Start‐up of advanced manufacturing systems – a case study

The introduction of advanced manufacturing technologies can result in prolonged start‐up phases long after commercial production has started up. Progress of manufacturing performance is often prevented owing to extensive start‐up losses, giving rise to uncertainty. Based on a longitudinal case study of a Swedish manufacturer of engines for the automotive industry, the paper investigates the start‐up process of an advanced manufacturing system. The theory underlying learning curves and manufacturing progress functions are used to illustrate progress in manufacturing performance that takes place as time passes and the production volume is accumulated. A start‐up methodology, the concept of full‐speed testing, is outlined, empirically documented and analyzed by means of qualitative and quantitative inquiry. Full‐speed testing is a methodology for detecting potential problems and limitations in technology and organization, and for increasing the rate of direct labor‐ and cognitive learning. Tentative support is found for the notion that material supply, organization design and increased problem‐solving capacity are related to the rate with which manufacturing performance progresses as time passes and production capacity is accumulated.