Journal of Japan Industrial Management Association
Online ISSN : 2187-9079
Print ISSN : 1342-2618
ISSN-L : 1342-2618
Volume 54 , Issue 6
Showing 1-19 articles out of 19 articles from the selected issue
  • Type: Cover
    2004 Volume 54 Issue 6 Pages Cover11-
    Published: February 15, 2004
    Released: November 01, 2017
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  • Type: Cover
    2004 Volume 54 Issue 6 Pages Cover12-
    Published: February 15, 2004
    Released: November 01, 2017
    JOURNALS FREE ACCESS
    Download PDF (479K)
  • Type: Index
    2004 Volume 54 Issue 6 Pages Toc6-
    Published: February 15, 2004
    Released: November 01, 2017
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  • Shoichi SATO, Mitsuyoshi HORIKAWA, Shuichi FUKUDA
    Type: Article
    2004 Volume 54 Issue 6 Pages 357-364
    Published: February 15, 2004
    Released: November 01, 2017
    JOURNALS FREE ACCESS
    This paper provides investigative insights into the impact of operational flexibility on manufacturing performance in the metal parts fabrication process. The orders from customers for each item that arrive randomly in a planning period are periodically loaded for processing. They are launched at the beginning of the week. There often occurs a large difference in the processing workload among the machines, resulting in a long flow time for orders and low machine utilization. It is necessary to improve manufacturing performance by introducing operational flexibility. Machine and routing flexibility are selected from various types of operational flexibility, because they are typical and elemental types of flexibility. Machine flexibility is the capability of a machine to perform different operations required by a given set of part types, and includes quick machine setup and jig changing. It allows smaller lot sizes, resulting in shorter manufacturing lead times, higher machine utilization, and lower inventory levels. Routing flexibility is the capability of processing a given set of part types using more than one route (alternative routing). It allows for efficient scheduling due to alternative routing capability, and can help handle contingencies such as machine breakdown and rush orders. The objective of this paper is to understand the influence of operational flexibility in a simulation-based investigation, by answering the following fundamental questions in the assessment of the two types of flexibility. (1) How does each type of flexibility affect manufacturing performance? (2) How is manufacturing performance improved by introducing these flexibilities simultaneously? (3) How should the production planning and scheduling system be redesigned by introducing the operational flexibility, that is, how many lot sizes for each family should be set, and which scheduling rule should be adopted? The flow time for each order and machine utilization ratio are adopted as criteria for manufacturing performance measurements. The results will enable manufacturers to gain better insight into the potential benefits of the different types of flexibility and their implementation.
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  • Fumiko KOGA, Heihachiro FUKUDA, Tetsuko MATSUO
    Type: Article
    2004 Volume 54 Issue 6 Pages 365-372
    Published: February 15, 2004
    Released: November 01, 2017
    JOURNALS FREE ACCESS
    In recent years, service industries have been developing. The authors have developed a quality evaluation technique for service enterprises through the laundry business as the service business that is closest to manufacturing businesses. This paper applies this technique to the home laundry business in Japan. A home laundry business consists of a concentrate processing factory, its direct management store and its agency. The acquired competition of markets among service enterprises grows in intensity, and excessive competition, such as low price competition, has developed. In this paper, the authors have conducted the following trial steps for the purpose of constructing fundamental management models to improve the marketable quality of enterprise on the relationship between a cleaning enterprise with a processing factory and an agency. By developing Koga's technique, we seek, theoretically, the formation of a system of commission rates to decide each other's relation, and investigate its actuality. By considering the results, on the case of utilizing and reducing available capacity, we construct and analyze models for improvement in marketable quality conformed to a company's management ability. The principal results are the following four models. (1) The theoretical standard value of a laundry commission rate is calculated, and the results are correlated to the real value of large and "medium and small" enterprises. (2) From the standpoint that laundry enterprises utilize available capacity, an enterprise selected model was derived for an agency to maintain and improve marketable quality. (3) By raising the operation rate and decreasing the capacity cost directly to reduce capacity, the scope to maintain and improve marketable quality was clarified. (4) When we think of enterprises and agencies as one system from a utilizing available capacity standpoint, regions to improve marketable quality through a practical low price strategy have been offered.
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  • Hiroumi MORIYAMA, Takao HADA
    Type: Article
    2004 Volume 54 Issue 6 Pages 373-381
    Published: February 15, 2004
    Released: November 01, 2017
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    Currently, the plan to route an optical fiber cable line to households is in progress. In this planning, generally, the object households to which the optical fiber cable line is connected are divided into several blocks. The trunk line is then constructed in a tree-like fashion in each block utilizing electric power company or communication firm poles. A closure (splice closure) is installed on a specific pole of the trunk line, and branch lines extend from the closure to respective households. During the above routing process of trunk and branch lines, expenses including the material cost, the rental fee of poles, and the construction cost are incurred. Also there are several types of closures that accommodate different numbers of cables. The routing cost varies with the selection of the type of closure, and the selection of the pole on which the closure is installed. Thus, when an optical fiber cable line is extended to ordinary households, a planning problem arises in which the type of closure to be used, the poles that bear the closures, and the routing methods of the trunk and branch lines have to be determined simultaneously so that the total cost can be minimized. This study proposes a near-optimal solution of the planning problem on the basis of the Lagrangian heuristic. Initially, the planning problem is formulated as a 0-1 integer programming problem, and a method to determine the lower bound of the planning problem is shown by solving the knapsack problem and the minimal spanning tree problem. Then, we propose a method to determine a near-optimal solution of the planning problem by successively decreasing the difference between upper and lower bounds (duality gap). Finally, the effectiveness of the proposed method is verified through computational experiments.
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  • Naoshi TAMANOUCHI, Yasufumi SARUWATARI
    Type: Article
    2004 Volume 54 Issue 6 Pages 382-389
    Published: February 15, 2004
    Released: November 01, 2017
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    Due to deregulation, domestic corporate pension plans are now allowed to allocate their assets quite flexibly. On the other hand, they have the responsibility to provide continuous and stable pension benefits for their plan participants. So, it is necessary for them to make investments from a long-term viewpoint. Policy asset allocation plays an important role in this sense. It is an asset allocation which should be kept firmly for a long period, and should also be regarded as a benchmark for Japanese corporate employees' pension plans in managing their investments. In this paper, we propose an optimization model to obtain a policy asset allocation. In order to construct a model, the behaviour of investors in actual investments is took in consideration, since actual asset allocation is determined by the actual economic environment. In addition, a down-side risk is employed as an objective function when we derive the optimization model. In particular, we present an approximation algorithm in order to solve the model efficiently. The algorithm solves relaxation problems iteratively, and seeks for the best solution under certain conditions. We implemented the algorithm and carried out some computational experiments. The results showed the validity and applicability of our model for practical use.
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  • Hiroyuki TANIUCHI, Shigeji MIYAZAKI
    Type: Article
    2004 Volume 54 Issue 6 Pages 390-398
    Published: February 15, 2004
    Released: November 01, 2017
    JOURNALS FREE ACCESS
    A great deal of attention has been paid to the global environmental problems related to the manufacturing industry. The main target is to prevent global warming and reduce industrial waste disposal, and there is also a compelling business reason; that is, products which are not manufactured in compliance with strict EU regulations cannot be exported to European countries. In order to clear this hurdle, environmentally conscious designing in which much consideration is paid to assembly and disassembly at the initial stage of designing is strongly requested to the designers of new products. This paper is a pigeonhole of designing know-how that designers should be aware of for designing environmentally conscious products. The first step to solve the global environmental problems is to apply this know-how to product designing. This paper also proposes a new evaluation method for product designing, which can evaluate whether the design meets the standard in terms of disassembly together with the example of a product actually designed and manufactured applying this evaluation method. Through resolving the problems found by this method, more environmentally conscious products can be achieved. It is also expected that this know-how can change the mindset of product designers and their idea about manufacturing.
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  • Shigenori KOTANI, Takahiro ITO, Katsuhisa OHNO
    Type: Article
    2004 Volume 54 Issue 6 Pages 399-409
    Published: February 15, 2004
    Released: November 01, 2017
    JOURNALS FREE ACCESS
    This paper deals with a sequencing problem of a mixed-model assembly line in the Toyota production system. It is important to level work loads on each station of the assembly line. The sequencing problems of leveling the work loads have been studied by many researchers and are known as NP-hard problems. Most researchers assume that the work overload on each station is always completed by utility workers and the assembly line does not stop. That is, the number of utility workers is sufficiently large and workers are helped by the utility workers at any time. Few researchers have studied models of the assembly line with line stoppages. In fact, line stoppages occur in the assembly line of the Toyota production system. Whenever a worker in the assembly line judges a possible failure to complete operations within the work zone, a push of an assembly line button summons an auxiliary worker, different from the utility worker, who will assist in the operation. A group, which is a formal organization of the workplace of the assembly line, consists of about 20 workers and is manned by only one auxiliary worker. Therefore, the worker calls the specific auxiliary worker. If the worker can complete operations with the auxiliary worker within the work zone, the line does not stop. Otherwise, the line stops at the downstream limit of the worker's station until they complete the operations. Moreover, when the auxiliary worker helps the other station, the worker can not call the auxiliary worker. That is, the worker can not be helped by the auxiliary worker and the line may stop. To our knowledge, no one has studied the sequencing problem of minimizing total line stoppage time of the mixed-model assembly line with the auxiliary workers. This paper investigates this sequencing problem. Since this problem is NP-hard and the size of practical problems at Toyota Motor Corporation is huge, we propose an approximation algorithm that adapts the goal chasing method, which was developed by the first author of this paper, and show its efficiency through numerical examples.
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  • Wonhee PARK, Incheon PAIK
    Type: Article
    2004 Volume 54 Issue 6 Pages 410-417
    Published: February 15, 2004
    Released: November 01, 2017
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    A manufacturing industry improves an existing product, or develops an innovative new product for new market. The product is devised and improved based on cost, quality, function, and technology factors. e-Business, using information technology (IT), makes the supply chain management (SCM) in Business to Business (B2B) more efficient in order to help companies develop and improve their product. Reliability problems remain, however, on a collaboration level among related companies with respect to providing consistently high levels of customer satisfaction and timely deliveries. This paper explains the construction of information infrastructure to share product attribute information among companies on the Internet. The information infrastructure creates a database for the four attributes of a product : cost, quality, function, and technology. A cross-reference between each database table enables a display of mutual product attribute information on the Web. The companies that are involved in the supply chain can share information anywhere to further develop the information infrastructure. The concept of four product attributes and their classification, database for four attributes, and application of database on a prototype were described.
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  • Type: Appendix
    2004 Volume 54 Issue 6 Pages 418-
    Published: February 15, 2004
    Released: November 01, 2017
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  • Type: Appendix
    2004 Volume 54 Issue 6 Pages 419-
    Published: February 15, 2004
    Released: November 01, 2017
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  • Type: Index
    2004 Volume 54 Issue 6 Pages 420-421
    Published: February 15, 2004
    Released: November 01, 2017
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  • Type: Index
    2004 Volume 54 Issue 6 Pages 422-424
    Published: February 15, 2004
    Released: November 01, 2017
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    Download PDF (180K)
  • Type: Appendix
    2004 Volume 54 Issue 6 Pages App26-
    Published: February 15, 2004
    Released: November 01, 2017
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    Download PDF (63K)
  • Type: Appendix
    2004 Volume 54 Issue 6 Pages App27-
    Published: February 15, 2004
    Released: November 01, 2017
    JOURNALS FREE ACCESS
    Download PDF (63K)
  • Type: Appendix
    2004 Volume 54 Issue 6 Pages App28-
    Published: February 15, 2004
    Released: November 01, 2017
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    Download PDF (63K)
  • Type: Appendix
    2004 Volume 54 Issue 6 Pages App29-
    Published: February 15, 2004
    Released: November 01, 2017
    JOURNALS FREE ACCESS
    Download PDF (63K)
  • Type: Appendix
    2004 Volume 54 Issue 6 Pages App30-
    Published: February 15, 2004
    Released: November 01, 2017
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    Download PDF (63K)
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