Browsing by Author "Baines, Tim"
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Item Open Access An advanced decision process for capacity expansion in manufacturing networks(Cranfield University, 2008-04) Julka, Nirupam; Baines, Tim; Tjahjono, BennyManufacturing companies develop multiple production sites for various reasons from cheaper labour to access to local markets. Expansion of capacity in such a manufacturing network is a complex decision and requires consideration of multiple factors. Traditionally, industrial decision makers attempt to minimise the cost of expansion and, usually as an afterthought, consider soft factors like manpower availability and logistics connectivity. This approach has gained acceptance as the research community has focused on developing better mathematical representations of the problem rather than investigate the larger decision process. A review of the literature revealed that all existing processes for multi-site capacity expansion decision fail in this way. Therefore, this research sets out to fulfil the needs of practitioners by developing a more complete process for the capacity expansion decision in multi-site manufacturing networks. The research programme consists of five parts. In the first part an extensive literature review is conducted to identify the state-of-the-art in capacity expansion decision processes. Then, in the second part, a representative process is formed and industrially tested. This generates the specifications for an advanced decision process which addresses the shortcomings of the present body of knowledge and is developed in the third part of the research. In the fourth part the advanced decision process is applied in an industrial setting to validate its effectiveness. Finally, in the fifth part the advanced decision process is refined and illustrated. The outcome of this research is an improved decision making capability. The advanced decision process has been both validated and appreciated by industrial practitioners. Specifically the contribution to knowledge is an advanced decision process for capacity expansion in multi-site manufacturing network.Item Open Access A decision model for manufacturing best practice adoption: Linking practices to competitive strategies(Cranfield University, 2007-10) Lee Gan Kai, William; Baines, Tim; Tjahjono, BennyThis thesis describes research that has developed a decision model for the analytical selection of manufacturing best practices. The competitiveness and growth in the manufacturing sector is critical for Singapore economy. Design and improvement of manufacturing systems is imperative to sustain the competitiveness of manufacturing organisations in the country. It is common for companies to adopt manufacturing best practices in this design process to emulate the success and performance of their counterparts. However, practices should be adapted to the competitive environment and strategy of the company to yield the desired results. Therefore, linkages between best practices and their associated competitive priorities will present useful guidelines for action to help manufacturing organisations achieve superior performance. The research programme has set out to define a decision model for best practice adoption. A broad taxonomy of manufacturing strategies and concepts has been used to identify and cluster a list of popular best practices commonly adopted. The decision framework for best practice adoption process is then formulated and a preliminary decision model constructed. This model is verified through semistructured interviews with industry and academic experts. Validation of model is conducted via case study research on eight manufacturing organisations. Linkages between practices and competitive strategies are then constructed to establish the final decision model. Finally, this decision model is illustrated in the form of a guidebook to help practitioner in the best practice selection process. This research has bridged the fields of manufacturing strategy and best practice research by establishing a comprehensive taxonomy of manufacturing strategies and concepts to classify the popular and commonly adopted best practices. A decision model that links best practices to competitive strategies has been developed to select the most appropriate practices for an environment. Thus, the work presented in this thesis has made a significant and original contribution to knowledge on the provision of analytical decision support for practitioners engaging in the manufacturing best practice adoption process.Item Open Access Development and assessment of a methodology for the business process improvement(Cranfield University, 2002-05) Adesola, Modupeola Olusola; Baines, TimThere appears to be an ever insatiable demand from markets for organisations to improve their products and services. In response, the concept of Business Process Improvement (BPI) has been developed in recent years as a useful aid. Unfortunately, there is no robust methodology that practitioners can use to apply this concept. Therefore, the intention of this research is to provide a generic and practical methodology to support the implementation of business process improvement within organisations. The research described in this thesis has set out to form a BPI methodology through a structured research programme. A pilot methodology was formed on the basis of existing contributions in the literature. This was initially refined through discussion with experts in the field, and a primary field trial. After refinement, the methodology was more thoroughly tested through case studies at three companies. The fully tested and refined methodology is presented as a workbook in the appendix of this thesis. The outcome of this research is a structured step by step methodology which is an aid to BPI. This methodology takes the practitioner through such steps as; understanding business needs, understanding the process, redesigning the process, implementing the new process, and reviewing the new process. The outcome of executing the methodology is a documented business process. The work described in this thesis has made a significant contribution to the knowledge on methodologies for BPI. It has also demonstrated that such methodologies can be formed and tested rigorously in an industrial context.Item Open Access Development and assessment of a methodology for the implementation of strategic manufacturing initiatives(Cranfield University, 2004-10) Minarro Viseras, Enrique; Baines, TimThe competitiveness and growth in the manufacturing sector is critical for the UK economy. It is imperative that the design and improvement of manufacturing systems is a constant and dynamic task in the British manufacturing environment. Unfortunately, many companies are still facing major difficulties during the implementation of strategic decisions derived from the formulation of manufacturing strategies. Current project management methodologies and techniques provide inadequate support for managers facing the implementation of strategic manufacturing initiatives (SMI). Therefore, the intention of this research is to provide a rigorous and successful SMI implementation methodology whose structure and contents include the most critical aspects relevant to the strategic manufacturing environment. The research described in this thesis has set out to form a SMI implementation methodology through a structured research programme. Initially existing literature related to SMI implementation methods was reviewed and analysed. A pilot methodology was then formed by contrasting literature against a list of key success factors in the implementation of strategic manufacturing initiatives determined from a worldwide survey. The pilot methodology was evaluated by a selection of practitioners, and results were used to refine the methodology. Finally, a validation test in a manufacturing organisation was conducted through a case study demonstrating the feasibility, usability and usefulness of the methodology. The fully tested and refined methodology is presented as a workbook in the appendix of this thesis. The outcome of this research is a structured step by step methodology which is an aid to the implementation of strategic manufacturing initiatives. The work described in this thesis has made a significant contribution to the knowledge on how to go about the implementation of strategic manufacturing initiatives.Item Open Access Development of a methodology for evaluating product service system as a competitive strategy for the Singapore manufacturing industry(Cranfield University, 2010-12) Ang, Gim Ching Jenny; Baines, TimProduct Service System (PSS) promotes the idea of selling value in use via an integrated combination of products and services. It has been regarded by many economic policy makers and researchers as a potential competitive strategy for the manufacturing industry in the developed country to gain competitiveness. Although currently there are a few PSS methodologies developed for the design and implementation of PSS, their approach is mainly biased towards using PSS as a tool to gain sustainability and to reduce environmental impact from selling more services instead of selling the physical product for example. In view of this, this research sets out to present a PSS Evaluation (PSSE) methodology, aiming at assisting manufacturer in assessing whether the adoption of a PSS is a good strategy from the point of competitiveness. The research programme begins with the identification of the requirements set of the PSSE methodology by gaining relevant knowledge from the literature and the Singapore‟s Manufacturing Industry. Existing potential methodologies were then selected against the requirements set to form the conceptual base of the new PSSE methodology. The developed new PSSE methodology was tested using two case studies during the primary evaluation and another four case studies during the secondary evaluation. The main contribution of this research is the development of a feasible, usable and useful methodology that can assist the manufacturer in assessing whether the adoption of a new PSS is a competitive strategy. The new seven-stage PSSE methodology provides well-constructed stages which are specially designed to be delivered via a facilitated workshop. This research has therefore made a significant contribution to the knowledge of the concept of PSS, and its application in the manufacturing industry in the area of methodology development.Item Open Access Development of a strategic supply chain positioning methodology for SMEs in Singapore(Cranfield University, 2007-10) Lim Yan Guan, Roland; Baines, Tim; Tjahjono, BennyThe Small and Medium Enterprises (SMEs) in Singapore face particular challenges from increasing competition from manufacturers in China, India and other East Asian countries. For these SMEs, survival and growth depend critically on defining their own competitive space among other companies in the manufacturing supply chains. Unfortunately there is little previous research on Strategic Supply Chain Positioning (SSCP) with most current frameworks and methodologies being developed from the perspective of the larger multinational companies (MNCs). Therefore this research has set out to develop a practical and robust SSCP methodology to support strategic decision making in SMEs in Singapore. The research programme began with a review of the existing methodologies and selecting the most promising methodology for further evaluation. Testing of this methodology was then carried out through four industrial case studies. Based on the results of the evaluation, the methodology was refined and a pilot SSCP methodology for SMEs was developed. Further testing was then carried out with another four case studies to identify particular characteristics for further improvement. The final SSCP methodology was then developed as a computerised software tool and presented in Chapter 9 of this thesis. The research has created a strategic supply chain positioning methodology that provides practical and procedural aid for strategic supply chain positioning efforts for SMEs in Singapore. This methodology guides the practitioner through a series of well-defined steps necessary to define the desired strategic positioning of the company in the supply chain. Such a methodology has been lacking in previous research and, hence, is the main contribution to knowledge in this thesis.Item Open Access Enhancing competitive advantage through successful lean realisation within the Aviation Maintenance Repair and Overhaul (MRO) industry(Cranfield University, 2015-10) Ayeni, P.; Ball, Peter D.; Baines, TimPurpose: Lean is increasingly being applied within the aviation Maintenance and Repair (MRO) Industry to mitigate industry challenges. This Lean application is premised on its success within other industrial contexts particularly the automotive industry. Furthermore, many organisations within automotive industry have attributed their enhanced competitive positioning to the Lean application. Indeed, Toyota (a pioneer of Lean) present Lean as a key proponent to its global success. However, with literature suggesting that there cannot be a direct transference of Lean from one industry to another and with the MRO having distinct characteristics different from the automotive industry, this research seeks to present how competitive advantage can be achieved through successful Lean realisation. Design/Methodology/Approach: The status of MRO Lean engagements presented is first presented based on the syntheses of literature review and empirical study (facilitate by an industry-wide survey). The means through which the MRO realises its value proposition is established and the structural assessment of the MRO industry as it pertains to competitiveness is also defined. The role of Lean in enhancing the value delivery system to enhance competitive positioning is operationalised through a case study. Findings: Using Porter’s forces of competition, this research establishes the competitive MRO landscape revealing the distinct characteristics of the MRO industry and how Lean can be accurately appropriated to enhance competitive advantage. The MRO Value Delivery System (VDS) is also delineated providing the complete system within which Lean is to be deployed (as opposed to the prevalent limited application of Lean in operational context alone). The case exemplar successfully validates and operationalises the approach to Lean application within MRO to enhance competitive advantage. Research Limitations: A case study example was used for this research, and whilst the outcomes were consistent with the research proposal, it still requires wider validation. Practical and Social Implications: This research demystifies and helps MRO organisations in assessing their Lean engagements but also in provide a roadmap and informs their strategy in improving their competitive status through Lean realisation.Item Open Access Impact of human performance variation on the accuracy of manufacturing system simulation models(Cranfield University, 2004-10) Siebers, P-O.; Baines, TimThe research described in this thesis is concerned with human performance modelling as an aid in the process of manufacturing systems design and re-design. Most manufacturing systems are highly complex constructs and their behaviour is of a dynamic and stochastic nature. They have to be constantly designed and re-designed as organisations are continually being pressured to change their manufacturing facilities, technologies, methods, people and products. All design methods have some form of evaluation where discrete event simulation models are usually used to undertake a comparative analysis of different system designs. Within these discrete event simulation models it is common practice to represent workers as simple resources, often using deterministic performance values. Conversely, the work measurement literature indicates that worker task performance varies between different workers carrying out the same task and moreover for the same worker when repeating a task. The current approach of representing workers within discrete event simulation models ignores the potentially large effect that human performance Variation can have on system performance. This omission affects in particular simulation models of labour intensive manufacturing systems like manual assembly flow lines. It appears that this adds to the inaccuracy of the simulation model output and that consequently the simulation model does not react the behaviour of a real system in an appropriate way. A research programme has been designed to investigate these issues. First, a long term data collection exercise has been conducted to quantify the performance Variation of workers in a typical automotive manual assembly flow line. The data have then been used in form of frequency distributions to represent worker performance Variation at individual Workstations within manual assembly line simulation models. Through designed simulation experiments the impact that this form of worker performance Variation representation has on the accuracy of manual assembly line model behaviour has been investigated. Overall this research has found that adding worker performance Variation models into manual assembly flow line models has an impact on the accuracy of these simulation models. The magnitude of the impact depends very much on the type of Variation to be represented as well as on the system to be modelled. This evidence is an important result to support justification for further research in this area. For a more sophisticated approach of modelling worker performance Computational Organisation Theory using the multi-agent paradigm has been identified as the most suitable way forward.Item Open Access Investigating the effects of the physical working environment upon direct manufacturing workers(Cranfield University, 2005-02) Mason, J. P.; Baines, TimWithin any developed nation a thriving manufacturing industry is a major driver behind economic prosperity. Key to maintaining a competitive manufacturing capability is the manufacturing system design process and the decisions made within it. The Ford Motor Company manufacturing design teams recognise that key decisions, regarding the physical working environment, can impact upon manufacturing workers, a key resource in maintaining competitiveness. The current problem centres on the lack of confidence among manufacturing system designers, in the tools and guidelines currently available to assess these effects. The working environment can be considered to consist of 'variable' factors (light, noise, temperature, etc.) and 'fixed' factors (equipment layout, hygiene facilities, resting areas, etc.). The aim of the research presented in this thesis, has been to identify the impact of the physical working environment upon manufacturing worker performance. Studies carried out within United Kingdom manufacturing facilities, provided an assessment of the impact of the variable and fixed physical working environment. The variable environmental factors were measured simultaneously against manufacturing worker performance and analysed for any relationships. The fixed environment factors were assessed to see whether their effect upon manufacturing worker motivation could be prioritised within a hierarchy. These studies have provided manufacturing system designers with the ability to make a more confident assessment of the physical working environment and its effect upon manufacturing worker performance. The contribution of this research is therefore, within the context of manufacturing system design, an improved understanding of the effects of the physical working environment upon the performance of manufacturing workers. Specifically, key findings identify the limits in which manufacturing worker performance is not affected by the variable working environment. Also identified, are a set of fixed environmental factors considered to impact the motivation of manufacturing workers. These findings are then used to present manufacturing system designers with a set of guidelines, that can provide assistance with the design of the physical working environment.Item Open Access Lead-time reduction and improving the operating efficiency(1999-09) Lestos, Simeon; Baines, TimFor a successful manufacturing company to consistently realise success invariably requires the organisation to find new methods of achieving competitive advantages. Today time is on the cutting edge and represents one of the most determinants of leading companies. This project is a part of an ongoing effort to sustain a competitive position and thus maintain company prosperity especially with new competitors entering the European Community (EU). Additionally reduced lead-time at Hephaestus S.A., will lead to reduced operating costs, which will enhance the profitability of this company. The aim of this project is to develop a generic tool based on the knowledge gained from a literature research into formal methodologies for reducing leadtime. This generic tool was tested by its application to the activities of Hephaestus S.A., and investigated how problems areas can be addressed. Finally recommendations have been made to Heaphaestus S.A. for reducing its lead-time and improving its operating efficiencyItem Open Access Made to serve: a model of the operations practices and technologies that deliver servitization(Cranfield University Press, 2013-09-19) Baines, Tim; Lightfoot, HowardThis paper explores how successfully servitised manufacturers deliver advanced services and proposes a model that describes how they configure their operations. A case study methodology is applied across four manufacturing organisations successful in delivering advanced services. A descriptive model is then formed based around six popular technologies and practices.Item Open Access Manufacturing systems simulation using the principles of system dy(Cranfield University, 2003-11) Oyarbide Zubillaga, A.; Baines, TimManufacturing is the largest single contributor to the global economy. The evolution of consumer demands has pressurised companies into producing a larger variety of products, with improved specifications, reduced costs, and shorter lead times. In this context, companies have found simulation techniques useful in their manufacturing systems design processes; simulation based on Discrete Event Simulation (DES) is the preferred technique. The complexity of manufacturing systems, and the mechanisms of DES, means that the simulation task often consumes excessive time and resources, such as data, software, and training. Evidence suggests that an alternative modelling technique, named System Dynamics (SD), is also appropriate for conducting this task. SD has been applied successfully in other fields, where its graphical notation is considered beneficial. However, the lack of an SD tool that is tailored toward manufacturing systems has prevented industry from adopting this technique more extensively. This thesis determines the extent to which SD can provide a credible alternative to DES in the manufacturing system design process. Information concerning DES, SD and practitioners' needs was gathered from published literature and from an interview survey. A functional prototype of a tool based on the SD principles, but tailored to model manufacturing systems was then developed. Three case studies then provided valuable information concerning the requirements of industry and the capabilities of the SD technique. This research programme has found SD to be sufficiently accurate and quicker than DES tools under certain conditions, requiring less data and skills. In addition, the user interface appears to have had a significant impact on the lack of adoption of SD techniques within the manufacturing sector. Simp1ifications made by this technique can reduce both model building and model execution time, and thus, experimentation time. However, evidence suggests that DES is still more prevalent, and that further work is required to develop SD based tools tailored to manufacturing systems. Therefore, this thesis provides a much improved understanding of the capabilities of SD as an aid to manufacturing systems design.Item Open Access Strategic positioning within global supply chains(Cranfield University, 2008-10) Chandraprakaikul, Watcharavee; Baines, TimThis thesis is concerned with the decision process of strategic positioning within global supply chains. The research provides insights into how companies currently form positioning decisions, and set out to develop a systematic methodology to assist practitioners in forming their strategic positioning decisions. Manufacturing in the UK is increasingly exposed to the effects of global competition. Many companies are facing difficulties to define the most advantageous position in their global supply chains in order to maximise their business competitiveness. The position of a company is concerned with deciding a boundary and configuration of internal and external business activities to the company and is directly related to initiatives such as outsourcing, make or buy, and offshoring. Unfortunately, current methodologies and tools do not provide adequate support to provide a holistic view for making such decisions. Hence, the purpose of this thesis is to provide a generic and practical methodology that is an integrated and holistic approach that assists practitioners to deal with strategic positioning within global supply chains. The research programme commenced by exploring the process and content of positioning decision from four actual manufacturing companies. The results from the exploratory case studies and existing contribution from literature have then been synthesised to form a pilot methodology. This is captured in the form of a paper-based workbook. This methodology has then been evaluated and refined through a primary application in two case studies with the researcher taking a role as a participant. Finally, wider applicability of the methodology has been assessed through four more case studies covering different types of manufacturing with the researcher not intervening but instead observing. The final methodology referred to in this thesis as the “SPGC methodology” has demonstrated that it provides practical support to industrial decision making. The outcome of this research is the step-by-step SPGC methodology supporting practitioners to deal with strategic positioning within global supply chains. The overall approach has been demonstrated to be feasible, usable and useful, and has been used in a range of manufacturing companies. This research has filled an industrial need and literature gap and has made a significant contribution to the knowledge on how manufacturing companies can form a strategic positioning within global supply chains.Item Open Access A strategy formulation methodology for companies seeking to compete through IVHM enabled service delivery systems(Cranfield University, 2012-05) Redding, Louis E.; Baines, Tim; Ball, Peter D.This thesis makes a contribution to knowledge through the development of a strategy formulation methodology for manufacturing organisations who wish to compete through advanced technology enabled service delivery systems. The research introduces the reader to the concept of Product Service Systems (PSS) and the process of ‘servitization’. It identifies Integrated Vehicle Health Management (IVHM) as one of a set of enabling technological applications, which if adopted, can facilitate the supply of “intelligent” or “informated” products. Such products enable the manufacturer to monitor the condition and usage of these products ‘in the field’ thereby enabling aligned service solutions to be offered. A five phase research programme is undertaken which seeks to understand the principles of IVHM and gain knowledge of the level of practitioner awareness of the concept and related issues. The research then explores and defines the concept of the service delivery system, and identifies and reviews operations strategy formulation methodologies. A pre-pilot methodology is adopted which is then tested via case application to generate a list of requirements and specification. A pilot methodology is designed to suit the specification and tested via industrial case studies and expert practitioner evaluation. The pilot methodology is finally refined prior to verification and validation through industrial case application and further expert practitioner evaluation. This research delivers a sequential and iterative strategy formulation methodology which fills a gap that is identified through a state of the art literature review and practitioner survey. The documented methodology is the result of a structured development and test programme and is shown to be feasible, useable and useful by test and validation by numerous manufacturing organisations. It makes a significant contribution to knowledge. This is attained through seeking to understand the organisation’s actual competitive position, its alignment to the stakeholder’s service requirements, and organisational structure. It also offers alignment relative to the level of technology adoption when offering intelligent/informated products. The research provides a strategy formulation methodology to deliver an enhanced service delivery system.Item Open Access A system development methodology for embedded applications(2009-07) Goh, Kiah Mok; Tjahjono, Benny; Baines, TimIn recent years, Singapore’s manufacturing sector has contributed more than a quarter of the total Gross Domestic Product (GDP) and has established global leadership positions in several manufacturing areas such as electronics, Information Technology (IT) and industrial automation. The Singapore Economic Review Committee (ERC) recommendation states that “software and embedded systems that drive products are one of the most important technologies for the manufacturing sector. “ With the increasing adoption of automated and intelligent products, embedded systems have emerged as a crucial technology for Singapore. However, the development of embedded applications is not a trivial undertaking as it can usually involve multi-discipline parties and different application platforms. Most embedded application developments use either vendor specific or desktop based methodologies. Vendor specific methodologies constrain the company to rely on the specific vendor's solutions, whereas desktop-based methodologies are not well suited to embedded application development. Therefore, this research aims to develop a standard-based system development methodology for embedded applications. The research programme comprises 5 stages. The first stage reviews the existing system development methodologies for embedded applications. The next stage formulates the proposed conceptual methodology followed by the development of the proof-of-concept tool to demonstrate the merits of the proposed approach. The methodology is then tested and evaluated respectively by using industrial experiments and feedback from a workshop. The final stage refines the methodology based on the feedback and presents the final system development methodology. The research has provided a sound foundation which future research in methodology for embedded applications to develop further.Item Open Access Towards the strategic adoption of Lean in aviation Maintenance Repair and Overhaul (MRO) industry: an empirical study into the industry’s Lean status(Emerald, 2016-02-01) Ayeni, Peter; Ball, Peter D.; Baines, TimDespite many Maintenance Repair and Overhaul (MRO) organisations alluding their positive business performances to the adoption Lean initiatives, there is a paucity of direct literature that validates this assertion. Thus, the purpose of this paper is to study empirically via the use of an industry-wide survey to establish and extent of Lean adoption and to verify its suitability in mitigating prevalent MRO challenges. Design/methodology/approach The empirical study contained in this paper is facilitated by an industry-wide survey to collect data from several firms across the MRO spectrum. The analysed responses from industry leaders, professionals and executives synthesised with existing literature was used in ascertaining the extent of Lean adoption within the operational framework of the industry. Findings The empirical study helped in validating the suitability of Lean in MRO context. However, it was also observed that the focus of its application was skewed towards its production-orientated functions more than its service-orientated functions. Nonetheless, this paper presents results of the positive influence of Lean in MRO context. Research limitations/implications This empirical study presented in this paper was carried out within a framework of key characteristics of operation. Although this approach is sufficient in assessing the industry’s Lean status, further assessment can also be achieved within the context of relevant performance metrics which was not included in this paper. Practical implications By exploring the industry’s Lean status within the context of operational characteristics of operation, this study provides MRO practitioners with more awareness into some of the critical factors required for successful holistic Lean realisation. Social implications The state-of-the-art of Lean within the aviation MRO context established through this research also contributes to the wider product-centric service environment by providing a platform that facilitates strategy development which ensures Lean success within this environment. Originality/value Apart from validating the suitability of Lean in MRO contexts, by establishing the extent of Lean adoption within the context of the operational framework, this paper provides a clearer insight as to how successful Lean implementation can be achieved via a holistic implementation strategy balanced between the product-centric and service-centric aspects of the industry.Item Open Access Understanding human variability to improve manufacturing system design(Cranfield University, 2004) Fletcher, Sarah; Baines, Tim; Asch, RachelThe way in which a manufacturing system is designed is a crucial determinant of its operational efficiency and profitability. System design is, therefore, a major consideration for organisations. However, the efficacy of current system design techniques could be improved. Designers still do not often construct assembly line layouts that provide the high level of efficiency and flexibility that is required by today's highly competitive organisations. One aspect of system design processes that has been found particularly deficient is the way in which human labour is considered. Current system design practices tend to disregard that workers may vary as they perform production tasks and the impact that this may have on the assembly line. In particular, system designers appear to have little understanding of how production work may be affected by workers' personal attributes. The research presented in this thesis sought to identify the nature and impact of human work performance to inform design stage practices. In particular, the research aimed to establish the extent to which the personal attributes of workers influence variations in their performance of production tasks. The research involved parallel data collection studies in a real manufacturing system where workers' performance of production tasks and their personal attributes in respect of work-related attitudes were measured and analysed. Overall, this research did not nd evidence of relationships between the particular work- related attitudes and production task performance that were measured in the study. However, indications were found that suggest production task performance variations may be produced by interactions between task characteristics and workers personal attributes. This evidence is an important development in understanding worker behaviour and informing manufacturing system designers that their neglect of worker performance variation in design stage evaluations may be a major cause of current design weaknesses.