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Benny Tjahjono

Coventry University, Centre for Business in Society, Faculty Member

Cranfield University, Supply Chain Research Centre, Faculty Member

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Professor of Supply Chain Management
Address: Coventry, United Kingdom

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Papers by Benny Tjahjono

Costing models for capacity optimization in Industry 4.0: Trade-off between used capacity and operational efficiency

Under the concept of "Industry 4.0", production processes will be pushed to be increasingly inter... more Under the concept of "Industry 4.0", production processes will be pushed to be increasingly interconnected, information based on a real time basis and, necessarily, much more efficient. In this context, capacity optimization goes beyond the traditional aim of capacity maximization, contributing also for organization's profitability and value. Indeed, lean management and continuous improvement approaches suggest capacity optimization instead of maximization. The study of capacity optimization and costing models is an important research topic that deserves contributions from both the practical and theoretical perspectives. This paper presents and discusses a mathematical model for capacity management based on different costing models (ABC and TDABC). A generic model has been developed and it was used to analyze idle capacity and to design strategies towards the maximization of organization's value. The trade-off capacity maximization vs operational efficiency is highlighted and it is shown that capacity optimization might hide operational inefficiency.

Six Sigma: a literature review

by Peter Ball and Benny Tjahjono

International Journal of Lean Six Sigma, 2010

Purpose: The purpose of the work presented in this paper is to capture the current state of Six S... more Purpose: The purpose of the work presented in this paper is to capture the current state of Six Sigma as well as to document the current practices of Six Sigma through a systematic literature review so as to extend and update the previous work of Brady and Allen (2006). Design/methodology/approach: The approach to this research is to answer the questions such as what is Six Sigma?, what are the applications of the Six Sigma?, what are the main enablers and barriers to its application?, and what are the emerging trends? These questions are used to guide the search of papers from various publication databases even if it is expected that existing literature might not be sufficiently developed to translate each question directly into a finding. The literature is then analysed and the major emerging themes are presented. Findings: Seven key findings (topics on which the views of the authors converged) and two issues (topics on which authors had differing views) have been established. These include the interpretation of Six Sigma, tools and techniques, implementation of Six Sigma, benefits, adoption, enablers and links to other disciplines. Originality/value: The systematic literature review approach used in this paper allows emerging trends and issues in Six Sigma to be highlighted in a structured and thematic manner, enabling the future work to progress as Six Sigma continues to develop and evolve. The findings also open up new opportunities to apply Six Sigma in the fields that are not widely explored before for instance sustainability and Product-Service Systems (PSS).

An integrated shipment planning and storage capacity decision under uncertainty

International Journal of Physical Distribution & Logistics Management, 2015

In transportation and distribution systems, the shipment decisions, fleet capacity, and storage c... more In transportation and distribution systems, the shipment decisions, fleet capacity, and storage capacity are interrelated in a complex way, especially when we take into account uncertainty of the demand rate and shipment lead time. While shipment planning is tactical or operational in nature, increasing storage capacity often requires top management's authority. This paper presents a new way to integrate both operational and strategic decision parameters, namely shipment planning and storage capacity decision under uncertainty. The ultimate goal is to provide a near optimal solution that leads to a striking balance between the total logistics costs and product availability, critical in maritime logistics of bulk shipment of commodity items.

Applying performance measures to support decision-making in supply chain operations: a case of beverage industry

International Journal of Production Research, 2015

Performance Measurement Systems (PMS) have commonly been applied to evaluate and reward performan... more Performance Measurement Systems (PMS) have commonly been applied to evaluate and reward performances at managerial levels, especially in the context of supply chain management. However, evidence suggests that the effective use of PMS can also positively influence the behaviour and improve performance at an operational level. The motivation is to accomplish organisational goals, namely to increase supply chain flexibility by responding to evermore-varying customer demands in a timely manner. The purpose of the study described in this paper is to develop a conceptual framework that adopts performance measures for ex-ante decision-making at an operational level within the supply chain. To guide the research, five questions were asked and subsequently key gaps have been identified. In an attempt to fill the gaps, a case study at a major global brand beverage company has been carried out, and as a result, a conceptual framework of the performance measurement system has been developed. Overall, the research offers a foundation of the applicability and impact of PMS in the supply chain and provides a framework that attends to some of the potential uses of PMS that so far have not been practically applied. The outcomes from the testing indicate that the initial gaps identified in the literature have been addressed and that the framework is judicious with scope for practical applicability. The framework is deemed worthy of further testing in different operational contexts of the supply chain.

Life-cycle-Based (LCB) online acquisition framework for supporting Mass Customisation (MC) in practice

Mass Customisation (MC) has been perceived in many articles as a strategy of choice for any compa... more Mass Customisation (MC) has been perceived in many articles as a strategy of choice for any company. However, Mass Customisation (MC) can be easily discussed at a strategic level; but it is rather more complicated to undertake it organisationally and operationally. The aim of this paper is to explore an effective framework that can support the development of Mass Customisation

e-Knowledge: An Approach To Fostering Manufacturing Know-how At The Shop Floor

This paper presents an application of the web technology in promoting knowledge management at the... more This paper presents an application of the web technology in promoting knowledge management at the shop floor, known as e-knowledge. The system is expected to promote sharing and reusing various levels of manufacturing information from assembly cell to testing area, and from documentation to training. The implementation of such a system has been made possible by utilising the web-programming environment. To investigate how the e-knowledge works, a case study involving a major cellular telecommunication industry is presented.

Simulation Modelling of Availability Contracts

Availability contract (also known as Performance-based Contract/Logistics) has been increasingly ... more Availability contract (also known as Performance-based Contract/Logistics) has been increasingly adopted in the context of Product-Service Systems (PSS). Despite the benefits, availability contract imposes major risks to the manufacturers due to the dynamic behaviour caused by the service delivery mechanisms. This paper aims to explore potential approaches that can be used to model the availability contract. The overall goal is to enable the manufacturers to assess the potential impacts of the contract to their manufacturing operations before actually committing to the changes. The work described in the paper involves the development of a simulation model from an example of an availability contract scenario. The outcomes from the simulation model provide an estimation of availability level, average delay and penalty cost subject to the given resource level and maintenance schedules. Based on this information, the OEM can decide whether the targets proposed in the contract is achievable. The outcome supports the potential and validity of the simulation approaches adopted in this study.

Evaluation of A Manufacturing Task Support System Using The Task-Technology Fit Model

This paper presents an exploratory study of a Task Support System (TSS) supporting manufacturing ... more This paper presents an exploratory study of a Task Support System (TSS) supporting manufacturing task operations. The study investigated the degree to which a TSS, in use in a company, actually supports the task of the shop floor personnel. The approach has been to adopt the Task-Technology Fit (TTF) instrument to measure the degree of fitness between the TSS and the associated task. The analysis gives an indication of the state of the TSS and the potential improvements that can be made. The study also shows that the instrument can be used as a foundation for the development of a hypermedia TSS and a benchmarking tool for a TSS.

Big Data Analytics in Supply Chain Management: Trends and Related Research

Big Data Analytics offers vast prospects in today's business transformation. Whilst big data ... more Big Data Analytics offers vast prospects in today's business transformation. Whilst big data have remarkably captured the attentions of both practitioners and researchers especially in the financial services and marketing sectors, there is a myriad of premises that big data analytics can play even more crucial roles in Supply Chain Management (SCM). This paper therefore intends to explore these premises. The investigation ranges from the fundamentals of big data analytics, its taxonomy and the level of maturity of big data analytics solutions in each of them, to implementation issues and best practices. Finally, some examples of advanced analytics applications will also be presented as a way of unveiling some of the relatively unexplored territories in big data analytics research.

Simulation Modelling of Through-life Engineering Services

by S. Alfaro and Benny Tjahjono

This paper presents a fundamental online simulation that can be used to support operational decis... more This paper presents a fundamental online simulation that can be used to support operational decisions related to maintenance scheduling, resource allocation, spare parts inventory etc., within the context of Through-life Engineering Services. As an online system, the simulation model is physically coupled to the assets being maintained. In this way, every time there is a change in the asset condition (i.e. degradation), the simulation model will be automatically run to evaluate a set of operational decisions as a consequence of the degradation. Experimental cases comparing the proposed simulation model against the traditional approach will also be presented. The results showed the role of online simulation in enabling effective operations of engineering services.

Design of a new IEC 61499-based embedded system development framework

by Benny Tjahjono and Kiah Mok Goh

Developing an embedded software solu-tion can be time consuming and challenging. Tradi-tionally, ... more Developing an embedded software solu-tion can be time consuming and challenging. Tradi-tionally, embedded software is programmed manually in proprietary computer languages such as C, C++, Java and assembly languages. In addition, most of the embedded software design environments do not cater for both microprocessors-based and Field Program-mable Gate Array (FPGA) based embedded platforms. This paper proposes s a conceptual design of a new embedded system code generator framework which is based on the IEC61499 Function Block to address the code generation issues. This involves the design and testing of the framework through the development of a prototype. An embedded system is a special-purpose, small size hardware device and software system commonly used in standalone products or added on to other equipment to enhance their functionalities. Examples include consumer products and industrial control equipment often found in manufacturing or aerospace sectors. By using embedded systems...

No Training wheels required

Industrial Engineer

performance prior to implementation is one part of the process of designing a manufacturing syste... more performance prior to implementation is one part of the process of designing a manufacturing system. Manu-facturing system design does not typically promote the use of simulation modeling to help improve and validate designs, but some companies have found simulation to be a valuable and integral tool. While simulation is often considered a re-source-intensive activity requiring great skill, some simula-tion tools can be used quickly by non-simulation experts to improve designs and justify them to senior management. Two case studies show how simulation supported the manufacturing system design process. The first case is about a small bicycle manufacturer redesigning its manufacturing system to cope better with high-variety, customized produc-tion. The second involves a large automotive company itera-tively designing large, complex flow lines. In both cases, the companies looked outside their organiza-tions for technical expertise to conduct the simulations. The support came from two g...

Modeling a Complex Production Line Using Virtual Cells

Lecture Notes in Electrical Engineering, 2012

Product-service system design concept development based on product and service integration

by Berry Yuliandra, Rika Ampuh Hadiguna, and Benny Tjahjono

J. of Design Research, 2015

Today's business environment pressurises many high-technology companies to continuously improve t... more Today's business environment pressurises many high-technology companies to continuously improve the value of their products and services to remain competitive. Product-Service Systems (PSS) is an emerging paradigm that enables a tighter integration between product and service offering. The research described in this paper aims to propose a new PSS design methodology based on the integrated product and service design requirements. The process consists of three stages: the identification of design requirements, the determination of design requirements rating and the integration of product and service design requirement in order to develop a PSS design concept. A case study of mobile phones design has been chosen to validate the proposed PSS design methodology.

Production Planning and Control in an Automobile Closed-Loops Assembly Line

Key Engineering Materials, 2012

a Luispintoferreira@eu.ipp.pt, b enrares@uvigo.es, c gupelaez@uvigo.es

Evaluation of the changes in working limits in an automobile assembly line using simulation

El objetivo del trabajo presentado consiste en el desarrollo de un sistema de apoyo a la toma de ... more El objetivo del trabajo presentado consiste en el desarrollo de un sistema de apoyo a la toma de decisiones, basado en modelos de simulación de eventos discretos, de una línea de montaje de automóviles, que fue implantado en un entorno de simulación Arena y enfocado a una clase muy específica de líneas de producción con una configuración en red de cuatro bucles cerrados. Esta distribución en planta refleja una de las configuraciones más comunes de líneas de transporte de automóviles para montaje y pre-montaje. La suma del número de palets en los almacenes intermedios, se mantiene constante, excepto en el cuarto bucle cerrado, en el que depende de la proporción de coches de cuatro puertas (x) implementado entre las estaciones de desmontaje y montaje de puertas en la carrocería. Algunas ecuaciones de control de los cuatro bucles cerrados no son compatibles con las capacidades de varios almacenes intermedios para ciertos valores de la variable x. Esta incompatibilidad muestra como la línea de montaje no puede funcionar en la práctica para x<0,37 y para x>0,97 en un régimen estacionario, debido al fenómeno de llegada nula o de falta de suministro en las máquinas de la línea de producción. Se ha evaluado el impacto del números de palets, que circulan en el primer bucle cerrado, en el rendimiento de la línea de producción, considerando el número de coches producidos/hora, con el fin de mejorar la disponibilidad del sistema de fabricación para cualquier valor de x. Hasta donde hemos podido conocer, hasta la fecha actual, no existen trabajos en la literatura especializada que presenten estos resultados.

Iterative Knowledge Based Embedded Systems Development Framework

Applications for Flexibility and Agility, 2011

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Simulation modeling of tool delivery system in a machining line

Proceedings of the 2011 Winter Simulation Conference (WSC), 2011

This paper describes an industrial project aiming to enhance the existing simulation modeling sui... more This paper describes an industrial project aiming to enhance the existing simulation modeling suites used at a car engine factory in the UK. The company continues to enhance its simulation modeling capabilities towards so called the 'total plant modeling' which not only covers the production facilities but also key ancillary facilities. Tool delivery is one such ancillary process. The existing modeling practices at the company are limited to modeling tool changes and assume that tools meet their expected life and the replacement is always available. In reality, the tools are not always reaching the expected life, the facilities in the tool crib are a limiting resource and the tool inventory has to be minimized. The tool delivery system developed in this project has specific features that model how the tool crib operates, how tools are supplied to the machining lines and various operating strategies.

Assembly line design principles using Six Sigma and simulation

Proceedings of the 2009 Winter Simulation Conference (WSC), 2009

Many variables and constraints must be taken into account when designing a manufacturing facility... more Many variables and constraints must be taken into account when designing a manufacturing facility such as an assembly line, which often depends on common practices and experience of the manufacturing engineers. Six Sigma has shown its benefits particularly in the process improvement and product development. This paper explores the applicability of Six Sigma and simulation techniques to derive a set of principles that can be used by manufacturing engineers to design assembly lines. The idea is to use simulation models as a basis for experimentation of parameters that are critical to the productivity of the lines. The sensitivity of these parameters were analyzed and the results from the experiments were then collated into a set of design principles that can be used as part of the facility design process.

Simulation Modelling of Product-Service Systems: the Missing Link

Proceedings of the 36th International MATADOR Conference, 2010

The Product-Service Systems (PSS) concept requires effective management of resources and supply n... more The Product-Service Systems (PSS) concept requires effective management of resources and supply networks in the long term which involve greater uncertainties than that in the productionbased system commonly found in manufacturing companies. This calls for a tool capable of evaluating the impacts of the shift of the business strategy to tactical and operational levels to help firms make decisions. The demand signals between production-based systems and PSS are typically different due to the customer involvements in service activities after product selling. For this reason, existing decision making tools in the production-based context may not be capable to suitably model PSS businesses. Simulation techniques can be used prior to the physical design of complex systems that incorporate internal interactions between entities in supply networks. This paper explores the application of simulation modelling within the PSS context. The current state of simulation modelling of PSS is summarised and the simulation parameters typically used in PSS modelling are described. The analysis shows various shortcomings of work in the literature. Existing simulation modelling approaches should, in fact, be enhanced to address different levels and types of performance measures required in PSS.