Effect of lean manufacturing tools on sustainability: the case of Mexican maquiladoras.

The Mexican maquiladora industry is applying Lean Manufacturing Tools (LMT) in its production lines; however, few studies have investigated its relationship with sustainability (social, economic, and environmental). This paper presents a second-order structural equation model (SEM) relating 8 LMT integrated into three independent latent variables: continuous improvement (Kaizen and Gemba), supporting tools (Andon, visual management, and Poka-yoke), and machinery and equipment (total productive maintenance, overall equipment effectiveness, and Jidoka) that are related to social, economic, and environmental sustainability as dependent variables. The model is validated with information obtained from 249 companies using partial least squares. Findings show that the application of LMT in the Mexican maquiladora industry avoids the generation of waste and reprocessing. Likewise, the improvement of production processes reduces the waste emitted into the environment and reduces energy consumption. Also, when companies have environmental programs, the work environment is safe, and labor relations are improved, increasing morale and the commitment to work for the company, gaining economic and ecological benefits.

Determining optimal laser-beam cutting equipment investment through a robust optimization modeling approach.

The acquisition of Advanced Manufacturing Technologies (AMT), such as high-power fiber or CO2 laser cutting equipment, generally involves high investment levels. Its payback period is usually more extended, and there is a moderate-to-high risk involved in adopting these technologies. In this work, we present a robust model that optimizes equipment investing decisions, considers the process's technical constraint and finds an optimal production plan based on the available machinery. We propose a linear investment model based on historical demand information and take physical process parameters for a LASER cutting equipment, such as cutting speed and gas consumption. The model is then transformed into a robust optimization model which considers demand uncertainty. Second, we determine the optimal production plan based on the results of the robust optimization model and assuming that demand follows a normal distribution. As a case study, we decided on the investment and productive plan for a company that offers Laser-Beam Cutting (LBC) services. The case study validates the effectiveness of the proposed model and proves the robustness of the solution. For this specific application of the model, results showed that the optimal robust solution could increase the company's expected profits by 6.4%.

Research on the energy-saving control strategy of a belt conveyor with variable belt speed based on the material flow rate.

Aiming at solving the problem of high energy consumption in the rated belt speed operation of a belt conveyor system when the material flow rate is reduced, the power consumption of the frequency converter, motor, and belt conveyor is analyzed, a power consumption model of the belt conveyor system is established, the relationship between the power consumption of the belt conveyor system and belt speed is obtained, and a energy-saving control strategy of the belt conveyor with variable belt speed based on the material flow rate is put forward. The energy consumption of the belt conveyor is analyzed for a practical case. Results show that the power consumption model is accurate and the control strategy effectively reduces energy consumption. The model has high application value in coal, ports, power, mine, metallurgy, chemical, and other industries.

Full shift assessment of back and head postures in overhead crane operators with and without symptoms.

OBJECTIVES: Prolonged sitting with a flexed back and neck is recognized as being associated with an increased risk of neck and back pain disorders among overhead crane operators. The aim of this study was to compare back and head postures over a full shift of work between operators who experience back and neck pain, and healthy operators. METHODS: In a first phase, the prevalence of musculoskeletal symptoms was assessed using the Nordic questionnaire among 120 crane operators. Based on first phase results, 17 operators with back/neck disorders were matched with 15 healthy operators based on age and selected to participate in the second phase of the study. Postures and movements were continuously measured over an 8 h shift using inclinometers. RESULTS: The highest 12-month prevalence of musculoskeletal disorders was found in the lower back, neck and knees. Case and control groups differed significantly in back and head flexion angles at the 50th percentiles APDF (p < 0.05). There was also a significant difference in the time spent working in an extreme posture of the back and head between groups (p < 0.05). CONCLUSIONS: This is the first study to document work postures assumed during a full work shift and to compare postures between symptomatic and healthy overhead crane operators. Physical exposure in case group operators was characterized by more awkward and extreme postures in the back and head. The results of this study demonstrate that effective prevention strategies directed towards musculoskeletal disorders are required that address awkward work postures for overhead crane operators.

Market Competitiveness Evaluation of Mechanical Equipment with a Pairwise Comparisons Hierarchical Model.

This paper provides a description of how market competitiveness evaluations concerning mechanical equipment can be made in the context of multi-criteria decision environments. It is assumed that, when we are evaluating the market competitiveness, there are limited number of candidates with some required qualifications, and the alternatives will be pairwise compared on a ratio scale. The qualifications are depicted as criteria in hierarchical structure. A hierarchical decision model called PCbHDM was used in this study based on an analysis of its desirable traits. Illustration and comparison shows that the PCbHDM provides a convenient and effective tool for evaluating the market competitiveness of mechanical equipment. The researchers and practitioners might use findings of this paper in application of PCbHDM.

Smart Manufacturing.

Historic manufacturing enterprises based on vertically optimized companies, practices, market share, and competitiveness are giving way to enterprises that are responsive across an entire value chain to demand dynamic markets and customized product value adds; increased expectations for environmental sustainability, reduced energy usage, and zero incidents; and faster technology and product adoption. Agile innovation and manufacturing combined with radically increased productivity become engines for competitiveness and reinvestment, not simply for decreased cost. A focus on agility, productivity, energy, and environmental sustainability produces opportunities that are far beyond reducing market volatility. Agility directly impacts innovation, time-to-market, and faster, broader exploration of the trade space. These changes, the forces driving them, and new network-based information technologies offering unprecedented insights and analysis are motivating the advent of smart manufacturing and new information technology infrastructure for manufacturing.