A stepped composite methodology to redesign manufacturing processes through re‐engineering and benchmarking

Describes the redesign of manufacturing processes through re‐engineering and benchmarking. Demonstrates how to redesign an existing process and make it more effective to fit the needs of existing and future customers better. A four‐step composite methodology was adopted and implementation was carried out in six phases. Considers all aspects of the implementation: the initial analysis of the process of an existing manufacturing system; process redesign; implementation; and performance measurement. Measures the performance of the resulting process system using quantitative indicators which include process cycle times and saving of overheads. A maximum 33 per cent of accumulative improvement in turnaround time and a 50 per cent saving of the supervision overhead were observed. Discusses other features, such as increased commitment from top management, increased customer satisfaction, stronger team spirit, increased worker satisfaction, and innovativeness, which cannot be measured directly, and shows them to be major factors behind the successful implementation.