Document Type: Review Article

Authors

1 Mechanical and Industrial engineering department, University of Dar es Salaam, Tanzania.

2 Chicago, Illinois, USA.

Abstract

Cycle time is one of the viable parameters which needs to be optimised as much as possible whenever the manufacturing industry is trying to improve efficiency, cost base and customer responsiveness. This systematic study presents on the reduction of cycle time for productivity improvement in the manufacturing industry. In industries, cycle time should be focused due to the high need of balancing man, machine, materials, methods and management. It must be renowned that the reduction of cycle time is not an easy task. Productivity improvement process involves many factors in achieving the maximum reduction of unnecessary time for higher improvement. The appropriate approaches to be implemented includes lean manufacturing tools, value stream method, method-time measurements, just in time for inventory control, motion study, process study, VAT plant classification, total productive maintenance, improved MRP (material requirements planning)-based production planning, theory of constraint, linear programming and other simulation related techniques. The V, A or T types of plant classification can also be classified using optimisation production technology (OPT).

Keywords

Agrawal, A., Minis, I., and Nagi, R., (2000). "Cycle time reduction by improved MRP-based production planning", International Journal of Production Research, Vol. 38, No. 18, pp. 4823–4841.

Anyaeche, C.O., and Adegbilero, B.O., (2014). "Performance Evaluation of a Production Firm Using System Cycle Time Approach", Industrial Engineering Letters, Vol. 4, No. 1, pp. 24–34.

Arvind, R. and Gunasekaran, N., (2014). "A Literature Review on Cycle Time Reduction in Material", International Journal for Research in Applied Science & Engineering Technology (IJRASET), Vol. 2, No. XII, pp. 70–72.

Bagri, G.P. and Raushan, P., (2014). "Productivity Improvement of Forging Section Using Work Study and Automation in Existing Axle", International Journal of Mechanical and Production Engineering, Vol. 2, No. 6, pp. 1–4.

Chandegra, P.N., and Deshpande, V.A., (2015). "Cycle Time Reduction of PCF Gearbox using Total Productive Maintenance (TPM ) approach", International Journal of Advance Industrial Engineering, E-ISSN 2320 –5539, Vol. 3, No. 2, pp. 60–67.

Chawasemerwa, T., Taifa, I.W., and Hartmann, D., (2018). "Development of a Doctor Scheduling System : A Constraint Satisfaction and Penalty Minimisation Scheduling Model", International Journal of Research in Industrial Engineering, Vol. 7, No. 4, pp. 396–422.

Chen, T., (2013). "A systematic cycle time reduction procedure for enhancing the competitiveness and sustainability of a semiconductor manufacturer", Sustainability, Vol. 5, No. 11, pp. 4637–4652.

Han, K.H., Lee, G. and Choi, S.H., (2013). "Manufacturing cycle time reduction for batch production in a shared worker environment", International Journal of Production Research, Vol. 51, No. 1, pp. 1–8.

Hetzel, W.B., (1993). Cycle Time Reduction and Strategic Inventory Placement Across a Multistage Process, Massachusetts Institute of Technology, Massachusetts Institute of Technology.

Hopp, W.J. and Spearman, M.L., (2008). Factory Physics, Vol. 2, New York: McGraw-Hill/Irwin New York.

Jovanovic, J.R., Milanovic, D.D., and Djukic, R.D., (2014). "Manufacturing Cycle Time Analysis and Scheduling to Optimize Its Duration", Strojniški Vestnik – Journal of Mechanical Engineering, Vol. 60, No. 7–8, pp. 514–524.

Kagermann, H., Wahlster, W., and Helbig, J., (2013). Recommendations for Implementing the Strategic Initiative INDUSTRIE 4.0: Final Report of the Industrie 4.0 Working Group, Technical report, acatech -- National Academy of Science and Engineering, München.

Khan, W.N. and Sharma, S., (2014). "Cycle Time improvement in structure secton of an automobile Industry: A case study", 2014 1st International Congress on Computer, Electronics, Electrical, and Communication Engineering (ICCEECE2014), Vol. 59, IPCSIT Press, Singapore, pp. 149–154.

Klarin, M., Spasojevi, V., Golubović, T., Stanisavljev, S., Brkić, A. and Sajfert, Z., (2016). "Production cycle time reduction in low and medium-low-tech companies: a case study for Serbia", Tehnicki Vjesnik - Technical Gazette, Vol. 23, No. 4, pp. 1103–1108.

Kriett, P.O., Eirich, S., and Grunow, M., (2017). "Cycle time-oriented mid-term production planning for semiconductor wafer fabrication", International Journal of Production Research, Vol. 55, No. 16, pp. 4662–4679.

Kumar, P., Shetty, R., and Rodrigues, L.L.R., (2014). "Overall Equipment Efficiency and Productivity of a News Paper Printing Machine of a Daily News Paper Company - A Case Study", International Journal of Engineering Practical Research, Vol. 3, No. 1, p. 20.

Kumar, S.S., and Kumar, M.P., (2014). "Cycle time reduction of a truck body assembly in an automobile industry by lean principles", Procedia Materials Science, Vol. 5, pp. 1853–1862.

Kumbhar, S.K., Niranjan, M.R., and Satpute, S.T., (2014a). "Assembly line production improvement by optimization of cycle time", International Journal of Mechanical And Production Engineering, Vol. 2, No. 8, pp. 29–33.

Kumbhar, S.K., Niranjan, M.R., and Satpute, S.T., (2014b). "Assembly Line Production Improvement by Optimization of Cycle Time", Proceedings of 10th IRF International Conference, 01st June-2014, Vol. 2, Pune, India, pp. 124–128.

Leachman, R. c, and Ding, S., (2011). "Short Papers Semiconductor Manufacturing", IEEE Transactions on Automation Science and Engineering, Vol. 8, No. 1, pp. 112–117.

Mahatme, N.N., and Dahake, S. V., (2016). "Productive improvement and cycle time reduction in CNC machining- a case study", International Journal of Research in Advent Technology, pp. 34–37.

Marr, B., (2017). "Why Everyone Must Get Ready For The 4th Industrial Revolution", Forbes.

Meidan, Y., Lerner, B., Rabinowitz, G., and Hassoun, M., (2011). "Cycle-time key factor identification and prediction in semiconductor manufacturing using machine learning and data mining", IEEE Transactions on Semiconductor Manufacturing, Vol. 24, No. 2, pp. 237–248.

Murali, B., and Nagaraja, S., (2014). "A review report on productivity improvement in pumping unit manufacturing line by using value stream mapping", International Journal for Research in Applied Science & Engineering Technology (IJRASET), Vol. 2, No. XI, pp. 447–449.

Nazzal, D., Mollaghasemi, M., and Anderson, D., (2006). "A simulation-based evaluation of the cost of cycle time reduction in Agere Systems wafer fabrication facility—a case study", International Journal of Production Economics, Vol. 100, pp. 300–313.

Panneerselvam, R., (2012). Production and Operations Management, 3rd ed., PHI Learning Private Limited, New Delhi.

Patel, H., and Shah, S.C., (2014). "Review on Cycle Time Reduction in Manufacturing Industries", Journal of Emerging Technologies and Innovative Research (JETIR), Vol. 1, No. 7, pp. 955–957.

Pereira, A.C., and Romero, F., (2017). "A review of the meanings and the implications of the Industry 4.0 concept", Procedia Manufacturing, Vol. 13, pp. 1206–1214.

Prashar, A., (2018). "Toward cycle time reduction in manufacturing SMEs: Proposal and evaluation", Quality Engineering, Taylor & Francis, pp. 1–16.

Rajenthirakumar, D., Sridhar, R. and Janani, K.. (2015), “Measuring the Impact of lean tools in a printing machinery Manufacturing Company”, Annals of Faculty Engineering Hunedoara – International Journal of Engineering, ISSN 1584 – 2673, Vol. 3, pp. 149–154.

Rajesh, G., (2015). "Implementation of a Lean Model in Manufacturing Industry", SSRG International Journal of Industrial Engineering (SSRG-IJIE), Vol. 2, No. 2, pp. 10–14.

Rekha, R.S., Periyasamy, P., and Nallusamy, S., (2017). "Manufacturing Enhancement through Reduction of Cycle Time using Different Lean Techniques", IOP Conference Series: Materials Science and Engineering, Vol. 225 No. 1, doi: 10.1088/1757-899X/225/1/012282.

Ronen, B., and Starr, M.K., (1990). "Synchronized manufacturing as in OPT: from practice to theory", Computers & Industrial Engineering, Vol. 18, No. 4, pp. 585–600.

Saraswat, P., Kumar, D., and Kumar Sain, M., (2015), "Reduction of Work in Process Inventory and Production Lead Time in a Bearing Industry Using Value Stream Mapping Tool", International Journal of Managing Value and Supply Chains (IJMVSC), Vol. 6, No. 2, pp. 27–35.

Saravanan, J., and Thakkar, J.J., (2018). "An integrated approach for lead time reduction of military aircraft major overhaul: a case of ABC Company", International Journal of Quality & Reliability Management, Vol. 35, No. 1, pp. 2–33.

Schlaepfer, R.C., Koch, M., and Merkofer, P., (2015), Industry 4.0 Challenges and Solutions for the Digital Transformation and Use of Exponential Technologies.

Schrauf, S., and Berttram, P., (2017). Industry 4.0: How Digitization Makes the Supply Chain More Efficient, Agile, and Customer-Focused.

Selladurai, R.S., (2004). "Mass customization in operations management: Oxymoron or reality?”, Omega, Vol. 32, No. 4, pp. 295–300.

Simonis, K., Gloy, Y.-S., and Gries, T., (2016). "Industrie 4.0 - Automation in weft knitting technology", IOP Conference Series: Materials Science and Engineering, Vol. 141, pp. 1–11.

Sivakumar, A.I., and Chong, C.S., (2001). "Simulation based cause and effect analysis of cycle time distribution in semiconductor backend", Computer in Industry, pp. 59–78.

Sreelekshmy, K.K.R., Rajesh, P.G., Santhosh, M.B. and Anoop, K.S., (2013). "The Impact of Lean Production on the Cycle Time : A Case Study of a Welding Assembly Line in Kerala", IJSRD - International Journal for Scientific Research & Development, Vol. 1, No. 6, pp. 6–9.

Stainer, A., (1995). "Productivity management: the Japanese experience", Management Decision, Vol. 33, No. 8, pp. 4–12.

Stalk, G., (1998). "Time – The next source of competitive advantage", Harvard Business Review, Vol. 66, No. 4, pp. 41–51.

Swamidass, P.M., and Majerus, C., (1991). "Statistical control of manufacturing cycle time and project time: Lessons from statistical process control", International Journal of Production Research, Vol. 29, No. 3, pp. 551–563.

Taifa, I.W., (2016). Integration of Quality Function Deployment (QFD) and Ergonomics Principles in Product Design Improvement. Case Study: Student Desk at Engineering College, Dissertation, Gujarat Technological University.

Taifa, I.W., and Desai, D.A., (2015a). "Quality Function Deployment integration with Kano model for ergonomic product improvement (Classroom furniture) - a review", Journal of Multidisciplinary Engineering Science and Technology (JMEST), Vol. 2, No. 9, pp. 2484–2491.

Taifa, I.W., and Desai, D.A., (2015b). "A review and gap analysis on integration of Quality Function Deployment and ergonomics principles for product improvement (Classroom furniture)", Industrial Engineering Journal, Vol. VIII, No. 12, pp. 16–25.

Taifa, I.W., and Desai, D.A., (2016). "Student-defined quality by Kano model: A case study of Engineering students in India", International Journal for Quality Research, Vol. 10, No. 3, pp. 569–582.

Taifa, I.W., and Desai, D.A., (2017a), "Anthropometric measurements for ergonomic design of students’ furniture in India", Engineering Science and Technology, an International Journal, Vol. 20, pp. 232–239.

Taifa, I.W., and Desai, D.A., (2017b). "User requirements customization and attractive quality creation for design improvement attributes", International Journal for Quality Research, Vol. 11, No. 1, pp. 131–148.

Taifa, I.W.R., Desai, D.A., and Bulsara, N.M., (2018). "The development of an ergonomically designed product through an integrated product team approach", International Journal of Occupational Safety and Ergonomics, Taylor & Francis, pp. 1–19, doi: 10.1080/10803548.2018.1557398.

Toyota Industries Corporation. (2019), "History", Toyota Industries Corporation.

Toyota Motor Corporation. (2003), "The more uncertain the future is, the more important it is to have this courage", Toyota Motor Corporation.

Vaidya, S., Ambad, P., and Bhosle, S., (2018). "Industry 4.0 - A Glimpse", Procedia Manufacturing, Vol. 20, pp. 233–238.

Venkataraman, K., Ramnath, B.V., Kumar, V.M., and Elanchezhian, C., (2014). "Application of Value Stream Mapping for Reduction of Cycle Time in a Machining Process", Procedia Materials Science, Vol. 6, pp. 1187–1196.

Vignasathya and Bhaskar, (2012). "Assembly Line Balancing of Watch Movement Assembly", International Journal of Modern Engineering Research (IJMER), Vol. 2, No. 2, pp. 543–546.

Zhao, Y., Xu, X., Li, H., and Liu, Y., (2018). "Stochastic customer order scheduling with setup times to minimize expected cycle time", International Journal of Production Research, Taylor & Francis, Vol. 7543, pp. 1–23.

Zhong, R.Y., Xu, X., Klotz, E., and Newman, S.T., (2017). "Intelligent Manufacturing in the Context of Industry 4.0: A Review", Engineering, Vol. 3, No. 5, pp. 616–630.