Purpose - To investigate the influence of organisational culture on the implementation of ISO 14001:1996 environmental management system (EMS) standard in two manufacturing case study organisations (CSOs).Design/methodology/approach - This research is a case study action research conducted in two manufacturing organisations in the UK.Findings - The hassles authors identified a framework of four dimensions of organisational culture that play an important role during the ISO 14001:1996 implementation process of. These are recognised as people, process, structure and environment.Research limitation/implications - The study is limited to two case organisations, which are based in the UK.Practical implications - The four dimensions of organisational culture identified through this research can help practitioners to coordinate their ISO 14000:1996 implementation projects.Originality/value - This paper fulfils the need to improve the understanding of the impact of the organisational culture on ISO14001:1996 implementation projects within the manufacturing environment.

This paper discusses teamwork, development of a team‐based organisation and performance measurement issues. This discussion leads to the formulation of a methodology to measure the organisational journey towards a team‐based organisational paradigm. The TEaM model, a model based on the EFQM excellence model, is suggested as a self‐assessment tool for the measurement of teamwork culture in organisations. Consequently, a five step‐approach aimed at successful acquisition of the proposed model is recommended. The authors demonstrate the usefulness of TEaM, not only in the improvement of teamwork culture in organisations, but also in reducing the resistance to change efforts while supporting the knowledge exchange through continuous self‐assessment of teams.

Overall equipment effectiveness (OEE) is being used increasingly in industry. This paper defines OEE and explores the purpose of this concept in modern operations. The paper discusses OEE as a total measure of performance that relates the availability of the process to the productivity and quality of the product. Therefore, the concept of OEE is appropriate to all operations containing plant and machinery. Research has shown that the most successful method of employing OEE is to use cross‐functional teams aimed at improving the competitiveness of business.

With ever-increasing importance, plant maintenance is no more regarded as second line or non-productive activity. It is about time maintenance received due attention from various business improvement initiatives such as total quality management or business process reengineering (BPR). This paper builds on previous work by the authors that examines the role of performance measurement systems (PMS) in maintenance, with particular reference to developing a new PMS framework using the quality function deployment (QFD) technique. In the light of the fact that there is only limited evidence of BPR applications pertinent to equipment maintenance, this paper explores the use of the PMS framework to enable and guide sound BPR endeavors in maintenance. Condensed literature on BPR is presented followed by an outline of the PMS framework. The benefits of utilizing such a framework are examined with reference to BPR in maintenance. The practical implications of the findings are discussed based on a case study conducted in a local company.

Agrees that the evidence of a vast array of research concerning teamwork is conclusive: teams are capable of outstanding performance and are the primary unit of performance for increasing numbers of organisations. Nevertheless, high performance teams (HPTs) are a rarity. Presents the results of collaborative research aimed at determining the factors affecting successful implementation of HPTs. The factors have been derived from literature on teamwork, quality management, and a review of case study literature. This research has led to the development of a model for the successful implementation of HPTs, which has been tested through a case study organisation. Furthermore, the results were used to develop an implementation program aimed at rejuvenating team performance in UK small‐ to medium‐sized enterprises.

The role of maintenance in modern manufacturing is becoming ever more important, with companies adopting maintenance as a profit-generating business element. As a result, traditional terms used to describe maintenance such as “necessary evil” seem to be obsolete. It would appear that the aim of the maintenance function is to contribute towards an organisation’s profit, clearly bringing the need for maintenance operations to be in harmony with corporate business objectives. As the measurement activity provides the link between the actual output and the desired results, performance measurement systems are crucial to those who have a stake in maintenance, to ensure that they are not in conflict with the overall business needs. This paper looks at the role of performance measurement systems (PMS) in maintenance, with particular reference to developing a new PMS using the quality function deployment (QFD) technique. First, a literature review on performance measurement is presented, in which the key factors for an effective PMS are identified. Second, common PMSs for maintenance are examined. Then, based on the principles of an effective PMS a discussion on PMSs is presented, when applied to the maintenance function. Next, a framework is developed to embrace these key facets, which is followed by a discussion of its practical implications, in the light of its application within a SME.

The business environment is one which is ever more demanding on companies, due to its sheer dynamism, which means that they are constantly having to improve their manufacturing performance. Organisations are continuously having to cope with changing markets that are unpredictable and more diversified, increasing global competition and ever changing customer demands. Companies now have to be able to not only predict variations and changes within the market and socio-economic and political environments but must also be able to adapt and change in accordance with these environments. As a result, this demands that an organisation develops and sustains an inherent ability to continuously change. Such a demand can be met by adopting the management philosophy of agile manufacturing. In embracing such an approach, there are a lot of key concepts and enabling technologies that are required to be able to implement agile manufacturing and many companies do not know how far down the path they are towards becoming agile manufacturing organisations. Hence, in providing a deeper understanding, this paper proposes a conceptual model, based on joint research, which has been developed to identify where UK's best practice companies are in their quest to become agile manufacturing organisations. In support of this, a questionnaire has been developed and completed by best practitioners of manufacturing, to assess the model, and establish whether they are making progress to becoming agile manufacturing organisations.

Modern manufacturing requires that to be successful organisations must be supported by both effective and efficient maintenance. One approach to improving the performance of maintenance activities is to implement and develop a total productive maintenance (TPM) strategy. However, it is well documented that a number of organisations are failing to successfully implement such strategies. This paper outlines research carried out by the Aeronautical, Mechanical and Manufacturing Engineering Department at Salford University aimed at discovering the factors affecting the successful implementation of TPM. This research has led to the development of a generic model indicating factors affecting the successful implementation of TPM. The validity of the generic model has been tested in a UK manufacturing small‐ to medium‐size enterprise (SME) and the case study research findings further triangulated through a review of documented case study evidence. This research has also led to the development of recommendations to improve the TPM development and implementation program of the case study organisation. Further development of the research has resulted in a step‐wise program or generic roadmap for UK SMEs which is proposed as a tool for the implementation or rejuvenation of an organisation’s TPM program.

The author's of this paper illustrate the idiosyncratics of SMEs and large organisations in relation to the formulation and implementation of new product development (NPD) processes.The various characteristics of the three case study manufacturing companies are discussed and comparisons are made to illustrate potential 'learning' points.The findings presented in the paper concentrate in two main areas: decision making, resources allocation and utilisation in NPD.The author's conclude with an emphasis of the need to introduce flexibility in the traditionally rigid NPD processes as applied in large organisations and to integrate some level of formal control mechanisms in the traditionally unstructured and flexible NPD processes in SMEs.

The application of automation for handling non-rigid products is limited due to the lack of suitable end effecters. The majority of end effecters used for handling electromechanical parts in industry an not easily applicable, because non-rigid products (particularly food products) have a somewhat unpredictable and unstable behaviour which arises from their individual physical properties. End effectors based on multiple fingers are difficult to control in real time when dealing with non-rigid materials, whose behaviour under dynamic and gravitational forces needs to be accommodated.This paper introduces a new material handling system for use in industry. This system consists of a novel non-contact end effector, which has been developed and applied at the University of Salford. The end effector operates on the principle of generating a high-speed fluid Row between the nozzle(s) and product surface, thereby creating a vacuum which levitates the product. Guidelines will be provided for the design of a non-contact end effector that is suitable for the handling of a specific material in a practical handling application. A design and development procedure and the concept of a non-contact end effector handling system will be explained. Conclusions drawn from the experimental results will be discussed. (C) 1998 Elsevier Science Ltd. All rights reserved.

This paper provides a case study of implementing total quality management (TQM) into a maintenance function within a traditional manufacturing company. It identifies the key quality related activities taken by the maintenance management team within the company and shows that the results of implementing TQM into maintenance can be quite dramatic in contributing to improved manufacturing performance.

This paper identifies the need for a new range of end effectors suitable for handling non-rigid products in the food industry. The mechanical properties and handling difficulties of food products are introduced. Hygiene and the hygienic requirements in the food industry are discussed in detail from a consumer health and a safety point of view. The usage of automation and robotics in the manufacturing industry and food industry are briefly introduced. The end effectors which are available are discussed from the usage point of view in the food sector. Finally a novel end effector is introduced with fundamental working principles and examples given of applications of the end effector used with actual food products.

This paper identifies the need for a new range of end effectors suitable for non-rigid products and introduces a novel non-contact gripping device. The end effector operates on the principle of generating a high-speed flow between the end effector and product surface thereby creating a vacuum which levitates the product. The lifting forces and conditions are theoretically discussed. The experimental results are presented using the end effector that has been operated to lift non-rigid food materials such as jelly blocks.

The classification of parts to be handled in an automation system is important in order to reduce the cost of peripherals. In this paper, a classification system for the robotic handling and packaging of food products in a high speed automated packaging cell, is discussed. The system can be used to best advantage at the stage of the end effector feasibility, design and selection process. Such a classification system would lead to a reduction in the number of tool and end effector changes during the handling and packaging process of food products.

Teamwork is increasingly becoming a prerequisite for many job functions in those learning organizations striving towards total quality management (TQM). However, the daunting task of creating a teamwork environment in many manufacturing companies is often left to proactive senior management, who assume the responsibility for creating a culture of interdependency, among all employees. This opportunity for maximizing employee potential through empowered teamwork represents a challenge for many managers. These “champions for success” will inevitably contribute towards improving business performance through re‐engineering the people process. Their actions will also facilitate the development of an organizational culture, which thrives on teamwork. Describes a case experience of an SME that has developed a team‐based learning organization, where all employees are empowered to challenge the status quo and make continuous improvements. Then reports on how the formation of self‐directed work teams (SDWTs) have been used as a strategy for getting a diverse group of people with different attitudes, skills and personalities, to work together towards common goals. Continues by presenting the use of a simple decision‐making framework which was developed by the case study company, and is contributing towards the empowerment of all team members. Concludes with some of the benefits experienced by the company, during their pursuit of TQM, through flexible SDWTs.

The paper develops a replacement action decision aid for a key furnace component subject to condition monitoring. A state space model is used to predict the erosion condition of the inductors in an induction furnace in which a measure of the conductance ratio (CR) is used to indirectly assess the relative condition of the inductors, and to guide replacement decisions. This study seeks to improve on this decision process by establishing the relationship between CR and the erosion condition of the inductors. To establish such a relationship, a state space model has been established and the system parameters estimated from CR data. A replacement cost model to balance at any time costly replacements with possible catastrophic failure is also proposed based upon the predicted probability of inductor erosion conditional upon all available information. The well known Kalman filter is employed to derive the predicted and updated probability of inductor erosion level conditional upon CR data to date. This is the first time the condition monitoring decision process has been modelled for real plant based upon filtering theory. The model fits the data well, gives a sensible answer to the actual problem, and is transferable to other condition monitoring contexts. Possible extensions are discussed in the paper.

The paper identifies the need for a new range of end effectors suitable for compliant products and briefly introduces a novel non-contact end effector which has been developed at the University of Salford. This end effector operates on the principle of generating a high-speed fluid flow between the nozzle and product surface thereby creating a vacuum which lifts the product. The gap between nozzle and product is to some extent self-regulating and imposes local rigidity which is useful during manipulation.

This paper reports on the progress of an effort to understand how the phenomenon of extrudate swell occurs as it flows through a die. It addresses the problem of designing extrusion die for breakfast cereals and suggest a possible approach to solve it. It presents a method of decomposing the 2-D geometry of the die into simple shapes and presenting them in symbolic representations. A method of designing streamlined dies is also demonstrated.

Some food products such as portions of meat or poultry are generally assembled manually on trays as the initial stage in packaging. Automation of this process is desirable to provide improved hygiene and to produce goods of consistent high quality. Flexible automation can facilitate the rapid introduction of new products, a rapid response to changes in market demand, and the economical production of small batches for just-in-time marketing. This paper arises from an initial investigation carried out to assess the applicability of modern manufacturing technologies to the primary packaging of discrete solid food products. An experimental primary assembly system is described.

Knitting machines convert yarn into fabric using a latch-needle-cam system. The latch needles, cams and yarn are the key elements. The forces that arise in this system are critical in limiting machine speed and fabric quality due to either needle or yarn breakage. Typical high speed commercial knitting machines have between 2000 and 4000 needles of approximately 0.45mm in thickness. Just one damaged needle will severely affect the fabric quality therefore knowledge of needle condition is vital to maximise machine productivity. Existing instruments can only detect broken needles. Several novel sensitive transducers were designed and developed to measure cam-needle and yarn-needle forces which were capable of identifying damaged needles. The transducers were controlled by microcomputer and along with other ancilliary instrumentation formed the basis of an on-line condition monitoring system of the key elements in high speed knitting machines. The transducers used in the research were for one particular machine but can be further developed to form a portable condition monitoring system for use as a portable diagnostic tool on a textile production floor containing many knitting machines.