Transportation Research Part E-logistics and Transportation Review, Nov 1, 2020
The expectation of the largest gap between two consecutive picks in an aisle is a basic building ... more The expectation of the largest gap between two consecutive picks in an aisle is a basic building block in modelling the pick travel distance for the largest gap routing policy in a warehouse. Researchers have predominantly used either simulation or recursive algorithms for its estimation. This paper develops analytical expressions for this statistic in, both, continuous and discrete aisles using the statistical theory of ordered uniform spacings. We further demonstrate how these results can apply to the entire multi-aisle warehouse. Our results show that these expressions are accurate and extremely fast to evaluate as compared to the existing approaches.
Multi-aisle AS/RS using shared S/R machines offer significant cost advantage over AS/RS employing... more Multi-aisle AS/RS using shared S/R machines offer significant cost advantage over AS/RS employing dedicated S/R machines. The expected travel time of the S/R machine is an important warehouse performance measure and it needs to be kept at a minimum. In this paper, we consider a single crane multi-aisle AS/RS using single command cycle and carry out simulation experiments to understand the impact of different design parameters and storage policies on travel time. The interactions of these input factors are studied leading to key insights which can be useful for designers and practitioners.
The International Journal of Advanced Manufacturing Technology, Feb 4, 2014
Superior manufacturing capability provides long lasting competitive benefits to a company in the ... more Superior manufacturing capability provides long lasting competitive benefits to a company in the market. It is thus imperative to have an instrument to assess the manufacturing capability of companies. However, empirically tested and reliable tools for the purpose of evaluation of manufacturing capability along different decision areas are scarcely available in the literature. This paper develops questionnaires based on generally accepted principle of instrument design to assess the manufacturing capabilities along different decision areas for four categorization schemes of manufacturing decision areas reported in the literature. The reliability and validity of all four instruments are assessed through responses from managers of 32 manufacturing units and are found to be satisfactory for most of the factors. The criterion validity is found to be fairly good for all the four instruments.
This article considers a two-block warehouse with low-level aisles having dedicated pickers who f... more This article considers a two-block warehouse with low-level aisles having dedicated pickers who follow a return routing policy within the aisle. Travel distance models are formulated assuming a given product density distribution in aisles for multi-item picks. An analytical recursive procedure is developed to find optimal n-class partitions of each warehouse aisle. A range on the number of classes and number of picks for which class-based storage is an attractive option over the random storage policy is determined through a computational study. The article also presents an iterative hierarchical framework to simultaneously obtain pick list size, number of aisles, and class storage boundaries. A sensitivity analysis of optimal pick travel distance against important warehouse design parameters is presented.
International Journal of Production Research, Aug 1, 2013
We consider a low level picker-to-parts system in a one-block warehouse with P/D point located at... more We consider a low level picker-to-parts system in a one-block warehouse with P/D point located at a corner point. We develop new and exact analytical models to estimate travel distance for random, full turnover and class-based storage in which a single picker follows an S-shaped traversal routeing policy. Our analytical results for random, full turnover and class-based storage follow corresponding simulations very closely with an accuracy of within 2% for the range of warehouse parameters considered. We also report the percentage improvement obtained by the optimal 3-class storage strategy over the random storage policy and the potential gain of this 3-class policy as compared to the full turnover policy. Further, we conduct a computational study to determine the optimal layout parameters for a warehouse with a 3-class optimal storage strategy for a given pick size per tour. Sensitivity analysis of pick travel distances with important warehouse parameters is also presented.
Journal of Manufacturing Technology Management, Jul 4, 2016
Purpose The purpose of this paper is to explore the relationship of strategic manufacturing effec... more Purpose The purpose of this paper is to explore the relationship of strategic manufacturing effectiveness utilizing the four-stage model of Hayes and Wheelwright (H-W) with overall performance of manufacturing, market alignment and production competence (PC). In addition, it attempts to understand the relationship of strategic manufacturing effectiveness with manufacturing capability development modes, strategic groups of companies and the nature of improvement programs being employed. Design/methodology/approach Structured questionnaire was used to capture data from manufacturing organizations. Responses from managers of 47 Indian manufacturing companies were used to test the seven propositions that were developed to examine the paradigms of manufacturing competence. Findings The analysis revealed that the strategic manufacturing effectiveness of manufacturing companies based on H-W’s four-stage model has significant positive correlation with the overall performance of manufacturing and PC of the company. Further, the analysis substantiated the relationship of strategic manufacturing effectiveness with capability development process and the nature of improvement programs. Research limitations/implications This exploratory study is based on a small sample of manufacturing companies with diversity and hence it may not be representative of all industry sectors. Second, it has used several scales for measuring the relevant constructs which themselves are not proven, hence, the findings should be taken with caution. Originality/value This is an initial research focussing on the relationships among different elements of manufacturing competence such as manufacturing capabilities, PC, manufacturing capability development mode and overall performance of manufacturing with strategic manufacturing effectiveness using H-W model. H-W model was primarily proposed as an audit tool for managers, was hitherto not adequately studied in relation to other paradigms of manufacturing competence.
International Journal of Production Research, Feb 26, 2016
The pick distance models for a unit load warehouse employing fishbone layout conventionally use s... more The pick distance models for a unit load warehouse employing fishbone layout conventionally use semicircular approximation for distance contour which can result in significant error. This paper develops discrete and continuous pick distance models for fishbone layout under random, full turnover, and class-based storage policies based on exact polygonal distance contour. Class-based storage policy with three classes was found to give pick distance comparable to full turnover policy over a range of demand skews and warehouse shapes studied. The discrete and continuous models are compared considering finite storage space, aisle width and discontinues in the ABC curve for a real life data. The sensitivity of warehouse performance over a range of warehouse parameters is studied. We also outline a methodology for class-based storage design where class partitions can be derived for a warehouse of any dimension from the results of a unit area warehouse.
International Journal of Production Research, Jul 15, 2012
The configuration of a production system can be described by the choices a firm makes in its manu... more The configuration of a production system can be described by the choices a firm makes in its manufacturing decision areas. Manufacturing strategy literature lacks empirical research in manufacturing decision areas. The current paper is an exploratory study using six case companies on alternative configurations that can exist in a batch production system. Choices made in decisions such as layout, shop
The International Journal of Advanced Manufacturing Technology, Mar 3, 2012
The objective of this research is to study the configuration of decisions in manufacturing decisi... more The objective of this research is to study the configuration of decisions in manufacturing decision areas for a line production system. A case study approach is used by analyzing the decision choices selected by five case companies that satisfy characteristics of line production system. The paper identifies decision choices specific to line shop as well as decisions that are influenced by non-process specific factors such as competitive priorities (order winner), strategic orientation of manufacturing (stages in H-W model), top management decisions, and size of the company. Findings on several decision choices are new to manufacturing literature. These research findings should be helpful to practitioners and researchers.
Journal of Manufacturing Technology Management, Jul 19, 2013
PurposeThe four stage model of Hayes and Wheelwright (H‐W) describing the strategic role of manuf... more PurposeThe four stage model of Hayes and Wheelwright (H‐W) describing the strategic role of manufacturing function is widely accepted in the literature. However, there is little research that has examined the underlying factors of the H‐W model. This paper aims to fill this research gap by developing an instrument for measuring factors of strategic manufacturing effectiveness of a company based on the H‐W model.Design/methodology/approachThe general principle of designing an instrument is followed in this paper. Attributes of strategic manufacturing effectiveness are identified from critical analysis of the original text of Wheelwright and Hayes, and Chase and Hayes. Then these attributes are grouped into four factors: catalysts of manufacturing initiatives; proactiveness of manufacturing function; attitude of top management towards manufacturing; and nature of manufacturing initiatives. Question for each attribute along continuum of four stages in the H‐W model is developed. The reliability and validity of the instrument are assessed through responses obtained from managers of 28 manufacturing units.FindingsThe empirical evidence supports that the proposed instrument has quite good reliability (Cronbach's α for different factors in the range of 0.575 to 0.705) and validity (multiple correlation coefficient between factors and manufacturing performance of 0.801).Practical implicationsThis instrument can be used to position the companies along the continuum of four stages. Also, this can help managers assess the strengths and weaknesses in manufacturing for making the improvements.Originality/valueThis study is one of its kind which focuses on the development of an instrument to assess the strategic role of manufacturing based on the H‐W model.
PurposeDespite its great practical and theoretical significance, research on how and to what exte... more PurposeDespite its great practical and theoretical significance, research on how and to what extent sustainable manufacturing capabilities (SMCs) provide competitive advantage to firms remains scarce. Towards bridging the gap, this paper conducts an enquiry into the competitive value of SMCs.Design/methodology/approachA theoretical framework on the competitive value of four SMCs, namely, pollution control (PC), pollution prevention (PP), product stewardship (PS) and clean technology (CT) is developed through synthesis of literature. More specifically, competitive value is characterised in terms of enabling key resources and market positioning opportunities. A case study, using a deductive qualitative approach is conducted to test the framework by analysing reported sustainable manufacturing practices (SMPs) of three multinational firms. Observed compliances and deviations to the framework are analysed and accordingly few propositions are framed.FindingsThe empirical findings largely...
Purpose The researchers maintain that when a firm tackles “green concerns,” there could be severa... more Purpose The researchers maintain that when a firm tackles “green concerns,” there could be several repercussions for manufacturing strategy decision areas (MS DAs). However, such repercussions are complex and have not been widely researched. This paper aims to propose a conceptual maturity stage model to study the configuration of MS DAs. Design/methodology/approach Firms exhibit different levels of “green” maturity in their journey and tend to make different choices in green technologies (GTs), resulting thereby in other compatible choices in their MS DAs. Extant literature has been synthesized in this light to build a conceptual maturity stage model in two steps. First, what is the GT that is involved! The second step discusses the possible implications of such a GT for MS DAs. Further, such information is organized according to a firm’s four maturity stages for all GTs that may be applicable. A case study has been undertaken to illustrate the model. Findings The results show good...
Case studies are useful in imparting decision-making skills to students. Warehousing is a critica... more Case studies are useful in imparting decision-making skills to students. Warehousing is a critical part of most supply chains, but case studies based on warehousing methods and operations therein are rare. Recognizing the need to bridge this gap, a case study is designed to present a real-life scenario at the carriage repair workshop of Indian Railways. The case study facilitates the learning of students regarding operations in automated warehousing and relevant storage strategies. Additionally, the case encourages the students to explore the use of heuristics and optimization models. This case article highlights the major learning objectives of the case study and discusses the classroom teaching experience. This case can be used in various courses and the case questions can be selected based on the teaching objectives and/or the educational background of the students.
International Journal of Productivity and Performance Management, 2021
PurposeSustainable manufacturing is gaining prominence in light of the rising environmental and s... more PurposeSustainable manufacturing is gaining prominence in light of the rising environmental and social concerns worldwide. One major task to enhance manufacturing sustainability is assessment of the current state of sustainability of a manufacturing firm. This paper reviews the existing sustainability assessment approaches applicable for manufacturing firms and observes that most of these approaches are not easy to apply for reasons such as high amount of skill, data and time requirement. Towards bridging this gap, this study proposes a sustainability assessment approach.Design/methodology/approachThe assessment approach proposed in the paper uses a predefined list of potential sustainable manufacturing practices (SMPs) covering the primary and support activity domains of a manufacturing firm's value chain. It proposes a method to assess the extent of implementation of SMPs and identify associated drivers and barriers for each SMP area/category along the value chain of a firm as...
Transportation Research Part E-logistics and Transportation Review, Nov 1, 2020
The expectation of the largest gap between two consecutive picks in an aisle is a basic building ... more The expectation of the largest gap between two consecutive picks in an aisle is a basic building block in modelling the pick travel distance for the largest gap routing policy in a warehouse. Researchers have predominantly used either simulation or recursive algorithms for its estimation. This paper develops analytical expressions for this statistic in, both, continuous and discrete aisles using the statistical theory of ordered uniform spacings. We further demonstrate how these results can apply to the entire multi-aisle warehouse. Our results show that these expressions are accurate and extremely fast to evaluate as compared to the existing approaches.
Multi-aisle AS/RS using shared S/R machines offer significant cost advantage over AS/RS employing... more Multi-aisle AS/RS using shared S/R machines offer significant cost advantage over AS/RS employing dedicated S/R machines. The expected travel time of the S/R machine is an important warehouse performance measure and it needs to be kept at a minimum. In this paper, we consider a single crane multi-aisle AS/RS using single command cycle and carry out simulation experiments to understand the impact of different design parameters and storage policies on travel time. The interactions of these input factors are studied leading to key insights which can be useful for designers and practitioners.
The International Journal of Advanced Manufacturing Technology, Feb 4, 2014
Superior manufacturing capability provides long lasting competitive benefits to a company in the ... more Superior manufacturing capability provides long lasting competitive benefits to a company in the market. It is thus imperative to have an instrument to assess the manufacturing capability of companies. However, empirically tested and reliable tools for the purpose of evaluation of manufacturing capability along different decision areas are scarcely available in the literature. This paper develops questionnaires based on generally accepted principle of instrument design to assess the manufacturing capabilities along different decision areas for four categorization schemes of manufacturing decision areas reported in the literature. The reliability and validity of all four instruments are assessed through responses from managers of 32 manufacturing units and are found to be satisfactory for most of the factors. The criterion validity is found to be fairly good for all the four instruments.
This article considers a two-block warehouse with low-level aisles having dedicated pickers who f... more This article considers a two-block warehouse with low-level aisles having dedicated pickers who follow a return routing policy within the aisle. Travel distance models are formulated assuming a given product density distribution in aisles for multi-item picks. An analytical recursive procedure is developed to find optimal n-class partitions of each warehouse aisle. A range on the number of classes and number of picks for which class-based storage is an attractive option over the random storage policy is determined through a computational study. The article also presents an iterative hierarchical framework to simultaneously obtain pick list size, number of aisles, and class storage boundaries. A sensitivity analysis of optimal pick travel distance against important warehouse design parameters is presented.
International Journal of Production Research, Aug 1, 2013
We consider a low level picker-to-parts system in a one-block warehouse with P/D point located at... more We consider a low level picker-to-parts system in a one-block warehouse with P/D point located at a corner point. We develop new and exact analytical models to estimate travel distance for random, full turnover and class-based storage in which a single picker follows an S-shaped traversal routeing policy. Our analytical results for random, full turnover and class-based storage follow corresponding simulations very closely with an accuracy of within 2% for the range of warehouse parameters considered. We also report the percentage improvement obtained by the optimal 3-class storage strategy over the random storage policy and the potential gain of this 3-class policy as compared to the full turnover policy. Further, we conduct a computational study to determine the optimal layout parameters for a warehouse with a 3-class optimal storage strategy for a given pick size per tour. Sensitivity analysis of pick travel distances with important warehouse parameters is also presented.
Journal of Manufacturing Technology Management, Jul 4, 2016
Purpose The purpose of this paper is to explore the relationship of strategic manufacturing effec... more Purpose The purpose of this paper is to explore the relationship of strategic manufacturing effectiveness utilizing the four-stage model of Hayes and Wheelwright (H-W) with overall performance of manufacturing, market alignment and production competence (PC). In addition, it attempts to understand the relationship of strategic manufacturing effectiveness with manufacturing capability development modes, strategic groups of companies and the nature of improvement programs being employed. Design/methodology/approach Structured questionnaire was used to capture data from manufacturing organizations. Responses from managers of 47 Indian manufacturing companies were used to test the seven propositions that were developed to examine the paradigms of manufacturing competence. Findings The analysis revealed that the strategic manufacturing effectiveness of manufacturing companies based on H-W’s four-stage model has significant positive correlation with the overall performance of manufacturing and PC of the company. Further, the analysis substantiated the relationship of strategic manufacturing effectiveness with capability development process and the nature of improvement programs. Research limitations/implications This exploratory study is based on a small sample of manufacturing companies with diversity and hence it may not be representative of all industry sectors. Second, it has used several scales for measuring the relevant constructs which themselves are not proven, hence, the findings should be taken with caution. Originality/value This is an initial research focussing on the relationships among different elements of manufacturing competence such as manufacturing capabilities, PC, manufacturing capability development mode and overall performance of manufacturing with strategic manufacturing effectiveness using H-W model. H-W model was primarily proposed as an audit tool for managers, was hitherto not adequately studied in relation to other paradigms of manufacturing competence.
International Journal of Production Research, Feb 26, 2016
The pick distance models for a unit load warehouse employing fishbone layout conventionally use s... more The pick distance models for a unit load warehouse employing fishbone layout conventionally use semicircular approximation for distance contour which can result in significant error. This paper develops discrete and continuous pick distance models for fishbone layout under random, full turnover, and class-based storage policies based on exact polygonal distance contour. Class-based storage policy with three classes was found to give pick distance comparable to full turnover policy over a range of demand skews and warehouse shapes studied. The discrete and continuous models are compared considering finite storage space, aisle width and discontinues in the ABC curve for a real life data. The sensitivity of warehouse performance over a range of warehouse parameters is studied. We also outline a methodology for class-based storage design where class partitions can be derived for a warehouse of any dimension from the results of a unit area warehouse.
International Journal of Production Research, Jul 15, 2012
The configuration of a production system can be described by the choices a firm makes in its manu... more The configuration of a production system can be described by the choices a firm makes in its manufacturing decision areas. Manufacturing strategy literature lacks empirical research in manufacturing decision areas. The current paper is an exploratory study using six case companies on alternative configurations that can exist in a batch production system. Choices made in decisions such as layout, shop
The International Journal of Advanced Manufacturing Technology, Mar 3, 2012
The objective of this research is to study the configuration of decisions in manufacturing decisi... more The objective of this research is to study the configuration of decisions in manufacturing decision areas for a line production system. A case study approach is used by analyzing the decision choices selected by five case companies that satisfy characteristics of line production system. The paper identifies decision choices specific to line shop as well as decisions that are influenced by non-process specific factors such as competitive priorities (order winner), strategic orientation of manufacturing (stages in H-W model), top management decisions, and size of the company. Findings on several decision choices are new to manufacturing literature. These research findings should be helpful to practitioners and researchers.
Journal of Manufacturing Technology Management, Jul 19, 2013
PurposeThe four stage model of Hayes and Wheelwright (H‐W) describing the strategic role of manuf... more PurposeThe four stage model of Hayes and Wheelwright (H‐W) describing the strategic role of manufacturing function is widely accepted in the literature. However, there is little research that has examined the underlying factors of the H‐W model. This paper aims to fill this research gap by developing an instrument for measuring factors of strategic manufacturing effectiveness of a company based on the H‐W model.Design/methodology/approachThe general principle of designing an instrument is followed in this paper. Attributes of strategic manufacturing effectiveness are identified from critical analysis of the original text of Wheelwright and Hayes, and Chase and Hayes. Then these attributes are grouped into four factors: catalysts of manufacturing initiatives; proactiveness of manufacturing function; attitude of top management towards manufacturing; and nature of manufacturing initiatives. Question for each attribute along continuum of four stages in the H‐W model is developed. The reliability and validity of the instrument are assessed through responses obtained from managers of 28 manufacturing units.FindingsThe empirical evidence supports that the proposed instrument has quite good reliability (Cronbach's α for different factors in the range of 0.575 to 0.705) and validity (multiple correlation coefficient between factors and manufacturing performance of 0.801).Practical implicationsThis instrument can be used to position the companies along the continuum of four stages. Also, this can help managers assess the strengths and weaknesses in manufacturing for making the improvements.Originality/valueThis study is one of its kind which focuses on the development of an instrument to assess the strategic role of manufacturing based on the H‐W model.
PurposeDespite its great practical and theoretical significance, research on how and to what exte... more PurposeDespite its great practical and theoretical significance, research on how and to what extent sustainable manufacturing capabilities (SMCs) provide competitive advantage to firms remains scarce. Towards bridging the gap, this paper conducts an enquiry into the competitive value of SMCs.Design/methodology/approachA theoretical framework on the competitive value of four SMCs, namely, pollution control (PC), pollution prevention (PP), product stewardship (PS) and clean technology (CT) is developed through synthesis of literature. More specifically, competitive value is characterised in terms of enabling key resources and market positioning opportunities. A case study, using a deductive qualitative approach is conducted to test the framework by analysing reported sustainable manufacturing practices (SMPs) of three multinational firms. Observed compliances and deviations to the framework are analysed and accordingly few propositions are framed.FindingsThe empirical findings largely...
Purpose The researchers maintain that when a firm tackles “green concerns,” there could be severa... more Purpose The researchers maintain that when a firm tackles “green concerns,” there could be several repercussions for manufacturing strategy decision areas (MS DAs). However, such repercussions are complex and have not been widely researched. This paper aims to propose a conceptual maturity stage model to study the configuration of MS DAs. Design/methodology/approach Firms exhibit different levels of “green” maturity in their journey and tend to make different choices in green technologies (GTs), resulting thereby in other compatible choices in their MS DAs. Extant literature has been synthesized in this light to build a conceptual maturity stage model in two steps. First, what is the GT that is involved! The second step discusses the possible implications of such a GT for MS DAs. Further, such information is organized according to a firm’s four maturity stages for all GTs that may be applicable. A case study has been undertaken to illustrate the model. Findings The results show good...
Case studies are useful in imparting decision-making skills to students. Warehousing is a critica... more Case studies are useful in imparting decision-making skills to students. Warehousing is a critical part of most supply chains, but case studies based on warehousing methods and operations therein are rare. Recognizing the need to bridge this gap, a case study is designed to present a real-life scenario at the carriage repair workshop of Indian Railways. The case study facilitates the learning of students regarding operations in automated warehousing and relevant storage strategies. Additionally, the case encourages the students to explore the use of heuristics and optimization models. This case article highlights the major learning objectives of the case study and discusses the classroom teaching experience. This case can be used in various courses and the case questions can be selected based on the teaching objectives and/or the educational background of the students.
International Journal of Productivity and Performance Management, 2021
PurposeSustainable manufacturing is gaining prominence in light of the rising environmental and s... more PurposeSustainable manufacturing is gaining prominence in light of the rising environmental and social concerns worldwide. One major task to enhance manufacturing sustainability is assessment of the current state of sustainability of a manufacturing firm. This paper reviews the existing sustainability assessment approaches applicable for manufacturing firms and observes that most of these approaches are not easy to apply for reasons such as high amount of skill, data and time requirement. Towards bridging this gap, this study proposes a sustainability assessment approach.Design/methodology/approachThe assessment approach proposed in the paper uses a predefined list of potential sustainable manufacturing practices (SMPs) covering the primary and support activity domains of a manufacturing firm's value chain. It proposes a method to assess the extent of implementation of SMPs and identify associated drivers and barriers for each SMP area/category along the value chain of a firm as...
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Papers by Gajendra Adil