Thesis (M.B.A.)--Massachusetts Institute of Technology, Sloan School of Management; and, (S.M.)--Massachusetts Institute of Technology, Dept. of Materials Science and Engineering; in conjunction with the Leaders for Manufacturing Program at MIT, 2008. / Includes bibliographical references (p. 43). / In any aerospace manufacturing operation, including Pratt & Whitney's Compression Systems Module Center, producibility problems can be major drivers of cost. Much of the literature focuses on design for manufacturability as a solution to producibility problems. While this is a valuable approach, this study focuses on manufacturing process improvement as a solution to producibility issues. Two methods of process improvement are discussed, process automation and process reengineering. This thesis first surveys some of the major producibility problems at Pratt & Whitney's Compression Systems Module Center, as well as some of the efforts underway to address them. One of the largest issues, operator data input errors, is described in detail as a case study. Wireless gauging with automatic offset adjustment is proposed as a focused technological solution to this issue. As part of this study, funding has been obtained to implement the solution and testing has been conducted. This is an example of process automation. However, a broader process reengineering effort is also proposed. The fundamental question of why producibility problems tend to persist is also examined. / by Daniel Hoopes. / S.M. / M.B.A.

Thesis (M.B.A.)--Massachusetts Institute of Technology, Sloan School of Management; and, (S.M.)--Massachusetts Institute of Technology, Engineering Systems Division; in conjunction with the Leaders for Manufacturing Program at MIT, 2008. / Includes bibliographical references (p. 79-80). / This paper introduces multiple methods to set and optimize inventory levels. These methods are then classified based on the complexity involved to implement them. As an organization develops a deeper understanding of inventory, it becomes more mature and can apply more complex methods. This sequencing of methods is defined as a three phase maturity model. First, a foundational level of maturity is defined, which quantifies inventory levels based on future demand and business requirements. Second, a transitional level of maturity defines safety stock positioning in a single-echelon supply chain. Finally, the maturity model concludes with an optimal level of maturity that is based on principles of multi-echelon inventory optimization: safety stock at multiple positions of a supply chain. The setting for this paper was the Aerospace industry. Honeywell Aerospace is in the middle of a 3-year effort to re-engineer Sales, Inventory and Operations Planning (SIOP) systems. At the same time, Honeywell Aerospace is standardizing on a uniform implementation of an ERP system. Through SIOP, standard inventory and planning practices aided by the uniform ERP backbone and a strategic inventory program executive management hopes to reduce what is seen as a disproportionate contribution of inventory to Honeywell International. / by Joseph Mauro. / 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, 2008. / Includes bibliographical references (p. 73-74). / Manufacturing Flexibility is a broad term used to describe a metric that can be measured in many different ways. Current industry experts agree that Flexibility is one of the key measures that will help the automotive industry reduce current overcapacity and remain competitive. In addition to flexibility, General Motors is also focusing on fewer, interbuildable product architectures.To maintain and implement flexible manufacturing systems, General Motors has developed a list of Flexibility Enablers. These enablers identify critical product characteristics which affect the interbuildability of the product and the flexibility and of the subsequent manufacturing process.Market forces drive product requirements, and lead to designs that potentially violate the Flexibility Enablers. This thesis will look at GM's internal structure and how it has developed to support design decisions and issue resolution. It will then study cases in which the design requirements led to design, manufacturing and cost tradeoffs in an attempt to understand and document the different unwritten resolution processes in disparate groups.Keywords: Manufacturing Flexibility, Product Development, Flexibility Enabler, Interbuildability. / by Grace C. Tomlin. / 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, 2008. / Includes bibliographical references (p. 99-103). / Due to the highly regulated environment, it is difficult to implement changes to a pharmaceutical process. Even small change request approvals can require months of effort for pharmaceutical companies and regulatory agencies. This resource intensive process discourages continuous improvement and often results in outdated and inefficient manufacturing processes. In response to the growing need for improvement, the FDA issued a guidance to industry that provides a framework for acquiring improved process understanding and product quality in the manufacturing industry. The guidance is aimed at encouraging the use of process analytical technology (PAT) to monitor key quality attributes continuously during the process and enable early fault detection. The goal is to transition from the current method of quality through end of process testing to a new method of quality by design (QbD). In 2005 Novartis Pharma formed a unique collaboration with the FDA in an attempt to demonstrate the benefits and concepts of QbD. A cross-functional team was formed with the goal of developing a case study for one Novartis process that will serve as a model for future implementation of PAT and QbD.During a six month internship, I worked with the Global PAT team members to help ensure the successful implementation of the QbD tools outlined in the FDA Guidance. The internship focused only on the drug substance manufacturing process. Specifically, I was responsible for collecting and analyzing process data during the manufacturing campaign, coordinating the commissioning of an on-line NIR probe and PSD analyzer, and identifying and proposing future benefits of PAT applications to Novartis Pharma. / (cont.) I also conducted a throughput analysis after observing manufacturing operations and analyzing the process data collected during the campaign.My thesis provides a background of the QbD/PAT initiative and includes a thorough literature search to benchmark the progress other pharmaceutical companies have made at applying QbD/PAT. I discuss in more detail the Novartis PAT project, and my specific contribution including the results of the NIR and PSD installation and validation, full scale Design of Experiment activities, Multivariate Data Analysis modeling, and process throughput analysis. I conclude with an analysis of barriers to implementation and provide recommendations for future implementation to other processes and plants at Novartis. / by Stephanie Michelle Tozer. / 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, 1999. / Includes bibliographical references (p. 79). / This study analyses the information and material flow through a component manufacturing and turbine engine assembly system. The intent of this work was to understand the inefficiencies associated with the current system, and to propose solutions which would prove valuable to the entire value chain, not only to one manufacturing site. This work was accomplished by identifying a significant problem in the system, developing a model to replicate historical behavior, then developing solutions to improve material and information flow. The shipment rate of engines from the assembly facility was found to follow a "hockey stick" pattern throughout each production quarter (a three-month cycle), meaning that shipments increased exponentially toward the end of each quarter. Shipments were traced back through the component manufacturing facilities, and the exponential increase of component shipments was shown to follow that of assembly shipments. Interviews were primarily used to establish critical variables in the system, and a system dynamics modeling technique was used to generate a model that mirrored historical shipment data. The model was then manipulated to test the sensitivity of specific production variables, and suggestions were made to improve material and information flow. Finally, a component kit plan was developed that added value to the assembly facility by delivering gear products by order number rather than as separate components. Also, the component production facilities benefit by shortening the existing information feedback loop between component manufacturing and assembly and allowing more level production with less variability amplification from the bullwhip effect. Demand Flow Technology is introduced as a means to then affect the entire supply chain, including supporting functions not directly related to manufacturing. / by Thomas M. Blake. / 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, 2001. / Includes bibliographical references (p. 75-76). / Firms attempting to commercialize emerging technologies face unique challenges. Strategy making is one of the major challenges especially when the industry structure is embryonic. In this environment, it is important not only to remain flexible to accommodate the evolving market demands, but also to develop the infrastructure to respond to target markets quickly. This thesis presents a framework for developing a manufacturing strategy for emerging technologies and provides a case study for utilizing the model within fuel cell industry. The thesis develops a framework for manufacturing strategy, which includes four phases that lead to product introduction and capacity· expansion for the company to rapidly ramp up production if the product generates high demand. As further market information and customer input are obtained after product introduction, the different phases can be iterated to achieve low cost, high volume manufacturing for full commercialization. This framework was applied to understand International Fuel Cells business plan for residential/light commercial fuel cell commercialization, perform cost analysis on the product, identify core components, assess options for supplier development, determine operations requirements and examine options for capacity expansion. The business plan provided input into the project volumes of production. The production volumes were utilized to perform cost analysis. Cost analysis was used to identify potential technological breakthroughs that would render fuel cells competitive with existing technologies for power generation and transportation. Quality Function Deployment (QFD) was utilized to identify core subsystems and components. The different supply chain options and the applicable options for each of the core components were identified. These analyses provided insight into the components that needed investments for technology development. Operation requirements were estimated and capacity expansion options discussed. These options provided insight into the potential investments required. in the near term for residential fuel cell commercialization. / by Kalyan Raghava Tadikonda. / 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, 1998. / "June 1998." / Includes bibliographical references (p. 69). / This thesis analyzes the challenges associate with the rollout of the Toyota Production System (TPS) in a US vinyl extrusion plant. There is a cursory explanation of some of the Technical aspects of TPS, and implementation problems are examined and analyzed in the context of cultural barriers. The thesis contends that the softer, more subtle, leadership principles demonstrated by Toyota management are just as important to Toyota as is the elegance of its production system. Findings include the identification of three key leadership traits that are evident within Toyota, and that are necessary to facilitate the cultural shift to a TPS environment. Those leadership traits are: I) Set Consistent Direction with Fluid Constraints. 2) Create a Culture of Removing Barriers. 3) Develop the Capabilities of People to Improve. / by Brent M. Johnson. / 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, 2002. / Includes bibliographical references (leaf 69). / As companies outsource more manufacturing and design responsibilities to external vendors and therefore become less vertically integrated, the role of supply chain management becomes increasingly complex. Its role is particularly difficult when product generation follows a serial process flow, with the supply chain function residing at the end and where it inherits poorly defined supplier relationships. A more integrated approach that seeks to proactively design the supply chain during product generation is required. Central to this integrated approach is the timely exchange of information both within the company, between R&D and procurement, and external to the company, between procurement and its suppliers. The timing of the information flow is crucial. It needs to occur before the company is locked into a single supplier and when its bargaining power is the highest. It also needs to occur in a manner that does not slow down the product development process. In practice, that means that specific information needs to be exchanged and committed to prior to supplier selection. Ultimately, the information exchange described in this thesis leads to improved supplier relations that enable the company to shift its procurement practices from the tactical approach of buying materials to the strategic approach of buying supply services. The research for this thesis was conducted at a partner company of the Leaders for Manufacturing (LFM) program. The company manufactures test equipment used in the semiconductor industry. Due to the highly cyclical and unpredictable nature of this industry, supply chains that can guarantee responsiveness and availability are desirable. The supply chain design recommendations proposed in this thesis are based on an analysis of a recent product generation program at the company. By continuing to implement these recommendations, the company should benefit from shorter product development cycle times, smoother production ramps, improved customer service levels and lower sourcing costs. / by Jens P. Voges. / S.M. / M.B.A.

Thesis (M.B.A.)--Massachusetts Institute of Technology, Sloan School of Management; and, (S.M.)--Massachusetts Institute of Technology, Engineering Systems Division; in conjunction with the Leaders for Manufacturing Program at MIT, 2009. / Includes bibliographical references. / The ramp up phase is always the most risky part of any project, especially with a product material the company and its partners have very little experience with. One result of this lack of experience is frequent engineering changes to address design corrections and improvements. High levels of change create uncertainty within both the supply chain and the engineering change management systems. Just as a supplier may not be able to meet production requirements, elements of the change process may not be sufficiently flexible to account for the level of change the project experiences during production ramp up. A study of Bus Solution Systems' (BSS) Super Hotel Coach (SHC) program change management system will show that unsuitable change management system processes can cause downstream delays just as unsuitable supply chain strategy can cause the same. This thesis details a situation where the SHC program's Materials Management Department (MMD) was having difficulty with visibility into the change management system. As a result of the situation, SHC MMD did not have the ability to order parts on time. The effect was that there were an increased number of parts needed for manufacturing jobs but were not in stock, and sometimes yet to be ordered. The ultimate result of this problem, and the multitude of other problems impacting the SHC not investigated in this thesis, was a bus program that was 2 years behind schedule in early 2009. / (cont.) This thesis aims to correct the SHC MMD engineering change visibility issue by examining the current state of the engineering change process through a shortage part case study and by applying supply chain management strategy principles to extract part ordering information from the SHC General Engineering Change Process earlier. This thesis also proposes a long term systematic solution that would help prevent shortages from occurring in the future. The intent of the recommendation is to reduce the chance of shortage occurrences so as to prevent further delay of the SHC program. / by Sean Fortin. / S.M. / M.B.A.

Thesis (M.B.A.)--Massachusetts Institute of Technology, Sloan School of Management; and, (S.M.)--Massachusetts Institute of Technology, Engineering Systems Division; in conjunction with the Leaders for Manufacturing Program at MIT, 2009. / Includes bibliographical references (p. 94). / Global Automotive, a large US based, global manufacturer of automobiles, has made significant gains in manufacturing competitiveness, in part through application of a lean manufacturing approach to high volume assembly. A similar approach applied to product development can result in significant improvements in product design throughput, speed, cost, design quality, and innovation. With major product programs taking in excess of 36 months and a billion dollars to complete, the potential impact of process improvements is substantial. This thesis examines elements of Global Automotive Product Development Process. Some general guiding principles for Lean product development are also reviewed from the existing literature. Special attention is given to metrics for measuring product development performance at Global Automotive. The thesis focuses on the role of peer reviews in the development process. The analysis is performed using a work order data set for two automotive development programs. Score cards from Peer Review and a survey of the component engineering community are also used to assess the effectiveness and current state of the peer review process. The study found evidence that high scores on peer reviews do not guarantee that late changes will occur, if anything component groups with average lower scoring peer reviews generated led to consistent levels of late stage changes. The objective of peer reviews should clearly be to find as many problems as possible and participants should be encouraged to delivery "low scoring" reviews. Keywords: Product Development, Lean, Peer Reviews, Design Defects. / by Michael Boren. / S.M. / M.B.A.