A routine-based framework implementing workload control to address recurring disturbances

Abstract

This research focuses on responsiveness in high variety manufacturing environments. To achieve it, the article proposes to develop Dynamic Response Capabilities (DRCs) of the manufacturing system defined as the abilities to readjust the planned operating parameters of workload, capacity, and lead time, in the wake of disturbances. To inform their development, built on the Workload Control theory, a routine-based framework is proposed. The framework supports an integrated approach for the implementation of adaptive decision-making routines for workload, capacity, and lead time readjustments at different stages in the order fulfilment process. Findings from two empirical cases show the appropriateness of the framework to develop and utilise DRCs in different settings of disturbances. Results of a simulation study, with one of the case companies, also shows the effectiveness of the framework to drive performance improvements in presence of recurring disturbances leading to demand variability.

Keywords:

• High product variety
• order fulfilment process
• disturbances
• manufacturing responsiveness
• routines
• operations capabilities
• workload control

Acknowledgements

This paper is produced as part of the EMJD Programme European Doctorate in Industrial Management (EDIM) funded by the European Commission, Erasmus Mundus Action 1.

Disclosure statement

No potential conflict of interest was reported by the authors.

Additional information

Notes on contributors

Sayyed Shoaib-ul-Hasan

Sayyed Shoaib-ul-Hasan received his PhD degree in Management, Economics and Industrial Engineering from Politecnico di Milano (Italy). He is also enrolled at Universidad Politécnica de Madrid (Spain) under Erasmus Mundus Joint Doctorate program European Doctorate in Industrial Management (EDIM). He received MS degree in Industrial Engineering from South Korea, and BSc degree in Industrial Engineering and Management from Pakistan. His research interests include production and operations management, mass customization, manufacturing responsiveness, workload control, Industry 4.0, and operations capabilities.

Marco Macchi

Marco Macchi is an Associate Professor at Politecnico di Milano, Department of Management, Economics and Industrial Engineering. He is the chair of the IFAC Working Group on AMEST (Advanced Maintenance Engineering, Services and Technology), the vice-chair of the IFAC Technical Committee 5.1 Manufacturing Plant Control and Book Reviews Editor and Editorial Board Member of the International Journal of Production Planning & Control: The Management of Operations. He is also a member of the IFIP WG 5.7 Advances in Production Management Systems and a Fellow of the International Society of Engineering Asset Management. His research interests are advanced production systems, maintenance management and asset life cycle management.

Alessandro Pozzetti

Alessandro Pozzetti is a full professor of Operations Management at Politecnico di Milano, Department of Management, Economics and Industrial Engineering. At Politecnico di Milano he was the dean of the School of Systems Engineering and the head of the Department of Management, Economics and Industrial Engineering. He has published five books on operations management and design of production systems. His research publications have appeared in many conference proceedings and international journals, including International Journal of Production Research, International Journal of Operations & Production Management, International Journal of Quality & Reliability Management, Production Planning & Control, International Journal of Computer Integrated Manufacturing, and International Journal of Production Economics.

Ruth Carrasco-Gallego

Ruth Carrasco-Gallego is an assistant professor at Universidad Politécnica de Madrid, Department of Organizational Engineering, Management and Statistics, and a visiting scholar of the INSEAD Social Innovation Center. Her research is focused on supply chain networks, specifically on the areas of sustainability and humanitarian relief.