Yes / Global manufacturing industry mostly depends on new product development and processes to become competitive. The product development process for automotive industry is normally complicated, lengthy, expensive, and risky. Hence, a study of lean manufacturing processes for low volume manufacturing in automotive industry is proposed to overcome this issue by eliminating all wastes in the lengthy process. This paper presents a conceptual design approach to the development of a hybrid Knowledge Based (KB) system for lean process in Low Volume Automotive Manufacturing (LVAM). The research concentrates on the low volume processes by using a hybrid KB system, which is a blend of KB system and Gauging Absences of Pre-requisites (GAP). The hybrid KB/GAP system identifies all potential waste elements of low volume process manufacturing. The KB system analyses the difference between the existing and the benchmark standards for lean process for an effective implementation through the GAP analysis technique. The proposed model explores three major lean process components, namely Employee Involvement, Waste Elimination, and Kaizen (continuous improvement). These three components provide valuable information in order for decision makers to design and implement an optimised low volume manufacturing process, but which can be applied in all process manufacturing, including chemical processing.

The automotive manufacturing facility is extremely complex and expensive system. Managing and understanding the dynamics of automotive manufacturing is a challenging endeavour. In the current era of dynamic global competition, a new concept such as Collaborative Lean Manufacturing Management (CLMM) can be implemented as an alternative for organisations to improve their Lean Manufacturing Management (LMM) processes. All members in the CLMM value chain must work together towards common objectives in order to make the LMM achievable in the collaborative environment. The novel research approach emphasises the use of Knowledge-Based (KB) approach in such activities as planning, designing, assessing and providing recommendations of CLMM implementation, through: a) developing the conceptual CLMM model; b) designing the KBCLMM System structure based on the conceptual model; and c) implementing Gauging Absences of Pre-requisites (GAP) analysis and Analytic Hierarchy Process (AHP) approach in the hybrid KBCLMM. The development of KBCLMM Model is the most detailed part in the research process and consists of five major components in two stages. Stage 1 (Planning stage) consists of Organisation Environment, Collaborative Business and Lean Manufacturing components. Stage 2 (Design stage) consists of Organisation CLMM Capability and Organisation CLMM Alignment components. Each of these components consists of sub-components and activities that represent particular issues in the CLMM development. From the conceptual model, all components were transformed into the KBCLMM System structure, which is embedded with the GAP and AHP techniques, and thus, key areas of potential improvement in the LMM are identified for each activity along with the identification of both qualitative and quantitative aspects for CLMM implementation. In order to address the real situation of CLMM operation, the research validation was conducted for an automotive manufacturer¿s Lean Manufacturing Chain in Malaysia. Published case studies were also used to test several modules for their validity and reliability. This research concludes that the developed KBCLMM System is an appropriate Decision Support System tool to provide the opportunity for academics and industrialists from the fields of industrial engineering, information technology, and operation management to plan, design and implement LMM for a collaborative environment. / Universiti Utara Malaysia and Ministry of Higher Education of Malaysia

The automotive manufacturing facility is extremely complex and expensive system. Managing and understanding the dynamics of automotive manufacturing is a challenging endeavour. In the current era of dynamic global competition, a new concept such as Collaborative Lean Manufacturing Management (CLMM) can be implemented as an alternative for organisations to improve their Lean Manufacturing Management (LMM) processes. All members in the CLMM value chain must work together towards common objectives in order to make the LMM achievable in the collaborative environment. The novel research approach emphasises the use of Knowledge-Based (KB) approach in such activities as planning, designing, assessing and providing recommendations of CLMM implementation, through: a) developing the conceptual CLMM model; b) designing the KBCLMM System structure based on the conceptual model; and c) implementing Gauging Absences of Pre-requisites (GAP) analysis and Analytic Hierarchy Process (AHP) approach in the hybrid KBCLMM. The development of KBCLMM Model is the most detailed part in the research process and consists of five major components in two stages. Stage 1 (Planning stage) consists of Organisation Environment, Collaborative Business and Lean Manufacturing components. Stage 2 (Design stage) consists of Organisation CLMM Capability and Organisation CLMM Alignment components. Each of these components consists of sub-components and activities that represent particular issues in the CLMM development. From the conceptual model, all components were transformed into the KBCLMM System structure, which is embedded with the GAP and AHP techniques, and thus, key areas of potential improvement in the LMM are identified for each activity along with the identification of both qualitative and quantitative aspects for CLMM implementation. In order to address the real situation of CLMM operation, the research validation was conducted for an automotive manufacturer's Lean Manufacturing Chain in Malaysia. Published case studies were also used to test several modules for their validity and reliability. This research concludes that the developed KBCLMM System is an appropriate Decision Support System tool to provide the opportunity for academics and industrialists from the fields of industrial engineering, information technology, and operation management to plan, design and implement LMM for a collaborative environment.

The product development process for the automotive industry is normally complicated, lengthy, expensive, and risky. Hence, a study on a new concept for Low Volume Automotive Manufacturing (LVAM), used for niche car models manufacturing, is proposed to overcome this issue. The development of a hybrid Knowledge Based (KB) System, which is a blend of KB System, Gauging Absences of Pre-requisites (GAP), and Analytic Hierarchy Process (AHP) is proposed for LVAM research. The hybrid KB/GAP/AHP System identifies all potential elements of LVAM issues throughout the development of this system. The KB System used in the LVAM analyses the gap between the existing and the benchmark organisations for an effective implementation. The novelty and differences in the current research approach emphasises the use of Knowledge Based (KB) System in the planning and designing stages by suggesting recommendations of LVAM implementation, through: a) developing the conceptual LVAM model; b) designing the KBLVAM System structure based on the conceptual LVAM model; and c) embedding Gauging Absences of Pre-requisites (GAP) analysis and Analytic Hierarchy Process (AHP) approach in the hybrid KBLVAM System. The KBLVAM Model explores five major perspectives in two stages. Planning Stage (Stage 1) consists of Manufacturer Environment Perspective (Level 0), LVAM Manufacturer Business Perspective (Level 1), and LVAM Manufacturer Resource Perspective (Level 2). Design Stage (Stage 2) consists of LVAM Manufacturer Capability - Car Body Part Manufacturing Perspective (Level 3), LVAM Manufacturer Capability - Competitive Priorities Perspective (Level 4), and LVAM Manufacturer Capability - Lean Process Optimisation Perspective (Level 5). Each of these perspectives consists of modules and sub-modules that represent specific subjects in the LVAM development. Based on the conceptual LVAM model, all perspectives were transformed into the KBLVAM System structure, which is embedded with the GAP and AHP techniques, hence, key areas of potential improvement are recommended for each activity for LVAM implementation. In order to be able to address the real situation of LVAM environment, the research verification was conducted for two automotive manufacturers in Malaysia. Some published case studies were also used to check several modules for their validity and reliability. This research concludes that the developed KBLVAM System provides valuable decision making information and knowledge to assist LVAM practitioners to plan, design and implement LVAM in terms of business organisation, manufacturing aspects and practices.

The product development process for the automotive industry is normally complicated, lengthy, expensive, and risky. Hence, a study on a new concept for Low Volume Automotive Manufacturing (LVAM), used for niche car models manufacturing, is proposed to overcome this issue. The development of a hybrid Knowledge Based (KB) System, which is a blend of KB System, Gauging Absences of Pre-requisites (GAP), and Analytic Hierarchy Process (AHP) is proposed for LVAM research. The hybrid KB/GAP/AHP System identifies all potential elements of LVAM issues throughout the development of this system. The KB System used in the LVAM analyses the gap between the existing and the benchmark organisations for an effective implementation. The novelty and differences in the current research approach emphasises the use of Knowledge Based (KB) System in the planning and designing stages by suggesting recommendations of LVAM implementation, through: a) developing the conceptual LVAM model; b) designing the KBLVAM System structure based on the conceptual LVAM model; and c) embedding Gauging Absences of Pre-requisites (GAP) analysis and Analytic Hierarchy Process (AHP) approach in the hybrid KBLVAM System. The KBLVAM Model explores five major perspectives in two stages. Planning Stage (Stage 1) consists of Manufacturer Environment Perspective (Level 0), LVAM Manufacturer Business Perspective (Level 1), and LVAM Manufacturer Resource Perspective (Level 2). Design Stage (Stage 2) consists of LVAM Manufacturer Capability ¿ Car Body Part Manufacturing Perspective (Level 3), LVAM Manufacturer Capability ¿ Competitive Priorities Perspective (Level 4), and LVAM Manufacturer Capability ¿ Lean Process Optimisation Perspective (Level 5). Each of these perspectives consists of modules and sub-modules that represent specific subjects in the LVAM development. Based on the conceptual LVAM model, all perspectives were transformed into the KBLVAM System structure, which is embedded with the GAP and AHP techniques, hence, key areas of potential improvement are recommended for each activity for LVAM implementation. In order to be able to address the real situation of LVAM environment, the research verification was conducted for two automotive manufacturers in Malaysia. Some published case studies were also used to check several modules for their validity and reliability. This research concludes that the developed KBLVAM System provides valuable decision making information and knowledge to assist LVAM practitioners to plan, design and implement LVAM in terms of business organisation, manufacturing aspects and practices. / Universiti Malaysia Pahang and Ministry of Higher Education Malaysia

The dependency of maintenance as a manufacturing logistic function has made the considerations of maintenance decisions complex in nature. The importance of maintenance has escalated significantly by the increasing of automation in manufacturing processes. This condition switches the traditional maintenance perspective of “fire-fighter” into the business competitive driver. As a consequence, maintenance needs to consider other related aspects of decision making to achieve competitive advantage. This research aims to develop a hybrid Knowledge-Based (KB) System/GAP/AHP methodology to support the integration of maintenance decision with business and manufacturing perspectives. It constructs over 2000 KB rules on Strategic Stage (business and manufacturing aspects) and Maintenance Operations Stage (maintenance aspects). Each aspect contains KB rules attached with GAP analysis to assess the gap between current and prerequisite condition. AHP analysis is then deployed to compare those aspects structurally in a pair-wise manner to identify the critical ones to be rectified. This hybrid KB system is useful in reviewing the existing maintenance system performance and provides reasonable recommendations to improve maintenance performance with respect to business and manufacturing perspectives. Eventually, it indicates the roadmap from the current state to the benchmark goals for the maintenance system. This novel methodology of KBS/GAP/AHP to support maintenance decision is developed for a particular application in the automotive environment. The validation is conducted in two automotive companies in Indonesia and one published case study in an automotive company. The result confirms that the developed KB system can provide the valid, reasonable and consistent result to propose structured recommendation for maintenance improvement priority.

No / A conceptual design approach is an important stage for the development of a hybrid Knowledge-Based System (KBS) for Low Volume Automotive Manufacturing (LVAM). The development of a hybrid KBS, which is a blend of KBS and Gauging Absences of Pre-requisites (GAP), is proposed for LVAM research. The hybrid KB/GAP system identifies all potential elements of LVAM issues throughout the development of this system. The KBS used in the system design stage of the LVAM system analyses the gap between the existing and the benchmark organisations for an effective implementation through the GAP analysis technique. The proposed KBLVAM model at the design stage explores three major components, namely LVAM car body parts manufacturing perspective, LVAM competitive priorities perspective and LVAM lean environment perspective. Initial results reveal that the KBLVAM system has identified, for each perspective modules and sub-modules, the Problem Categories (PC) in a prioritised manner. / The financial support by the Malaysian Government, Universiti Malaysia Pahang and University of Bradford for this research is grateful acknowledged.