For the past two decades, the majority of Malaysia’s IT companies have been widely adopting a Quality Assurance (QA) approach as a basis for self-improvement and internal-assessment in IT project management. Quality Control (QC) is a comprehensive top-down observation approach used to fulfill requirements for quality outputs which focuses on the aspect of process outputs evaluation. However in the Malaysian context, QC and combination of QA and QC as a means of quality improvement approaches have not received significant attention. This research study aims to explore the possibility of integrating QC and QA+QC approaches through Six Sigma quality management standard to provide tangible and measureable business results by continuous process improvement to boost customer satisfactions. The research project adopted an exploratory case study approach on three Malaysian IT companies in the business area of IT Process, IT Service and IT Product. Semi-structured interviews, online surveys, self-administered questionnaires, job observations, document analysis and on-the-job-training are amongst the methodologies employed in these case studies. These collected data and viewpoints along with findings from an extensive literature review were used to benchmark quality improvement initiatives, best practices and to develop a Six Sigma framework for the context of the SMEs in the Malaysian IT industry. This research project contributed to both the theory and practice of implementing and integrating Six Sigma in IT products, services and processes. The newly developed framework has been proven capable of providing a general and fundamental start-up decision by demonstrating how a company with and without formal QIM can be integrated and implemented with Six Sigma practices to close the variation gap between QA and QC. This framework also takes into consideration those companies with an existing QIM for a new face-lift migration without having to drop their existing QIM. This can be achieved by integrating a new QIM which addresses most weaknesses of the current QIM while retaining most of the current business routine strengths. This framework explored how Six Sigma can be expanded and extended to include secondary external factors that are critical to successful QIM implementation. A vital segment emphasizes Six Sigma as a QA+QC approach in IT processes; and the ability to properly manage IT processes will result in overall performance improvement to IT Products and IT Services. The developed Six Sigma implementation framework can serve as a baseline for SMEs to better manage, control and track business performance and product quality; and at the same time creates clearer insights and un-biased views of Six Sigma implementation onto the IT industries to drive towards operational excellence.

In transport logistic operations, an efficient delivery plan and better utilisation of vehicles will result in fuel cost savings, reduced working hours and even reduction of carbon dioxide emissions. This thesis proposes various algorithmic approaches to generate improved performance in automated vehicle load packing and route planning. First, modifications to best-fit heuristic methodologies are proposed and then incorporated into a simple but effective “look-ahead” heuristic procedure. The results obtained are very competitive and in some cases best-known results are found for different sets of constraints on three-dimensional strip packing problems. Secondly, a review and comparison of different clustering techniques in transport route planning is presented. This study shows that the algorithmic approach performs according to the specific type of real-world transport route planning scenario under consideration. This study helps to achieve a better understanding of how to conduct the automated generation of vehicle routes that meet the specific conditions required in the operations of a transport logistics company. Finally, a new approach to measuring the quality of transportation route plans is presented showing how this procedure has a positive effect on the quality of the generated route plans. In summary, this thesis proposes new tailored and effective heuristic methodologies that have been tested and incorporated into the real-world operations of a transport logistics company. The research work presented here is a modest yet significant advance to better understanding and solving the difficult problems of vehicle loading and routing in real-world scenarios.

As a result of the remarkable demands on electronic and other portable compact devices, the need to produce various miniaturized parts, particularly those made from metallic sheet is growing. In other words, in order for manufacturing companies to stay in competition, they are required to develop new and innovative fabricating processes to produce micro components with more complex features and a high standard of quality and functionality. Microforming is a micro fabrication process that can be employed efficiently for mass production with the advantages of greatly minimizing material waste and producing highly accurate product geometry. However, since the clearance between the rigid tools, i.e. punch and die, utilized in microforming techniques is relatively very small, there is a high risk of damaging the tools during the forming operations. Therefore, the use of forming tools made of flexible materials in sheet metal forming processes at micro scale has powerful potential advantages. The main advantages include a reduction in the production cost, eliminating the alignment and mismatch difficulties, and also the creation of parts with different geometrical shapes using the same flexible tool. As the workpiece is in contact with a flexible surface, this process can significantly improve the quality of the obtained products. Despite these clear advantages, micro flexible forming techniques are currently only utilized in very limited industrial applications. One reason for this is that the deformation behaviour and failure mode of sheet metals formed at micro scale are not yet well understood. Additionally, the experience-based knowledge of the micro-forming process parameters is not sufficient, particularly when flexible tools are used. Hence, to advance this technology and to improve the production quality of formed micro parts, more investigation of the key process parameters related to the material deformation are needed. The main contribution of this work is the development of a novel technique for achieving micro deep drawing of stainless steel 304 sheets using a flexible die and where an initial gap (positive or negative) is adopted between the blank holder plate and an adjustment ring utilized in the size-scaled forming systems developed for this purpose. The interesting point here is that this study presents the first attempt of employing flexible material as a forming die tool in the micro deep drawing technology to produce micro metallic cups at different scaling levels. Polyurethane rubber materials are employed in this study for the forming flexible die with various Shore A hardness. Also, the stainless steel 304 sheets utilized for the workpieces have different initial thicknesses. Various parameters that have a significant influence on the sheet formability at micro scale are carefully considered, these include initial gap value, rubber material properties, initial blank thickness, initial blank diameter, friction coefficients at various contact interfaces, diameter and height of the rubber die and process scaling factor. The size effect category of process dimension was also taken into account using similarity theory. Three size-scaled micro deep drawing systems were developed correspondingly to three different scaling factors. In each case, finite element simulations for the intended micro drawing systems are performed with the aim of identifying optimum conditions for the novel forming methodology presented in this thesis. The numerical models are built using the known commercial code Abaqus/Standard. To verify the microforming methodology adopted for the proposal technique as well as to validate the predictions obtained from simulations, an appropriate number of micro deep drawing experiments are conducted. This is achieved using a special experimental set up, designed and manufactured to fulfil the various requirements of the micro-forming process design procedure. The new knowledge provided by this work provides, for the first time, a predictive capability for micro deep drawing using flexible tools that in turn could lead to a commercially viable production scale process.

In the current fiercely competitive market, engineering design change management in manufacturing companies is a critical factor for business success. Recognised as inevitable in product development, engineering changes may significantly influence lead time, development cost and product quality of new product development. It has been recognised that the earlier change issues are addressed, the greater product lifecycle costs can be saved. In this thesis, three main industrial requirements have been identified in engineering design change management, including: (i) a lack of formal methods to analyse the impacts of design changes on both functional requirements and physical components; (ii) a lack of methods to trace design change propagations; (iii) a lack of methods for conflict resolving in design change management. It is also identified that there is a lack of systematic method for reusing design knowledge to solve design conflicts. The literature review carried out in this project also confirms that there were no unified and systematic methods proposed to meet these industrial requirements. This thesis reports a methodology and tool to meet these requirements and help designers trace, analyse and evaluate engineering changes occurring in the product design phase. A modelling method is employed to enhance the traceability of potential design changes occurred between the functional requirements domain and physical structure domain of design. Based on functional and physical models, a matrix-based method is developed to analyse change propagations between components and help find out design conflicts arising from design changes. A knowledge based method has been proposed to resolve design conflicts by reusing previous design change knowledge. A web-based distributed system has been developed to implement the proposed methodology. An engineering design change example from the collaborating company has been used in a case study to help understand the methodology and prove its usefulness.

Western manufacturing companies are facing a challenging environment fraught with strong competition from India, China and other emerging economies. In this context, the effectiveness of the traditional production concepts of leanness and agility is being challenged. Against this background, the need for new manufacturing paradigms is set to provide new knowledge, techniques, and concepts useful for managers to address the difficulties of today’s business environment. This work extends the concept of production management beyond the achievement of efficiency short-term goals into the realms of strategic thinking by creating both the framework and the indices for an integrated production system. This research presents fit manufacturing as a new production model for a holistic manufacturing strategy that links the short-term goals of manufacturing effectiveness and efficiency embodied in lean and agile production strategies with the long-term objective of sustainable enterprise management. The research extends the concept of integration beyond ordinary manufacturing functions into the realms of strategic thinking. The thesis gives an operational definition for the concept of fit manufacturing by describing the structural and operational characteristics of the production philosophy. It proposes the central theme of fit xxiii manufacturing as a manufacturing strategy essential to creating an integrated view of the factory – inside out and vice-versa. The idea of an overall fitness index combining measures of leanness, agility and economic sustainability is put forward and justified and the necessary conditions for fitness are derived. A case study showing an application of these different measures and the overall production fitness index is presented. This research has shown that the fit production model combines the strengths of lean and agile manufacturing, with the long-term sustainability and viability of the enterprise. The model can be used to assess the performance of the production process, to evaluate investment proposals such as adding a new product line or increasing the overall capacity of the factory, and to build the enterprise of the future.

Three methods, based on Evolutionary Algorithms (EAs), to support and automate the design of dispatching rules for complex and dynamic scheduling problems are proposed in this thesis. The first method employs an EA to search for problem instances on which a given dispatching rule performs badly. These instances can then be analysed to reveal weaknesses of the tested rule, thereby providing guidelines for the design of a better rule. The other two methods are hyper-heuristics, which employ an EA directly to generate effective dispatching rules. In particular, one hyper-heuristic is based on a specific type of EA, called Genetic Programming (GP), and generates a single rule from basic job and machine attributes, while the other generates a set of work centre-specific rules by selecting a (potentially) different rule for each work centre from a number of existing rules. Each of the three methods is applied to some complex and dynamic scheduling problem(s), and the resulting dispatching rules are tested against benchmark rules from the literature. In each case, the benchmark rules are shown to be outperformed by a rule (set) that results from the application of the respective method, which demonstrates the effectiveness of the proposed methods.

The fundamental structures that underpin business activities must evolve and change in order to equip companies to thrive in a market whose characteristics are increasing competition and instability. The incremental advances in applied computing technology and business methodologies which focus on improving one aspect of company operations ignore the need for an underlying structure and model through which to engage any and all functions in a consistent and integrated fashion. Indeed, many exacerbate the problem through closed architectures, isolationist views of entity data storage and rigid methodologies imposed on the company that employs them. The Product Model proposed fulfils that role. It is a model of the processes and entities that a company uses to conduct its business, at all levels and across all departments. Two other concepts are exposed: product model data and the design history record. Product model data are the values of instances of product model entities and relations, created to represent a particular design, artefact or object. The design history record captures the data and functions used in a transaction and the order and context in which they are used. To exercise these concepts, a software suite was written, the Glasgow Utility for Integrated Design, Guide. It supports the definition of a proud model and its subsequent use in the creation of product model data. Each interaction with the system is recorded, thus capturing the design history record, which can subsequently be processes to various advantageous ends. The major such uses are for re-use of part information in other designs and the extraction of design best practice with which to augment the company's design methodology. It is a comprehensive record, since all business processes are supported by, and can be transacted through Guide. Guide has been used to validate the adequacy of the product model and has established many benefits through its use. Applications in many spheres are possible; engineering has been the primary focus for exemplars and case studies. The development was carried out under the scrutiny of constant validation and testing in live situations with several industrial partners. Guide is built on industry standard tools and uses relational database technology to store frame-based representations of entities, methods and relationships. The design of project plans is carried out on the same platform used to support the project itself; the design data are not dissociated from the project controlling mechanism. Resources, including staff, are engaged according to requirements and audit mechanisms allow for constant re-evaluation of the project development. Control and communication mechanisms support applications in an extended enterprise environment and the distribution of resources that this entails.

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The thesis draws on official statistics to examine comparative historical developments in the humanization of work in manufacturing industry, engaging with vital debates on societal distinctiveness. The empirical analysis spans the manufacturing sectors of eleven of the leading industrialised nations over the period 1960-95. This substantive core of the thesis is informed by an examination of research method in the field of employment relations. Initial assessment of the availability and construct validity to aggregate statistical indicators of the humanization of work results in consideration of three phenomena; the rate of incidence of fatal injuries, average annual hours actually worked, and the relative extent of managerial hierarchy. Detailed assessment of the conceptual basis of the available statistics then follows, with the aim of obtaining historically consistent and cross-nationally comparable data on these aspects of work humanization. Although dependable data on fatalities and hours are derived, the limits of the aggregate indicator of managerial hierarchy are ultimately stressed. The comparative historical patterns in the data are then examined for evidence of cross-national convergence in experiences of work humanization. With little indication of any historic convergence apparent the analysis turns to consider the forces which may shape distinctive societal experiences. Quantitative gauges of the shape of the broad political economy are assembled, with a particular attention focused on the quantitative characterisation of the power resources of employees, whether collective or individual. The meaning of these necessarily crude indicators is given extensive consideration. The thesis culminates in separate panel econometric investigations of the political economic characteristics associated with comparative fatal injury incidence and actual annual hours of work. Substantial evidence is presented that the humanization of work is associated with an attenuation of the vulnerability of employees to managerial prerogative.

The objective of the work was to develop systems of solid free form (SFF) manufacture capable of being used for mass production as well as for rapid prototyping (RP). Existing commercial RP systems are far too slow for mass production and are limited in the range of materials they can use. This restricts them to specialised applications and the production of prototypes. Literature search, followed by analysis and assessment pointed to printing and thermography as the most suitable technologies for further investigation. A major aim was to take advantage of existing technologies as far as possible. The main components of a prototype system were then analysed in order to identify necessary adaptations and improvements. This generated a number of highly innovative developments that were then combined to produce a system involving concurrent printing, thermographing, annealing, stacking, registering, bonding and height adjustment of coatings (SFF layers) to form parts. To confirm the level of innovation and likely future development, assessment was made of current developments in the field of SFF manufacture and printing. Prospects for commercialisation were identified by reference to extensive market research relating to the system. The concurrency of the system allows it to be substantially faster than commercial systems that are largely consecutive in their modes of operation (between 150 and 800 times faster than an SLA 5000). The use of the thermography allows a high deposition rate of a wide range of materials including thermopolymers, thermosets, metals, ceramics and glass. These advantages make the system very suitable for mass-production. Financially, the system is likely to be relatively inexpensive (around £6,000 compared with £327,300 for an SLA 5000), since it makes use of existing highly developed and readily available technologies. Several of these inventions have been patented and a company, “Rapid Manufacturing Systems Limited” has now been formed to exploit the innovations.