A review of literature on manufacturing systems productivity measurement and improvement

International Journal of Industrial and Systems Engineering

Volumn 1, Issue 4, 2006, Pages 461-484

  Muthiah, Kanthi M N ^a   Huang, Samuel H ^a  

^a University of Cincinnati   (United States)

Author keywords

bottleneck detection; continuous improvement; factory diagnostics; hidden capacity; manufacturing systems; Operations Research (OR); performance metrics; productivity improvement; productivity measurement; systems analysis

Indexed keywords

EID: 84952955816     PISSN: 17485037     EISSN: 17485045     Source Type: Journal    
DOI: 10.1504/IJISE.2006.010387     Document Type: Article

References (112)

1. Al-Ahmari, A.M.A. and Ridgway, K. (1999) ‘An integrated modeling method to support manufacturing systems analysis and design’, Computers in Industry, Vol. 38, pp.225–238.
2. Alford, L.P. (1934) Henry Laurence Gantt: Leader in Industry, New York: Society of Mechanical Engineers.
3. Ames, V.A., Gililland, J., Konopka, J., Schnabl, R. and Barber, K. (1995) ‘Semiconductor manufacturing productivity overall equipment effectiveness (OEE) guidebook’, International SEMATECH, Report Technology Transfer 95032745A-GEN.
4. Atherton, L.F. and Atherton, R.W. (1995) Wafer Fabrication: Factory Performance and Analysis, Boston: Kluwer Academic Publishers.
5. Beineke, L.W. and Wilson, R.J. (1978) Selected Topics in Graph Theory, New York: Academic Press.
6. Bonal, J., Ortega, C., Rios, L., Aparicio, S., Fernandez, M., Rosendo, M., Sanchez, A. and Malvar, S. (1996) ‘Overall fab efficiency’, Proceedings of the Seventh Annual IEEE/SEMI Advanced Semiconductor Manufacturing Conference, Cambridge, MA.
7. Bravoco, R. and Yadav, S. (1985) ‘A methodology to model functional structure of an organization’, Computers in Industry, Vol. 6, pp.345–361.
8. Carrie, A. and Macintosh, R. (1997) ‘An assessment of GRAI grids and their use in the strathclyde integration method’, Production Planning and Control, Vol. 8, pp.106–113.
9. Chand, G. and Shirvani, B. (2000) ‘Implementation of TPM in cellular manufacture’, Journal of Materials Processing Technology, Vol. 103, pp.144–154.
10. Colquhoun, G., Baines, R. and Crossley, R. (1993) ‘A state of the art review of IDEF0’, International Journal of Computer Integrated Manufacturing, Vol. 6, pp.252–264.
11. Crosby, P.B. (1979) Quality is Free, New York: McGraw Hill.
12. Dale, B.G. (1999) Managing Quality, Blackwell Publishers.
13. Deming, W.E. (1982) Quality, Productivity and Competitive Position, Cambridge, MA: MIT, Centre of Advanced Engineering Study.
14. Deming, W.E. (1986) Out of the Crisis, Cambridge, MA: MIT, Centre of Advanced Engineering Study.
15. Deo, N. (1974) Graph Theory with Applications to Engineering and Applied Science, New Jersey: Prentice-Hall.
16. Desrochers, A.A. (1990) Modeling and Control of Automated Manufacturing Systems, Washington, DC: IEEE Computer Society Press.
17. Dove, R. (1993) ‘Lean and agile: synergy, contrast, and emerging structure’, Proceedings of Defense Manufacturing Conference 93’, San Francisco, CA.
18. Doumeingts, G. (1985) ‘How to centralize decision through GRAI model in production management’, Computers in Industry, Vol. 6, pp.501–514.
19. Doumeingts, G., Vallespir, B. and Chen, D. (1995) ‘Methodologies for designing CIM system: a survey’, Computers in Industry, Vol. 25, pp.263–280.
20. Down, E., Clare, P. and Coe, T. (1988) Structured System Analysis and Design Method, New York: Prentice-Hall.
21. Dubbey, J.M. (1978) The Mathematical Work of Charles Babbage, Cambridge.
22. Eva, M. (1992) SSADM Version 4 – A User Guide, London: McGraw-Hill.
23. Evans, J.R. (1996) ‘Graph theory and networks’, Mathematical Programming for Industrial Engineers, New York: Marcel Dekker, Inc., pp.271–306.
24. Feigenbaum, A.V. (1956) ‘Total quality control’, Harvard Business Review, Vol. 34, pp.93–101.
25. Feigenbaum, A.V. (1991) Total Quality Control, New York: McGraw Hill.
26. Ford, F.N., Bradbard, D.A., Ledbetter, W.N. and Cox, J.F. (1987) ‘Use of operations research in production management’, Production and Inventory Management, Vol. 28, No. 3, pp.59–62.
27. Ford, H. (1988) Today and Tomorrow, Cambridge: Productivity Press (special reprint edition of the 1926 book).
28. Forgionne, G.A. (1983) ‘Corporate management science activities’, Interfaces, Vol. 13, No. 3, pp.20–23.
29. Gaither, N. (1975) ‘The adoption of operations research techniques by manufacturing organizations’, Decision Sciences, Vol. 6, No. 4, pp.797–813.
30. Gershwin, S.B. (1994) Manufacturing Systems Engineering, Englewood Cliffs, NJ: Prentice-Hall.
31. Gershwin, S.B. (2000) ‘Design and operation of manufacturing systems: the control-point policy’, IIE Transactions, Vol. 32, pp.891–906.
32. Giegling, S., Verdini, W.A., Haymon, T. and Konopka, J.M. (1997) ‘Implementation of overall equipment effectiveness (OEE) system at a semiconductor manufacturer’, Proceedings of 1997IEMT Symposium, Austin, TX.
33. Gilbreth, F. and Gilbreth, L. (1917) Applied Motion Study, New York: Sturgis & Walton Co.
34. Goldratt, E. (1990) What is This Thing Called Theory of Constraints and How Should it be Implemented?, North River Press.
35. Goldratt, E.M. and Cox, J. (1986) The Goal, North River Press.
36. Goldratt, E.M. and Fox, R.E. (1986) The Race, North River Press.
37. Green, C.M. (1956) Eli Whitney and the Birth of American Technology, New York: Addison Wesley Longman, Inc.
38. Green, T.B., Newsom, W.B. and Jones, S.R. (1977) ‘A survey of the applications of quantitative techniques to production/operations management in large corporations’, Academy of Management Journal, Vol. 20, No. 4, pp.669–676.
39. Greene, M. (1991) ‘Plant-wide systems: a world class perspective’, Production Inventory Management, Vol. 11, pp.14–15.
40. Grislain, J. and Pun, L. (1979) ‘Graphical methods for production control’, Fifth International Conference on Production Research, Amsterdam, pp.265–270.
41. Grünberg, T. (2003) ‘A review of improvement methods in manufacturing operations’, Work Study, Vol. 52, No. 2, pp.89–93.
42. Hansen, R.C. (2002) Overall Equipment Effectiveness – A Powerful Production/Maintenance Tool for Increased Profits, New York: Industrial Press, Inc.
43. Harrington, H.J. (1995) Total Improvement Management: The Next Generation in Performance Improvement, New York: McGraw Hill.
44. Harrison, A. (1998) ‘Manufacturing strategy and the concept of world class manufacturing’, International Journal of Operations and Production Management, Vol. 18, pp.397–408.
45. Hawkings, L. (2001) ‘Productivity improvement tools for SMEs’, TechWatch, May.
46. Hayes, R.H. and Wheelwright, S.C. (1984) Restoring Our Competitive Edge: Competing Through Manufacturing, New York: John Wiley.
47. Hillier, S.H. and Lieberman, G.J. (2001) Introduction to Operations Research, New York: McGraw-Hill.
48. Hines, P. and Rich, N. (1997) ‘The seven value stream mapping tools’, International Journal of Operations and Production Management, Vol. 17, pp.46–64.
49. Hines, P. and Taylor, D. (2000) Going Lean, Cardiff, UK: Lean Enterprise Research Centre Cardiff Business School.
50. Huang, S.H., Dismukes, J.P., Shi, J., Su, Q., Razzak, M.A., Bodhale, R. and Robinson, D.E. (2003) ‘Manufacturing productivity improvement using effectiveness metrics and simulation analysis’, International Journal of Production Research, Vol. 41, No. 3, pp.513–527.
51. Huang, S.H., Dismukes, J.P., Shi, J., Su, Q., Wang, G., Razzak, M.A. and Robinson, D.E. (2002) ‘Manufacturing system modeling for productivity improvement’, Journal of Manufacturing Systems, Vol. 21, No. 4, pp.249–259.
52. Iacocca Institute (1991) 21st Century Manufacturing Enterprise Strategy: An Industry Led View, Bethlehem, PA: Iacocca Institute, Vols. 1 and 2.
53. James-Moore, S.M. and Gibbons, A. (1997) ‘Is lean manufacture universally relevant? An investigative methodology’, International Journal of Operations and Production Management, Vol. 17, pp.899–911.
54. Johansson, B. and Grünberg, T. (2001) ‘An enhanced methodology for reducing time consumption in discrete event simulation projects’, Proceedings of the 13th European Simulation Symposium: Simulation in Industry, SCS Europe Bvba, Marseille, pp.61–64.
55. Jones, D.T., Hines, P. and Rich, N. (1997) ‘Lean logistics’, International Journal of Physical Distribution and Logistics Management, Vol. 27, pp.153–173.
56. Jonsson, P. and Lesshammar, M. (1999) ‘Evaluation and improvement of manufacturing performance measurement systems: the role of OEE’, International Journal of Operations and Production Management, Vol. 19, No. 1, pp.55–78.
57. Juran, J.M. (1988) Quality Control Handbook, New York: McGraw Hill.
58. Kelada, J.N. (1995) Integrating Re-engineering with Total Quality, Milwaukee: ASQC Quality Press.
59. Kelton, W.D., Sadowski, R.P. and Sturrock, D.T. (2004) Simulation with Arena, New York: McGraw-Hill Higher Education.
60. Kidd, P.T. (1994) Agile Manufacturing: Forging New Frontiers, Addison-Wesley Publishers Ltd.
61. Law, A.M. and Kelton, W.D. (2000) Simulation Modeling and Analysis, New York: McGraw-Hill Higher Education.
62. Leachman, R.C. (1997) ‘Closed-loop measurement of equipment efficiency and equipment capacity’, IEEE Transactions on Semiconductor Manufacturing, Vol. 10, No. 1, pp.84–97.
63. Leon, V.J. (2004) ‘Operations research in manufacturing’, Manufacturing Engineering Handbook, New York: McGraw-Hill, pp.15.1–15.18.
64. Little, J.D.C. (1961) ‘A proof for the queuing formula: L = λW, Operations Research, Vol. 9, pp.383–387.
65. Marca, D.A. and McGowan, C.L. (1988) Structured Analysis and Design Technique, New York: McGraw Hill.
66. Maskell, B.H. (1991) Performance Measurement for World Class Manufacturing. A Model for American Companies, Cambridge, MA: Productivity Press.
67. McMullen, T.B. (1998) Introduction to the Theory of Constraints Management System, Florida: CRC Press LLC.
68. Monden, Y. (1993) Toyota Production System. An Integrated Approach to Just-In-Time, Georgia: Industrial Engineering and Management Press.
69. Morgan, C.L. (1989) ‘A survey of MS/OR surveys’, Interfaces, Vol. 19, No. 6, pp.95–103.
70. Murata, T. (1989) ‘Petri net properties’, Proceedings of the IEEE, Vol. 77, No. 4, pp.541–579.
71. Nakajima, S. (1988) Introduction to Total Productive Maintenance (TPM), Cambridge, MA: Productivity Press.
72. Ohno, T. (1988) Toyota Production Systems: Beyond Large-Scale Production, Cambridge, MA: Productivity Press.
73. Pandya, K. (1995) ‘Review of modeling techniques and tools for decision making in manufacturing management’, IEE Proceedings on Science, Management and Technology, Vol. 142, pp.371–377.
74. Pandya, K., Karlsson, A. and Carrie, A. (1997) ‘Towards the manufacturing enterprises of the future’, International Journal of Operations and Production Management, Vol. 17, pp.502–521.
75. Plonka, F.E. (1997) ‘Developing a lean and agile work force’, Human Factors and Ergonomics in Manufacturing, Vol. 7, pp.11–20.
76. Pojasek, R.B. (2003) ‘Lean, Six Sigma, and the systems approach: management initiatives for process improvement’, Environmental Quality Management, pp.85–92.
77. Radnor, M. and Neal, R.D. (1973) ‘The progress of management science activities in large US industrial corporations’, Operations Research, Vol. 21, No. 2, pp.427–450.
78. Ramirez-Serrano, A., Zhu, S.C., Chan, S.K.H., Chan, S.S.W., Ficocelli, M. and Benhabib, B. (2002) ‘A hybrid PC/PLC architecture for manufacturing system control – theory and implementation’, Journal of Intelligent Manufacturing, Vol. 13, pp.261–281.
79. Ross, D.T. (1985) ‘Application of SADT’, IEEE Transactions on Computers, April, pp.25–34.
80. Ross, D.T. and Schoman, K. (1977) ‘Structured analysis for requirement definition’, IEEE Transactions on Software Engineering, SE, Vol. 3, pp.6–15.
81. Rother, M. and Shook, J. (1999) Learning to See: Value Stream Mapping to Add Value and Eliminate Muda, Brookline, MA: The Lean Enterprise Institute, Inc.
82. Santarek, K. and Buseif, I.M. (1998) ‘Modeling and design of flexible manufacturing systems using SADT and Petri net tools’, Journal of Materials Processing Technology, Vol. 76, pp.212–218.
83. Schonberger, R.J. (1986) World Class Manufacturing: The Lessons of Simplicity Applied, New York: Free Press.
84. Scott, D. and Pisa, R. (1998) ‘Can overall factory effectiveness prolong Moore’s law?’ Solid State Technology, pp.75–82.
85. SEMI E124–0703 (2003) ‘Provisional guide for definition and calculation of the overall factory efficiency (OFE) and other associated factory-level productivity metrics’, Semiconductor Equipment and Materials International, San Jose, CA.
86. SEMI E79–0200 (2000) ‘Standard for definition and measurement of equipment productivity’, Semiconductor Equipment and Materials International, San Jose, CA.
87. Shannon, R.E. and Biles, W.E. (1970) ‘The utility of certain curriculum topics to operations research practitioners’, Operations Research, Vol. 18, No. 4, pp.741–744.
88. Sharma, U. (2003) ‘Implementing lean principles with the Six Sigma advantage: how a battery company realized significant improvements’, Journal of Organizational Excellence, pp.43–52.
89. Shorter, D. (1994) ‘An evaluation of CIM modeling constructs – evaluation report of constructs for views according to ENV 40 003’, Computers in Industry, Vol. 24, pp.159–236.
90. Shrock, D.L. and Ostrom, L.L. (1981) ‘A survey of the use of quantitative methods by motor carriers’, Transportation Journal, Vol. 20, No. 4, pp.86–92.
91. Slack, N. (2001) Operations Management, London: Pearson Education.
92. Smith, A. (1996) The Wealth of Nations, Middlesex, England: Penguin Books Ltd. (reprint edition of 1776 book).
93. Storrs, C. (1949) General and Industrial Management; Translated form the French Edition (Dunod), London: Pitman.
94. Sui-Pheng, L. and Khoo, S. (2001) ‘Enhancement through Japanese 5S principles’, Team Performance Management, Vol. 7, Nos. 7/8, pp.105–111.
95. Suparno Carrie, A.S. (1997) ‘GRAI method and simulation: an approach for assessment of the production planning and control systems’, Proceedings of 32nd International MATADOR Conference, Manchester, 10–11 July, pp.163–168.
96. Suri, R. (1998) ‘Quick response manufacturing: beyond the lean paradigm’, CEMS Business Review, Vol. 2, pp.251–267.
97. Taha, H.A. (2003) Operations Research: An Introduction, New Jersey: Pearsons Education, Prentice Hall.
98. Tangen, S. (2002) ‘A theoretical foundation for productivity measurement and improvement of automatic assembly systems’, Licentiate Thesis, The Royal Institute of Technology, Stockholm.
99. Tangen, S. (2003) ‘An overview of frequently used performance measures’, Work Study, Vol. 52, No. 7, pp.347–354.
100. Taninecz, G. (2004a) ‘Faster but not better’, Industry Week, May.
101. Taninecz, G. (2004b) ‘Long-term commitments’, Industry Week, February.
102. Taylor, F.W. (1967) The Principles of Scientific Management, New York: W.W. Norton & Company, Inc. (reprint edition of 1911 book).
103. Tennant, G. (2001) Six Sigma: SPC and TQM in Manufacturing and Services, Burlington, VT: Gower Publishing Company.
104. Thomas, G. and DaCosta, J. (1979) ‘A sample survey of corporate operations research’, Interfaces, Vol. 9, No. 4, pp.102–111.
105. Turban, E. (1972) ‘A sample of operations research activities at the corporate level’, Operations Research, Vol. 20, No. 3, pp.708–721.
106. Vakola, M. and Rezgui, Y. (2000) ‘Critique of existing business process re-engineering methodologies’, Business Process Management Journal, Vol. 6, No. 3, pp.238–250.
107. Vatter, W.J. (1967) ‘The use of operations research in American companies’, Accounting Review, Vol. 42, No. 4, pp.721–730.
108. Watson, H.J. and Marrett, P.G. (1979) ‘A survey of management science implementation problems’, Interfaces, Vol. 9, No. 4, pp.124–127.
109. Womack, J.P. and Jones, D.T. (1996) Lean Thinking: Banish Waste and Create Wealth in Your Corporation, New York: Simon & Schuster.
110. Womack, J.P., Jones, D.T. and Roos, D. (1990) The Machine that Changed the World, New York: Macmillan Publishing Company.
111. Zhou, M.C. and DiCesare, F. (1993) Petri Net Synthesis for Discrete Event Control of Manufacturing Systems, Boston, MA: Kluwer Academic Publishers.
112. Zhou, M.C., Thorniley, G.A., Wang, J., Huang, Z. and Zhuang, Y. (1994) Performance Modeling and Optimization for Manufacturing Systems Using Petri Nets, Amsterdam: Elsevier.