteria related to the functioning of automotive concept design processes or new acceptance criteria through one-on-one interviews in the field;constitutes the focus of the research. The research has examined the new interdisciplinary studies and effects of new autonomous vehicle technologies in the automotive concept design phase, which is the first step of lean product development, with local and global automotive industry company comparisons in operation. Therefore, the differences and similarities between the concept design stages of global automotive companies that are both co-developers of new autonomous vehicle technologies and manufacturing automotive products and local automotive manufacturing companies that only assemble them determine the future competitive structuring of the industry.

Approaching lean product development using system dynamics:investigating front-load effects

Competing with successful products has become perplexing with several uncertainties and transmutes from time to time as customers' expectations are dynamic.That is why manufacturing firms exhaustively strive to look for a better competitive frontier using wellestablished and innovative product development(PD)processes.In this paper,we would like to answer three research questions:(i)What would be the effects of frontloading in PD?(ii)Can we improve our PD process endlessly?(iii)When is the critical time that the firm should take remedial action for improvements?As a contribution to the vast numbers of improvement methods in new product development(NPD),this paper investigates the effects of front-loading using set-based concurrent engineering(SBCE)on cost and lead time.Models are developed and treated using a system dynamics(SD)approach.We assign a hypothetical upfront investment for SBCE and compare its effects on total cost and lead time of the development process.From the research,it is found that the total cost of PD is reduced almost by half-although the front loading is higher in order to encompass multiple design alternatives.The total product lead time is reduced by almost 20%.The model reveals the critical time for improvement of the PD process.We use SD tool(e.g.,STELLA)for simulation and visualization of the complex PD model,using SBCE as one of several strategies to frontload activities in the NPD process.