Operations Management and Systems Engineering (eBook)

Dr. Anish Sachdeva is Professor in the Department of Industrial and Production Engineering at Dr. B.R. Ambedkar National Institute of Technology, Jalandhar. He obtained his bachelors in Industrial Engineering from Regional Engineering College, Jalandhar in 1994; masters in Industrial Engineering from Punjab Technical University, Jalandhar in 2003; and his Ph.D from IIT Roorkee in 2008. He has published more than 100 research articles in international journals and conferences. His academic activities include serving as a peer reviewer in journals, acting as session chair in many international conferences, and conducting a number of training programs. His areas of interest include reliability and maintenance engineering, advanced machining, supply chain management, stochastic modeling, and system simulation. Dr. Pradeep Kumar is Professor in the Department of Mechanical & Industrial Engineering at Indian Institute of Technology, Roorkee. He obtained his bachelors (Industrial Engineering) in 1982; masters (Production Engineering) in 1989; and Ph.D. in Manufacturing and Production Engineering in 1994, all from the University of Roorkee. He has been a visiting faculty at West Virginia University, Wayne State University, AIT Bangkok, and King Fahd University of Petroleum and Minerals, Saudi Arabia. He served at the Delhi Technological University as Vice-Chancellor during 2014-15. He has published around 580 research papers in international and national journals, and conference proceedings. Dr. Kumar has completed 43 consultancy projects of various organizations, and 18 sponsored research projects in India and 1 sponsored project in USA. He also has 4 patent disclosures. His research interests include advanced manufacturing processes, microwave joining of metals, metal casting, industrial engineering, supply chain management, quality engineering, and production and operations management. Dr. Om Prakash Yadav is Professor and Interim Department Chair, Industrial and Manufacturing Engineering, North Dakota State University, Fargo. He obtained his bachelors in Mechanical Engineering from Malviya National Institute of Technology, Jaipur in 1986; masters in Industrial Engineering from National Institute of Industrial Engineering, Bombay in 1992; and Ph.D. in Industrial and Manufacturing Engineering from Wayne State University, Detroit in 2002. He has published more than 120 scientific papers in international journals and conferences, and edited more than 15 books and proceedings. He has successfully completed nearly 30 fully funded research and consultancy projects.  His research interests include quality and reliability engineering, production and operations management, supply chain (logistics), inventory modeling, lean manufacturing, quantitative modeling, statistical analysis, fuzzy logic, and neural networks.

About This Book 6
Contents 7
About the Editors 9
1 Tolerance Analysis of Mechanical Assemblies Using Monte Carlo Simulation—A Case Study 11
1.1 Introduction 11
1.2 Literature Review 13
1.3 Design of Simulation Methodology—Monte Carlo Simulation 13
1.4 Case Study–Cylinder-Piston Assembly 14
1.4.1 Random Sampling of Dimensions 16
1.4.2 Tolerance Analysis and Yield Estimation 17
1.4.3 Normal Distribution 19
1.4.4 Beta Distribution 19
1.5 Discussion 19
1.6 Conclusion 24
References 24
2 Operationalization and Measurement of Service Quality in Manufacturing Supply Chains: A Conceptual Framework 26
2.1 Introduction 26
2.2 Manufacturing Supply Chains 28
2.3 Different Perspectives of Service Quality 30
2.3.1 Partnership, Coordination, and Collaboration 33
2.3.2 Enterprise-Wide View of the Supply Chain 34
2.4 Major Research Findings 34
2.4.1 Actionable Framework 37
2.4.2 Managing Service Quality in Manufacturing Supply Chains 37
2.4.3 Recommendations 40
2.4.4 Concluding Remarks 41
References 41
3 A Novel Framework for Evaluation of Failure Risk in Thermal Power Industry 45
3.1 Introduction 46
3.2 Research Background 46
3.3 Fuzzy Concepts and Decision-Making Methods 48
3.3.1 Triangular and Trapezoidal Membership Functions 48
3.3.2 Improved Fuzzy FMEA 48
3.3.3 EDAS Method 51
3.3.4 Case Study 53
3.4 Proposed Framework Application 53
3.4.1 Improved FMEA Application 53
3.4.2 Fuzzy EDAS Application 55
3.5 Result Discussion 56
3.6 Conclusion 57
References 57
4 Modeling and Analysis of Critical Success Factors for Implementing the IT-Based Supply-Chain Performance System 59
4.1 Introduction and Background 60
4.2 Proposed Methodology 61
4.2.1 Interpretive Structural Modeling Approach 61
4.2.2 Preference Rating Approach 61
4.3 A Case Illustration 63
4.4 MICMAC Analysis 65
4.5 Results and Discussion 73
4.6 Conclusion 73
References 74
5 Lean-Sigma for Product Improvement Using the VoC for Enhancing the Product Competitiveness 76
5.1 Introduction 77
5.1.1 The Six Sigma Strategy 78
5.1.2 Lean Manufacturing Strategy 78
5.1.3 Merging Lean and Six Sigma 80
5.1.4 Lean-Sigma Approach 81
5.2 Case Study 83
5.2.1 Introduction 83
5.2.2 Problem Description 84
5.3 Methodology 86
5.4 Problem Analysis 87
5.4.1 Root Cause Analysis 88
5.5 Developing a Solution 92
5.6 Verify the Solution 93
5.7 Control Plan 96
5.8 Conclusions 97
References 98
6 Structural Equation Modelling Application to Assess Environmental Aspects in Implementing Sustainable Manufacturing 99
6.1 Introduction 100
6.2 Literature Review 101
6.2.1 Sustainable Manufacturing 102
6.2.2 Structural Equation Modelling (SEM) 102
6.3 Methodology 104
6.4 Proposed Model and Hypotheses 106
6.4.1 Proposed Framework for SM 106
6.4.2 Proposed Inner (Structural) Model and Hypotheses 106
6.5 Results and Discussions 108
6.6 Conclusion 112
References 114
7 Service Quality Through the Lens of SAP-LAP Methodology: A Case Study 117
7.1 Introduction 117
7.2 Literature Review 119
7.3 A Case Study on Technical Institution Using SAP-LAP 123
7.3.1 Background of ABC Group of Institutions, Punjab 123
7.3.2 Tool: Situation-Actor-Process–Learning-Action-Performance (SAP-LAP) 125
7.4 Key Learning Issues 133
7.5 Conclusions, Limitations, and Future Directions 133
7.6 Learning from This Research 133
References 137
8 Selection of the Optimum Hole Quality Conditions in Manufacturing Environment Using MCDM Approach: A Case Study 139
8.1 Introduction 140
8.2 Literature Review 140
8.3 Experimentation Work 141
8.3.1 Experimental Results 141
8.4 Decision-Making With the MCDM Approaches 143
8.4.1 The ARAS Method 146
8.4.2 The TOPSIS Method 147
8.5 Method 1: Implementation Steps of Aras Method for the Considered USM Case Study 148
8.5.1 Normalized Matrix for Raw Data 148
8.5.2 Weighted Normalized Matrix 148
8.5.3 Computation for the Optimality Function (Hole Quality Attribute Index (HQAI)–Sj) & Degree of Utility (Uj)
8.6 Method 2: Implementation Steps of Topsis Method for the Considered USM Case Study 151
8.6.1 Normalized Matrix 151
8.6.2 Weighted Normalized Matrix 151
8.6.3 Computation for the Particular Alternative to the Ideal Solution (Hole Quality Attribute Index (HQAI)-Pj) 155
8.7 Conclusions 155
References 157
9 Reliability Analysis of CNG Dispensing Unit by Lambda-Tau Approach 159
9.1 Introduction 160
9.2 Literature Review 161
9.3 Reliability Tools 161
9.3.1 Reliability Block Diagram 162
9.3.2 Fault Tree Analysis and Petri Nets 162
9.3.3 FMEA 163
9.3.4 Fuzzy Methodology 164
9.3.5 Fuzzification 164
9.4 Research Methodology 167
9.4.1 Illustrative Case Study 168
9.5 Result & Discussion
9.6 Conclusion 172
References 172
10 Assessment of Health Risks Among Tractor Operators Due to Whole-Body Vibration 175
10.1 Introduction 176
10.2 Background and Review 177
10.3 Assessment of Health Risks Among Tractor Operators 177
10.3.1 Assessment Survey 177
10.3.2 Survey Objective 178
10.4 Results and Discussion 178
10.4.1 Prevalence of MSDs in Non-tractor Operator 178
10.4.2 Prevalence of MSDs in Tractor Operator 180
10.4.3 Comparison for Prevalence of Pain, Aching or Discomfort in Non-tractor Operators and Tractor Operators 182
10.4.4 Statistical Analysis 182
10.4.5 Comparison for Prevalence of Pain, Aching or Discomfort Among Tractor Operators Who Used Cushion and not Used Cushion on Tractor Seat 184
10.5 Conclusions 187
References 189
11 Modelling, Simulation and Optimization of Product Flow in a Multi-products Manufacturing Unit: A Case Study 190
11.1 Introduction 191
11.2 Modelling and Simulation in Manufacturing Environment 192
11.3 Outcome of Literature Review 193
11.4 Objectives of Research 193
11.5 Methodology 194
11.6 Case Study of Gear Manufacturing Company 194
11.6.1 Production Scenario at XYZ Ltd. 196
11.7 Simulation Modelling of Gear Job Shop Manufacturing at XYZ Ltd. 197
11.7.1 Simulation Model Development 198
11.7.2 Verification and Validation 213
11.8 Results and Discussion 214
11.9 Conclusion and Future Scope 214
References 218
12 Benchmarking the Interactions Among Drivers in Supply Chain Collaboration 220
12.1 Introduction 221
12.2 Literature Survey 222
12.3 Problem Descriptions 223
12.4 ISM Methodology 227
12.5 Application of the ISM-Based Methodology for Collaborative Drivers to the Implementation of SCC 228
12.5.1 Overview of the Manufacturing Sector 229
12.5.2 Structural Self-interaction Matrix (SSIM) 229
12.5.3 Reachability Matrix 231
12.5.4 Level Partitions 231
12.5.5 ISM-Based Model 235
12.6 MICMAC Analysis 235
12.7 Results and Discussion 238
12.8 Managerial Implications 240
12.9 Conclusion 241
References 241
13 Significance of Electronic Waste Management for Sustainable Industrial Production 245
13.1 Introduction 245
13.2 E-Waste Toxicity to Human Beings 246
13.3 Impacts of E-Waste on Environment 247
13.4 Strategies to Manage E-Waste 248
13.5 The Characteristic Features of Tools for E-Waste Management 250
13.6 Conclusion 251
References 251