Thesis (S.M.)--Massachusetts Institute of Technology, Sloan School of Management; and, (S.M.)--Massachusetts Institute of Technology, Dept. of Chemical Engineering; in conjunction with the Leaders for Manufacturing Program at the Massachusetts Institute of Technology, 1995. / Includes bibliographical references. / This thesis follows the transfer of a thin film from development to manufacturing. Problems of differences in equipment and differences in manufacturing methods were overcome to complete the transfer. The film was characterized using UV-Visible, FTIR, and Raman spectroscopy. Hydrogen forward scattering, surface bead angle, and atomic force microscopy were also employed. A series of experiments was conducted to: 1) Analyze the impact of deposition parameters on the performance of the film. 2) Match the performance of films produced in the manufacturing site to the performance of films produced in the development site. Both the development and manufacturing sites were acquired by a new company during the period of this transfer. The cultures of the development and manufacturing sites had not merged before this occurred. This fact, coupled with subsequent reorganization undertaken by the new management, has the potential to slow product introductions. The transfer of this film was successful despite the organizational upheaval occurring at the same time. Three factors contributed to this success: 1) The development engineer stayed with the process throughout the transfer to manufacturing. 2) The collaboration of upstream manufacturing steps integrated the new process with the existing line. 3) Early involvement of manufacturing speeded acceptance and lessened training costs. Recommendations to better link the manufacturing and technology development groups, based on observations made during work on the film transfer, are presented for management's consideration. Key among these is the establishment of common goals and the building of a communication infrastructure between the two sites. / by Brad Houston. / S.M.

Thesis (S.M.)--Massachusetts Institute of Technology, Sloan School of Management; and, (S.M.)--Massachusetts Institute of Technology, Dept. of Chemical Engineering; in conjunction with the Leaders for Manufacturing Program at MIT, 2001. / Includes bibliographical references (p. 119-121). / In the industrialized world, the automotive industry faces growing environmental regulation in the form of standards for local air pollutant emissions and fuel economy. Yet another target for regulation in the near future could be carbon dioxide, as its greenhouse gas behavior becomes increasingly linked to climate disturbances on a global scale. And as the automotive industry expands its operations to emerging markets with exponential population growth, the appropriateness of a crude oil-dependent internal combustion infrastructure may be called into question for reasons of fuel availability and price. Out of concern for these developments, some auto companies are working to make the automobile more sustainable. A major part of their efforts involves pursuit of alternative propulsion systems in parallel with the evolving internal combustion engine. In this thesis, I explore how propulsion regimes might shift in the near term (ten-year) future using a set of scenarios generated with a system dynamics model. Moreover, in this way I test the usefulness of the system dynamics methodology for scenario creation. While a variety of fuels can be used to power a given propulsion system, I limit this study to one fuel option per system. Four specific systems are considered: a gasoline internal combustion engine (ICE); a gasoline hybrid system that combines an ICE with an electric motor to conserve fuel; a battery electric vehicle (EV) charged regularly from the electricity grid; and a fuel cell electric vehicle (FCEV) that electrochemically converts hydrogen to electricity for propulsion. I first examine the motivation and method for exploring future propulsion regimes, and then provide a technology assessment of propulsion attributes on the basis of existing studies. Next is a description of how these attributes can feed a system dynamics model to explore how technology demand might evolve in consideration of the relative presence of infrastructure, availability, and awareness for each propulsion option. Using this model, a set of three scenarios is created by adjusting model parameters and providing supporting rationale. Finally, I discuss strategic implications both of the scenarios themselves and of insights gleaned through the system dynamics modeling exercise. / by Sara Susanne Metcalf. / S.M.

Thesis (M.B.A.)--Massachusetts Institute of Technology, Sloan School of Management; and, (S.M.)--Massachusetts Institute of Technology, Dept. of Mechanical Engineering; in conjunction with the Leaders for Manufacturing Program at MIT, 2003. / Includes bibliographical references (p. 84-86). / by Louis W. Rassey. / S.M. / M.B.A.

Thesis (M.B.A.)--Massachusetts Institute of Technology, Sloan School of Management; and, (S.M.)--Massachusetts Institute of Technology, Dept. of Civil and Environmental Engineering; in conjunction with the Leaders for Manufacturing Program at MIT, 2004. / Page 146 blank. / Includes bibliographical references (p. 107-108). / Much academic literature exists in the fields of Product Development and Project Management. This thesis uses the framework provided by the literature to analyze a case study development project which the author led from January through August of 2003. The phases of the product development process are investigated as is the scheduling of the project. The case study project was an effort to develop a system to measure minute settlements in an existing London Underground subway tunnel as new tunneling work was taking place below it. The system developed would use wireless technology for its data communication. This development project was a part of a larger initiative to promote low-cost, low-impact wireless monitoring systems for ageing infrastructure. It was funded by the Cambridge-MIT Institute (CMI). Particular attention is paid in this thesis to the role uncertainty played in the development process. The importance of using flexibility in addressing uncertainty is highlighted. The relatively new field of Real Options is employed to frame the flexibility and uncertainty issues in an analytic light. / by James Raymond Brooks. / S.M. / M.B.A.

Thesis (M.B.A.)--Massachusetts Institute of Technology, Sloan School of Management; and, (S.M.)--Massachusetts Institute of Technology, Dept. of Chemical Engineering; in conjunction with the Leaders for Manufacturing Program at MIT, 2004. / Includes bibliographical references (p. 109-110). / The overriding objective of diagnostic assessment is change. Assessment processes are a mechanism to identify areas that merit change. In order to maximize the possibility that a company will adopt recommended changes following a diagnostic assessment, the assessment process itself must be matched to the companies needs. This research presents a model of factors that affect the level of change adoption in firms. From this model, a framework was developed to evaluate the degree to which diagnostic assessment processes facilitate change adoption in a firm. The framework was then applied to the Manufacturing Advisory Service (MAS), a business support service in the UK. Operational aspects of the MAS are also explored. The lessons of the MAS are then applied in the larger context of business support through policy recommendations for the UK Department of Trade and Industry. / by Amy S. Vallely. / S.M. / M.B.A.

Thesis (M.B.A.)--Massachusetts Institute of Technology, Sloan School of Management; and, (S.M.)--Massachusetts Institute of Technology, Dept. of Chemical Engineering; in conjunction with the Leaders for Manufacturing Program at MIT, 2004. / Includes bibliographical references (p. 94-96). / While the pace of technical innovation in the semiconductor industry continues to accelerate, business processes and supply chain techniques have not kept up. Microprocessor performance improvement continues to follow Moore's Law, but increased variability has complicated efforts to accurately forecast demand and set inventory targets. Products are becoming more complex, often containing assemblies of multiple parts. Lifecycles are becoming shorter; made possible by technology breakthroughs and efficient manufacturing ramp-ups. Demand and supply are ever more stochastic and non-stationary. Inventory is one of the few ways that a firm can buffer themselves from the inherent and increasing variability, while still meeting required service levels. We explore the sources of the variability in the semiconductor supply chain. On the supply side, we evaluate variability in throughput time, yield and other factors not explicitly considered in standard models. Here, we primarily focus on the natural stochasticity of the manufacturing process and disregard the variability arising from forecasting of these supply parameters. For demand, the natural stochastic process is not well understood, so we evaluate the forecast error and use it as a proxy for demand variability. We then apply these data to the base-stock model - constrained by its associated assumptions - to calculate inventory targets required to meet a certain level of service. Using a two-node base-stock model in conjunction with the actual variability data, we develop inventory estimates across the network and evaluate tradeoffs between different inventory strategies. We then determine what each variability parameter contributes to inventory. The combination of a simple yet representative / (cont.) model of the semiconductor supply chain with actual data from the variability characterization provides the tools to make powerful recommendations to reduce variability and decrease inventories throughout the supply network. / by Joseph C. Levesque. / S.M. / M.B.A.

Thesis (M.B.A.)--Massachusetts Institute of Technology, Sloan School of Management; and, (S.M.)--Massachusetts Institute of Technology, Dept. of Civil and Environmental Engineering; in conjunction with the Leaders for Manufacturing Program at MIT, 2004. / Includes bibliographical references (p. 89-90). / As most companies in the consumer products space develop operational capabilities to produce and distribute high-quality low-cost products, leading firms in the industry continuously seek new ways to increase profitability and provide value to their retail partners and end consumers. While firms such as Procter & Gamble (P&G) have developed lean and flexible supply chains, this innovation has not had significant impact on the actual sale of product to the customer in individual stores. Analysis shows that large differences in the level of consumer demand for specific products exist across retail chains. However, current practices typically treat all stores across a chain the same. This thesis presents methods to target store-level marketing levers, including product mix, promotions, pricing, distribution and inventory management levels, based on shopper demographics and past purchasing behavior. Specifically, a framework to divide large retail chains into smaller "virtual chains" and subsequently develop targeted micro-marketing strategies for these virtual chains is presented. Research for this thesis was conducted during a six and a half month internship with P&G's Product Supply group at the Cosmetics division in Hunt Valley Maryland. The internship was affiliated with the Massachusetts Institute of Technology's Leaders for Manufacturing Program. / by John P. Sharkey. / S.M. / M.B.A.

Thesis (M.B.A.)--Massachusetts Institute of Technology, Sloan School of Management; and, (S.M.)--Massachusetts Institute of Technology, Dept. of Mechanical Engineering; in conjunction with the Leaders for Manufacturing Program at MIT, 2005. / Includes bibliographical references (p. 137-139). / Competitive pressures in manufacturing industries have led to an increased utilization of outsourcing as a strategic alternative to vertical integration. This thesis develops a methodology to aid multi-business unit firms in formulating outsourcing strategies on the corporate or business group level. It offers frameworks for identifying non-core manufacturing capabilities and make versus buy decision making. In addition, it identifies critical organizational and communication linkages between levels of management and functional groups that are necessary precursors to developing a successful outsourcing strategy. Finally, it presents an analysis of the growing importance of the strategic sourcing function within the engineering firm, the informational inputs needed for the sourcing organization to adequately support activities across all business units, and investigates issues of measurement and performance within a cross-business unit support function. The research leading to the development of the described outsourcing methodology was conducted jointly between the MIT Leaders for Manufacturing Program and Honeywell International within the Honeywell Automation and Control Solutions Business Group. / by Ramy Abu-Khalil. / S.M. / M.B.A.

Thesis (S.M.)--Massachusetts Institute of Technology, Dept. of Materials Science and Engineering; and, (M.B.A.)--Massachusetts Institute of Technology, Sloan School of Management; in conjunction with the Leaders for Manufacturing Program at MIT, 2005. / Includes bibliographical references (p. 54-55). / As companies grow and innovate, they offer an increasing number of products. Product proliferation must be managed through a product development process, which is supported by key competencies of the company in the form of platforms. Product and technology platforms have been essential to the success of innovative companies. By leveraging core abilities, companies are able to bring products to market faster and at a lower cost for quality. In this research I present the concept of a manufacturing process platform and a framework for identifying and institutionalizing the platform. I present a case study of a manufacturing group in Eastman Kodak Company which has performed analysis of manufacturing processes and is attempting to implement a manufacturing process platform. Research for this thesis was conducted during a six and a half month internship with Eastman Kodak Company's High Performance Imaging Systems Manufacturing group in Rochester, NY. The internship was affiliated with the Massachusetts Institute of Technology's Leaders for Manufacturing Program. / by Justin Ging. / M.B.A. / S.M.

Thesis (M.B.A.)--Massachusetts Institute of Technology, Sloan School of Management; and, (S.M.)--Massachusetts Institute of Technology, Dept. of Mechanical Engineering; in conjunction with the Leaders for Manufacturing Program at MIT, 2005. / Includes bibliographical references (leaves 76-77). / Throughout the vehicle development process, automotive manufacturers must work to meet a variety of customer needs. One increasingly important attribute is vehicle exterior perceived quality, which is largely dependent on how well exterior parts fit together. Before vehicles are produced and sold to customers, manufacturers utilize several processes and tools to "tune in" vehicle exteriors. This thesis examines one manufacturer's approach to delivering vehicle exterior quality, including a recent change initiative to improve the tune in process. The overall vehicle development process is introduced, and then detail is provided for areas of the process that relate closely to vehicle exteriors. Two areas that are explored in depth are the manufacturer's tune in build strategy and a new exterior fitting fixture implementation. An assessment of build strategy is provided and a framework is proposed. The framework is based on functional build theory and Key Characteristic (KC) chains. Functional build is a process to ensure that the vehicle exterior meets specifications while allowing engineering teams to determine the best way to solve dimensional problems, which may or may not include forcing a component in the assembly to design intent. / (cont.) A KC chain analysis is one way to view how vehicle exterior requirements relate to each other and engineering organizational structure. Viewing build strategies with these two techniques illustrates how build decisions are impacted by organizational and technical complexity, as well as material rigidity. At an automotive manufacturer, several fitting fixtures are used during the tune in process. An initiative to implement a new fitting fixture is assessed. Both technical and organizational issues are addressed. The conclusion of this thesis is that several factors that are both organizational and technical must be considered in order to gain the benefit of the new fitting fixture. Some of the major factors include: build strategy alignment with the fixture, learning systems to support continuous improvement, and organizational leadership and ownership aligned to quickly solve problems. / by Paul T. Glomski. / S.M. / M.B.A.