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Research Article

International Journal of Engineering


Business Management
Volume 11: 1–14
The impact of intelligent manufacturing ª The Author(s) 2019
DOI: 10.1177/1847979019863955
elements on product design towards journals.sagepub.com/home/enb

reducing production waste

Jamal Ahmed Hama Kareem1,2

Abstract
With ever-increasing market competition and advances in technology, more and more countries are prioritizing for
advanced and intelligent manufacturing technology as a top priority for improving product design and reducing production
waste towards promoting economic growth. Consequently, this study empirically tests the set of intelligent manufacturing
elements (IMEs) that affect product design towards minimizing production waste at mineral water factories in the
Kurdistan region of Iraq. The results of this study were based on the data obtained from the mixed methods represented
in a questionnaire survey and semi-structured interviews in the framework of the case study. The questionnaire survey
already has been tested. The sample of the study was 269 respondents selected based on a stratified sampling technique.
The criteria for choosing the respondents to be part of the study were based on the status of full-time employee of the
organization. The findings showed that among the IMEs addressed in this study, each intelligent device and intelligent
process had had a strong impact on improving product design, and hence the efficient use of manufacturing resources
towards reducing manufacturing waste in the industrial organizations.

Keywords
Business intelligence, business process, industrial engineering, manufacturing, manufacturing operations and control,
manufacturing planning and execution, operations management

Date received: 26 January 2019; accepted: 24 June 2019

Introduction much as possible.2 As the development of automation is


constantly progressing, it is significant to tackle the crea-
It can be clearly and notably observed that manufacturing
tions and the conceivable applications of comprehensive
systems have undergone many changes. Such changes are
and beneficial manufacturing patterns by depending on
largely marked within the international setting of multifa-
Intelligent Manufacturing System (IMS). This mainly due
ceted industrial build-up. They can also be the result of the
age of an advanced competence, superior tractability and of
a product reduced cost. Historically, the process of manu-
1
facturing control dominated the early 50s where engineers College of Administration and Economics, University of Sulaimani,
Sulaymaniyah, Iraq
came up with numerous techniques which analyse or shape 2
College of Administration and Financial Sciences, Cihan University -
manufacturing processes to suit the demands of technolo- Sulaimani Campus, Sulaymaniyah, Iraq
gical processes, to specialize the manufacturing fields and
to apply pressure to the decrease of production costs.1 Corresponding author:
Thus, it was largely claimed that the ultimate goal was to Jamal Ahmed Hama Kareem, College of Administration and Economics,
University of Sulaimani, Sulaymaniyah, Iraq & College of Administration
raise demand for improved product design and optimal and Financial Sciences, Cihan University – Sulaimani Campus,
utilization of available resources by reducing the percent- Sulaymaniyah 46001, Iraq.
age of wastes towards raising the quality of the product as Email: ramanahmed79@yahoo.com

Creative Commons CC BY: This article is distributed under the terms of the Creative Commons Attribution 4.0 License
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further permission provided the original work is attributed as specified on the SAGE and Open Access pages (https://us.sagepub.com/en-us/nam/
open-access-at-sage).
2 International Journal of Engineering Business Management

to that this system (IMS) has a high ability to meet the (6) Digital Die Design System (3DS) which is a system for
needs of the market volatile in terms of the designs and constructing a powerful digital die design, it applies partic-
product specifications, as well as quality and price.3–5 ularly to sheet metal forming. (7) Rapid Product Develop-
IMS formally commenced in 1995 with the membership ment which is the approach that aims to explore, adapt and
of Japan, the United States, Canada, and Australia and the integrate tools and strategies for accelerating the develop-
projects established in the first 2 years were generally ment and deployment of new products with improved qual-
developments of those which had formed the basis of an ity. (8) Intelligent Composite Products, this is an approach
earlier 2-year feasibility study. The agreement in 1997 of that aims to develop an integrated design system for com-
Switzerland and the EU to join IMS and the opportunities posite materials based on the concept of parallel develop-
to link into the European Research and Technology Devel- ment of the product and process.
opment Framework programme have had a profound Thus, what the current research will make high interest
impact on the breadth of the IMS programme and provided for a wide range of organizations and people interested in
further recognition of its relevance and importance to the the current field of study is that the idea and main aim of
manufacturing world of today.6 Thus, almost all OECD the implementation of the IMS is akin to any normal man-
nations now participate in IMS. Each of these regions has ufacturing system in terms of increasing efficiency of the
established a domestic secretariat for IMS having direct manufacturing process and improving product design and
links with industry and the government and each of the reducing production waste, thereby meeting the challenge
regions contributes to the maintenance of the small inter- which represent in the globalization of the world economy
national secretariat located in Australia.7,8 and growth of competition as well as the rapidly changing
The international regulations of IMS include in provid- customer requirements in the market which, in turn, are
ing local assistance and a framework for companies and forcing major changes in the production styles and con-
research groups to identify and define issues requiring res- figuration of modern manufacturing organizations. All
olution, to seek appropriate project partners worldwide, to these towards pleasing the demands of the customers
establish a mutually beneficial agreement on workload and which are fluctuating promptly,12 where the appeal in
disposition of Intellectual Property Rights (IPR) and in favour of the customer is mostly accomplished when there
some instances, to link into sources of government funds.9 is an efficient level with a very reasonable cost in the
These regulations and provisions cover both mandatory and business environment.13,14
optional aspects and deal with the requirement for a coop- In addition, management and control of production
eration agreement between project partners, ownership of organizations currently are impossible without an applica-
intellectual property brought to a project (background) and tion of appropriate techniques supporting decision-making
developed within a project (foreground), the dissemination at each stage of an organization’s functioning from design
of information, licence rights, confidential information and through to product exploitation. Intelligent manufacturing
applicable law.8,9 techniques are an example of such available techniques that
On the other hand, the IMS consists of the many inter- enable composite automatization of technological and
national approaches and systems as follows8,10,11: (1) Next organizational preparation for manufacture, current super-
Generation Manufacturing approaches which are develop- vision, technological process control, organization and
ing and integrating intelligent information and processing management. These techniques have sufficient flexibility
technologies to support complete product life cycles for the in satisfying the changing production styles and highly
next generation of manufacturing systems. (2) Holonic dynamic variations in product requirements.15
Manufacturing approaches which are developing discrete, Moreover, in the business organization, the ultimate
continuous and batch manufacturing systems through inte- demand for manufacture improvement is to increase their
grating highly flexible, agile, reusable and modular manu- competitiveness in the world markets.16 Given the impor-
facturing units. (3) Knowledge Systematization – tance of the foregoing, the competitiveness is possible to
Configuration Systems for Design and Manufacturing achieve not only through improving product quality, short-
(Gnosis) that aims to establish the framework for a new ening of delivery date and decreasing of production costs,
manufacturing paradigm through the use of knowledge- but also through what the current study has been contributed
intensive strategies covering all stages of the product life in reviewing the set of intelligent manufacturing elements
cycle. (4) Metamorphic Material Handling system which is (IMEs) which will have an effective role during providing
able to change their shape in a highly flexible, automated and implementing them properly in influencing on improv-
and autonomous manner to meet the varying demands from ing and the permanent development of product design and
a flexible manufacturing system. (5) Organizational thereby increasing the efficiency of the manufacturing pro-
Aspects of Human-Machine Coexisting Approach which cess and reducing production waste towards promoting eco-
aims to pursue a practical methodology to establish the nomic growth. All these will be driving the business
optimum relationship between humans and manufacturing organizations to enhance their competitiveness in markets
facilities based on ergonomic, informational and sociotech- with volatile needs. Thus, the IMEs and their impact will
nical studies on next-generation manufacturing systems. be discussed in detail in the theoretical aspect of the current
Hama Kareem 3

research which, in turn, will more motivate on the impor- For example, in an intelligent device, the intelligent sensors,
tance of contribution which was highlighted in the current controls and software applications work together to obtain
search for those who are concerned in this field of the study. real-time information and share those with the arrival of final
goods down the production line. ‘Smart Devices’ will enable
machines to take independent actions.12,19
Literature review and hypothesis In order to effectively use manufacturing resources and
development the improvement of product design in line with rapidly
changing situations and requirements in the manufacture
Intelligent manufacturing is a comprehensive classification
of products in world markets, intelligent manufacturing
of manufacturing aiming at improving concept production
requires that intelligent devices be capable of changing
and product transaction. Manufacturing can be defined as a
their behaviour in response to these changes of situations
multistage process which creates a product from raw mate-
and manufacturing requirements. 12,20 Managing and
rials. On the other hand, intelligent manufacturing is a sub-
changing the behaviour of the intelligent device is basically
set used for computer control and high levels of flexibility
based on past experience and learning capabilities pos-
in physical processes. There is an increased training for the
sessed by those managing smart devices.18,21 The term
workforce for such flexibility and the use of technology
‘intelligent device management’ means using the software
rather than specific tasks as is customary in ordinary man-
to manufacture products that assist managers in controlling
ufacturing. Intelligent manufacturing also means the use of
devices and equipment through the global IP network. This
common intelligence for people, processes and machines to
type of resource is often used in manufacturing and in
influence the macroeconomics of manufacturing. Intelli-
other systems where many different devices have to
gent manufacturing aims to increase the efficiency of man-
communicate with each other and collaborate over long
ufacturing resources, improve product design, reduce
distances.22,23 Thus, according to the above, intelligent
production waste and thus improve business value and
manufacturing and efficient use of manufacturing
safety, all while meeting customer requirements in terms
resources and improved product design can have a signif-
of delivery and quality.
icant and real role towards reducing of manufacturing
However, there are the set of key elements of intelli-
waste which can occur as a result of rapid and sudden
gent manufacturing represented in intelligent devices,
changes in product design and manufacturing in order to
intelligent employees, intelligent processes, intelligent
respond to volatile market demands. As such, the following
connectivity and intelligent infrastructure, which have a
hypothesis can be formulated:
real and effective role in enhancing the efficiency of man-
ufacturing resources, improving product design and H1: Intelligent devices have an influential impact on
reducing the percentage of wastes in business organiza- product design towards reducing production waste in
tions. For this important issue, the current study sought to industrial companies.
investigate whether any of these elements have a greater
impact in improving the product design towards reducing
Intelligent employees. Intelligent is used in its broad sense to
production waste, thus improving the economic and com-
refer to the high intelligence quotient (IQ). Webster’s dic-
petitive situation of the organizations under study by
tionary defines it as ‘mentally alert, knowledgeable, witty
meeting the rapidly changing customer requirements in
and clever’.13 Yet, when it comes to the consideration of
terms of suitable quality and price. The following is a
intelligence in a more particular sense, it is possible to
discussion of the literature related to these set of elements
observe that an employee with a distinguished IQ differs
along with building the hypotheses that can reflect the real
from an intelligent employee. The former has skills of
reality for the impact of these elements.
comprehending, analysing and reproducing information.
The latter may have such qualities but must have possessed
IMEs and hypothesis development worldly wisdom and also have a common sense which is
The ultimate aim of the current study is to provide a better mainly a reflection of his own personal experience.24 A
understanding of the actual impact of the set of the IMEs on smart employee is likely to have an easier time developing
the product design towards minimizing production waste at cross-cultural communication skills if he or she does not
the Kurdish mineral water plants. Subsequently, the current already own them. Kwintessential, a trade organization
study will focus on the basic five elements of relevant specializing in cultural ethics, emphasizes that intercultural
intelligent manufacturing, each with their own hypotheses: communication skills are key to gaining a competitive
advantage in today’s business world. The intelligent
Intelligent devices. An intelligent device is any type of equip- employee sees the big picture and understands the political
ment, instrument or machinery which has the ability of its and competitive advantage associated with an ability to
own computing capability.5,17 As computing technology adapt to his or her surroundings.25
becomes more advanced and less expensive, it can be inte- Thus, as the vision of the intelligent factory has become
grated into an increasing number of devices of all types.18 a reality in today’s business environment, the abundance of
4 International Journal of Engineering Business Management

productive experience of the intelligent employees in the events, social media, embedded sensors, and so on which
industrial organizations that follow the smart manufactur- can be of great significance to accomplish business goals.32
ing approach will lead to much faster processes of product The key aim of intelligent processes is to consolidate the
design and manufacturing, greater flexibility and more effi- proficiency, increase worker performance, decrease the
cient exploitation of materials, with reduced complexity possible occurrence of work potential risks, and to improve
and downtime.12 Moreover, the intelligent employees are responding to the demands of the customers as soon as
very important to the success and effectiveness of any orga- possible.34 In addition, the full value of intelligent pro-
nization and the management should motivate them.26 As cesses is demonstrated by the achievement of significant
the continuous development of computer software and productivity gains in terms of increasing product design
machinery replaces labours in most industrial organiza- efficiency, minimizing manufacturing waste and improv-
tions, the intelligent employee is able to learn these systems ing both the safety of the working environment and the
and adapt to these changes and find methods to take a quality of the products.12 All these, in turn, enhance the
personal approach in an impersonal environment.27 Thus, confidence of the industrial organizations in achieving
motivating the organization’s management and their ability the rapidly changing market’s requirements and thereby
to communicate with intelligent people who may occupy enhancing the company’s economic value and competitive-
various jobs and are located in various geographical areas ness. In light of the discussion above, the following hypoth-
and providing them with relevant information in real time esis was formulated.
will enable them to provide the intelligent design for the
product and the optimal exploitation of the manufacturing H3: Intelligent processes would have a strong impact on
resources towards minimizing the production waste that product design towards reducing production waste in
may result from designs that do not meet the satisfaction industrial companies.
of customers in terms of quality and safety of the product.28
Out of the aforementioned discussion, the following Intelligent connectivity. Intelligent connectivity in industrial
hypothesis is considered: organizations is the culmination of the basic information and
communications technology that links everything that assists
H2: Intelligent employees influence the product design to walk the processes of production line smoothly and effi-
towards reducing production waste in industrial ciently in terms of smart sensors down to equipment that
companies. operates according to the principle of industrial intelligence
and rich infrastructure.5 Intelligent connectivity is often
Intelligent processes. Intelligent processes are dynamic, flex- referred to as ‘Internet of Things (IoT)’, where the invisible
ible processes that focus directly on the consumer that is system of interpersonal relationships, devices and equipment
constantly improving and adapting. In an era where com- that have built-in technology to communicate, sense or inter-
pliance and governance are essential, organizations must act with their external or internal environments provide
ensure these processes are transparent.29 Once a process is superior performance with guaranteed production levels.
transparent, it becomes possible to make it adaptive, driv- Moreover, IoT shows a networked world in which multiple
ing continuous improvement by evaluating how the process objects are integrated with electronic sensors, motors or
works, thus ensuring the process stays intelligent in the face other digital devices so that they can be networked and
of change.30 Also, the intelligent processes are the technol- connected for the purpose of collecting and exchanging
ogies that combine fundamental processes design with data.35 Generally, IoT can provide advanced communication
robotic process automation and machine learning (ML). with physical objects, systems and services, allowing com-
These are, indeed, the triggers of initiating progress as far munication between objects and data sharing. In various
as business is concerned and can be considered to a large industries, control and automation of lighting, heating, auto-
extent the future endeavour aiming at increasing the com- mation, automated vacuum and remote monitoring can be
petence of employees. This can be represented by the form achieved through the IoT. One of the key technologies in the
of avoiding repetition and routines of various tasks. Such IoT is automatic identification (auto-ID) technology, which
improvements will ultimately lead to a better connection can be used to perform smart operations.31,12
with the customers by providing more efficient services at Thus, intelligent communication of this level allows
different levels.31,32 Intelligent processes mimic the activ- complete business integration, with some potential of prod-
ities of human beings and learn over time to do them better. ucts that can exist outside the actual device in the product
The elements of intelligent rule-based operations are cloud. Data from these products can be evaluated to
enhanced by decision-making capabilities through improve operational efficiency and allow informed deci-
advances in deep learning and knowledge technology.33 sion-making.3 In terms of simplification, the benefit of
While intelligent processes take over rote tasks, workers harnessing intelligent connectivity for industrial organiza-
are capable of concentrating on properly replying to the tions allows for an interconnected management solution
needs and the demands of the customers. They ought to once products are connected. Organizations can then
consider new methods that are largely found in news, evolve to offer more complex product designs and less
Hama Kareem 5

damage in terms of manufacturing waste, which ultimately


makes these products have a higher value. All these, in turn, Intelligent Manufacturing Elements (IME)
can significantly improve efficiency and business growth,
thereby enhancing the economic and competitive position Intelligent Intelligent Intelligent Intelligent Intelligent
Devices Employees Processes Connectivity Infrastructure
of these organizations. Thus, according to the facts above,
the following hypothesis was set up:

H4: Intelligent connectivity would have a strong impact


on product design towards reducing production waste in
industrial companies.
Product Design Towards Reducing
Production Waste
Intelligent infrastructure. Intelligent infrastructure takes care
of real-time information available among various plants, Figure 1. Study model.
equipment, processes, devices and people. It may include Source: Organized by the researcher, adapted from Wadhwa45
information technology (IT) infrastructure such as Satellite and Malavasi and Schenetti.46
link, Ethernet connectivity, Wi-Fi routers, Remote PC ser-
vice, Data storage service, Fibre optic link, Civil structure, information from the officials and employees who work
Mechanical, Electrical and Electronic hardware.36,37 The full-time in Kurdish mineral water factories. The model
intelligent industrial infrastructure is also called the Con- of the study is established in accordance with the afore-
nected Enterprise, which is considered intelligent, opti- mentioned foregoing as in Figure 1.
mized and secure. The interrelated enterprise is the Based on the sampling table provided by Krejcie and
convergence of IT and operations technology (OT) in a Morgan,41 the sample size for a population of 891 is 269
single unified architecture to take advantage of operational, respondents in three Kurdish mineral water plants. On the
business and transactional data to improve enterprise per- basis of the strata and proportional representation condition
formance, processes and supply chain. By using intelligent of stratified sampling that satisfy verifying the key aim of
infrastructure components which interact with mobile the current study, the sample for each mineral water plant
devices, products and individuals, a conscious infrastruc- was 87, 89 and 93, respectively. It is worth noting that the
ture will better support complexity and enable more effi- trademarks of these plants are unrevealed as the human
cient manufacturing of goods.10,38 resources (HR) department of these plants recommended.
Intelligent infrastructure is also helping to improve the All the relevant and prerequisite data are provided by the
utilization of intelligent devices and equipment towards administrative boards of the plants and, hence, are consid-
design of products and to manufacture them more effi- ered the population of the study. The participants (who
ciently and with less damage in terms of production waste. represent the sample) varied according to the level of edu-
This is accomplished by the plant-floor OT and business- cation. Research strategy aids to a large extent in system-
level IT, which are characteristics of intelligent infrastruc- izing the operation variables, gathering reliable
ture. For example, an organization may incorporate information and analysing them and, by doing so, a solution
intelligent monitoring devices into its inhaler product lines can be founded to the key problematic areas which the
for real-time data collection and analysis to improve the research arises.42 As noted earlier, the current study aimed
design efficiency of products and their manufacture, thereby to explore and understand the impact of the set of IMEs in
maintaining their high quality.39,40 Thus, the fifth hypothesis the product design towards reducing production waste in
was formulated according to the above discussion. three Kurdish mineral water factories. On the basis of that,
the approach of mixed method by using both quantitative
H5: Intelligent infrastructure would have a strong and qualitative methods (survey questionnaire and semi-
impact on product design towards reducing production structured interviews concurrently) of data collection
waste in industrial companies. within the framework of the case study was selected, which
in turn makes the findings more valid and reliable. The
Methodology of study following is a detailed discussion of the methods used to
collect data in the present study.
This section discusses the methodology used in the study in
terms of the study model, the data collection tools and
procedures. The current study is descriptive and focuses
Data collection methods
mainly on obtaining better understanding of the true influ- The questionnaire used in the present study consisted of
ence of the set of IMEs in the product design towards three sections. The first section was related to IMEs which
reducing production waste. To achieve this end, the study consisted of intelligent devices, intelligent employees,
was performed by conducting a cross-sectional survey intelligent processes, intelligent connectivity and intelli-
along with semi-structured interview to obtain data and gent infrastructure. These five dimensions were measured
6 International Journal of Engineering Business Management

using 20 items (4 items for each dimension, respectively). After that, other colleagues and PhD students at the Faculty
The second section of the questionnaire was interested in of Management and Faculty of Engineering at the Univer-
the items measuring the implementation of IMS in terms of sity of Sulaymaniyah tested the draft of the questionnaire
improving product design and optimal utilization of avail- translated into Arabic. The remarks were considered by the
able resources by reducing the percentage of wastes, researcher and were implied in the final version of the
decreasing of production costs and meeting customer questionnaire. On the other hand, the translation was exam-
requirements in terms of quality, price and delivery date, ined carefully so as to ensure credibility and authenticity.
and other specifications which can explicitly demonstrate The Arabic version of the questionnaire was, then,
the insights of the employees concerning how to carry out examined practically matching it to the actual fieldwork.
the procedures of the IMS in their factories. These dimen- This was accomplished by sending it with a cover letter to
sions have been measured through 15 items, which were one of the plants participating in the research project so as
also classified on a five-point Likert-type scale on the basis to confirm its reliability. The production manager at this
of measuring the percentages of agreement or disagree- plant was asked to write his reflections on how clear the
ment. The third section of this survey encompassed the questions were and how easy they were to answer. After
demographic information of those involved as the sample that, the questionnaire was revised and retested again with
of the study like gender, age, fieldwork experience and the same manager. When the researcher was satisfied with
education level. To guarantee that the questionnaire the questionnaire, the required number of survey question-
achieves the aims of the study and to ensure obtaining naires had been reproduced and were given to the respon-
objective results as far as validity is concerned, the ques- dents through the senior managers of the chosen plants. The
tionnaire was subjected to test by using a special checklist, data were then collected from each of the respective plants.
this is for verifying whether the questionnaire covered all It is worth mentioning at this point that those in charge of
aspects considered necessary, such as organizational, edu- the administration in the three plants made the process of
cational, technical and environmental aspects. data collection possible, easier and efficient. The number
One of the most important criteria for designing a ques- of the respondents (which represent the sample of the
tionnaire is that the questions are short, relevant and easy to study) was 269. The method used was proportional sam-
understand. Meanwhile, it is important to ensure that pling method under stratified sampling technique which
respondents interpret the questionnaire questions correctly. can efficiently meet the requirements of the aims of the
Hence, the questionnaire contained a number of questions study. The total number of the collected questionnaires was
out of which the respondents have total freedom to choose 213, out of which 11 were neglected due to their inappro-
from a list of items. This is recommended in the post priateness. Thus, the final sample for data analysis was 202;
(mail) surveys. In cases where it is significant, an open- this indicates that the response rate has reached 75.09%.
ended choice is given to confirm that the questions are In addition to the survey questionnaire, the semi-
interpreted objectively and efficiently by the respondents structured interviews were also conducted for an efficient
so as to arrive to a precise interpretation of the given comprehension of how the set of IMEs in terms of improving
questions. This improves the reliability and validity of the product design influences the reduction of the production
instrument. To ensure a high degree of content and to waste in the mineral water industry. These interviews
build validity, the questionnaire was based on appropriate assisted the researcher to have more in-depth information
theory and literature and was previously tested by aca- about the implementation of the IMS, as well as the effect
demics and practitioners in the field of the IMS to ensure which the set of IMEs can have concerning improving prod-
that all terms used were relevant and clear. At the same uct design and reducing production waste in the factories
time, all data collection procedures have been written in under study. The main focus of the sample of the study was
detail to ensure that the process is replicated and that good on the middle management represented in Production, Main-
reliability is enabled. tenance, and HR of each selected mineral water plant. As far
The procedures of the questionnaire survey were as fol- as the respondents who were supposed to be part of the semi-
lows. The designed questionnaire was passed through the structured interviews, the purposive sampling technique was
procedures of drafting, pretesting, finalizing and produc- applied. Selecting the respondents for eliciting the replies
tion, which was followed by first mail, first reminder using through the interviews were based on the following criteria:
mail and the second reminder using the phone. Based on the
study, objective questions were formulated to cover all  functional level being the head of the department in
relevant aspects. The content of the question and formula the plant;
had been carefully chosen. The questionnaire (written in  staff members with efficient information and expe-
English) was then taken through a series of tests. The first rience concerning the process of applying the IMS;
test was conducted by the designers and then it was pre-  staff members having authorities and are decision
sented in a seminar as part of an annual meeting with the makers at the departmental level; and
industrial competitiveness centre at the Chamber of Com-  mainly and directly involved in implementing the
merce in the Sulaymaniyah city/Kurdistan region of Iraq. IMS.
Hama Kareem 7

Table 1. Respondents’ background (N ¼ 202).

Respondents’ background

Gender Age Fieldwork experience Education level

Items N % Items N % Items N % Items N %


Male 161 79.70 Under 25 years 59 29.21 <5 years 51 25.25 High school graduate 37 18.32
Female 41 20.30 25–34 years 74 36.63 5–10 years 70 34.65 Diploma degree 58 28.71
35–45 years 48 23.76 11–15 years 48 23.76 Bachelor’s degree 104 51.49
Over 45 years 21 10.40 >15 years 33 16.34 Advanced degree 3 1.48
Source: Organized by the researcher depending on the demographic details data of the questionnaire.

All the interviewees’ voices were recorded and then 34.65%, 25.25% less than 5 years, 23.76% between 11 and
written down for documenting the major ideas, views and 15 years, while the percentage of those who had more than
opinions. The written interviews were given to the respon- 15 years’ experience was 16.34%. Thus, the percentages
dents for credibility and to give more chances to either add clearly show that the majority had sufficient experience as
or delete something from what they had already said. Such far as tackling new systems, such as the IMS is concerned;
procedure would definitely validate the replies and hence this, in turn, implies that they are entirely capable of
would enhance the obtained results. achieving acceptable levels of the results when operating
with such systems, which represent in developing perfor-
mance, improving product quality and, most importantly,
Data analysis decreasing, as much as possible, manufacturing waste. As
The following are the findings that were obtained as a for the education level, the table shows that most of the
consequence of processing the collected data through the employees hold a bachelor’s degree (51.49%), diploma
survey questionnaire and the statistical techniques which degree (28.71%), and high school graduates (18.32%), in
were used to test the hypotheses along with the semi- addition to those who have a high educational degree with a
structured interviews. This is to get more knowledge and percentage of 1.48%. Such percentages clearly imply that
in-depth information about the influence that could be the majority of the employees have a good level of educa-
played by the set of IMEs towards improving product tion. This means that, in addition to being mostly young,
design and reducing production waste at the Kurdish they are capable of coping with modern technology and
mineral water plants. come up with good ideas and meaningful programmes that
make the implementation of IMS problem-free in their
plants.
General information of respondents involved in survey
questionnaire
This section is devoted to expose general information about
Profile of interview respondents
the respondents. The information comprised a number of This section is devoted to showing a brief illustration of
demographic characteristics such as gender, age, fieldwork respondents’ general information who were subject to
experience and education level. This is shown in Table 1. interviews. Semi-structured interviews were conducted
Table 1 shows that the percentage of males was 79.70% with the directors of the three main departments such as
and the females was 20.30%. Such percentages reflect a maintenance, production and HR. There were seven inter-
general and actual representation of male/female employ- view questions that were asked of the interviewees. These
ees in most industrial sectors in Kurdistan region of Iraq. questions focused on the importance of the implementation
As for Age, the above table shows that the percentage of the of the IMS in terms of improving the efficiency of the
respondents who were less than 25 years was 29.21%, the factory towards improving the design of products and their
percentage of those between 25 and 34 years was 36.63%, impact in reducing production waste along with the cap-
whereas the percentage of those between 35 and 45 years abilities enjoyed by employees in dealing with these intel-
was 23.76% and finally the percentage of those who were ligent systems and the difficulties they encounter during
more than 45 was 10.40%. Hence, the highest percentage implementation. The interviews were transcribed for anal-
were from the young generation who usually have suffi- ysis purposes and to identify major themes. Before analysis
cient capabilities and enjoy vitality and good response for was conducted, themes identified in the interviews were
modern and updated systems of technology and their coded using predetermined coding. This predetermined
implementation, such as the IMS. Fieldwork experience coding corresponded with the research questions of the
shows that most of the respondents had more than 5 years’ study. It is also worth mentioning that codes (A, B and
experience and less than 10 years and with a percentage C) were given to each of the three factories and their names
8 International Journal of Engineering Business Management

Table 2. Brief profile of interview respondents.

Code Designation Department Factory Profile


AR1 Director Maintenance A Director of the maintenance department since 2011. He is an Egyptian national. He holds a
Bachelor of Mechanical Engineering from the Cairo University of Egypt (1991). The
respondent has more than 15 years of experience in the field of maintenance and
operation of production equipment. He is currently a first supervisor on the
implementation of maintenance works and repair in factory A under study.
AR2 Director HR A Director of HR department, holds Iraqi nationality. He holds a Master of Business
Administration from the Baghdad University of Iraq (2007). The respondent has more
than 10 years of experience in the field of business management. He works as the
director of HR in the plant (A). Alongside his post, he is currently administratively
responsible for providing all the necessary requirements for proper working of the IMSs
in the plant.
AR3 Director Production A Director of the production department since 2010. He holds a Master of Mechanical
Engineering from the Baghdad University of Iraq (1997). The respondent has experience
exceeding 20 years in fieldwork, where he worked formerly as manager of production
northern region for the cement industry in Iraq as a whole. He is currently primarily
responsible for production lines in the factory (A) as a whole.
BR1 Director HR B Director of HR department since 2011. He holds a Bachelor of Business
Administration from the Baghdad University of Iraq (2000). The respondent has
more than 10 years of experience in the field of HR management. Alongside his
post, he is considered one of the supervisors on the employees’ train, including the
employees’ participants in implementing the intelligent manufacturing activities in
the factory (B).
BR2 Director Maintenance B Director of the maintenance department since 2011. He holds a Bachelor of Mechanical
Engineering from the Baghdad University of Iraq (1994). The respondent has more than
15 years of experience in his field. He is one of the supervisors on the maintenance of
the precision devices and equipment in the factory (B) as a whole.
BR3 Director Production B Director of the production department since 2010. He is an Egyptian national. He holds a
Bachelor of Mechanical Engineering from the Ain-Shams University of Egypt (1993). The
respondent has experience exceeding 15 years in his specialized field. He is currently the
first supervisor on the operation of production lines in the plant (B).
CR1 Director Maintenance C Director of the maintenance department since 2013. He is an Egyptian national. He holds a
Master of Mechanical Engineering from the Cairo University of Egypt (1996). The
respondent has experience exceeding 10 years in the field of maintenance of precision
devices and equipment. He is currently one of the supervisors on the proper operation
of IMSs’ activities in the plant (C) as a whole.
CR2 Director Production C Director of the production department since 2010. He holds a Bachelor of Mechanical
Engineering from the University of Technology in Iraq (2000). The respondent has more
than 10 years of experience in his work field. He is the first official responsible for
production lines in the factory (C) as a whole.
CR3 Director HR C Director of HR department since 2012. He holds a Master of Business Administration
from the Erbil University of Iraq (2005). The respondent has more than 10 years of
experience in the field of HR management. He participated in many international
conferences in the field of development of HR such as ‘Ways of developing the
organizational loyalty of employees’. Alongside his post, he is currently administratively
responsible for providing all the resources and services for employees in the plant (C).

Source: Organized by the researcher depending on interview respondents’ information.


HR: human resources; IMS: intelligent manufacturing system.

were not mentioned at the request of the HR department in Pearson correlation analysis for variables
these factories. Once coding was completed, interviews The main aim of using Pearson correlation was to establish
were analysed using content analysis approach. The con- a connection between the IMEs and product design aiming
tent analysis was used to triangulate the results of a quali- at reducing production waste. Pearson correlation checks
tative study with the results of quantitative analysis. The the significant connection between variables.42 The corre-
content analysis of the interviews has been done according lation findings were pointed out in Table 3.
to the questions that were asked from the interviewees. The Pearson correlation findings were found to be significant
brief profile of the interview respondents is provided for all study variables. The findings referred that the intel-
in Table 2. ligent devices, intelligent processes, intelligent employees
Hama Kareem 9

Table 3. Correlation matrix for variables of study. product manufacturing resources in line with rapidly
changing situations and requirements in the manufacture
ID IE IP IC II PD
of products in order to reduce production waste in the
Intelligent devices 1 industrial organizations.2,12,20 All these are mainly due to
Intelligent employees 0.571* 1 the fact that intelligent devices are capable of changing
Intelligent processes 0.582* 0.439* 1 their behavior in response to changes in situations and
Intelligent connectivity 0.553* 0.484* 0.552* 1
manufacturing requirements. Managing and changing the
Intelligent infrastructure 0.519* 0.464* 0.539* 0.537* 1
Product design 0.598* 0.571* 0.595* 0.544* 0.465* 1 behavior of the intelligent device is basically based on past
experience and learning capabilities possessed by those
Source: Organized by the researcher depending on the correlation matrix managing smart devices.5,18,21
data for variables of the study.
*Correlation is significant at the 0.01 level (two-tailed).
In addition, Chen33 said that the provision of cloud com-
puting technology which provides an Internet-based com-
puting service will make of the intelligent devices to collect
and intelligent connectivity have significant positive and the data and information in real time and well provide them
strong relationship with the product design (r ¼ 0.598, from all areas in the product life cycle. Thus, the data will
r ¼ 0.595, r ¼ 0.571, r ¼ 0.544), respectively. Intelligent then be processed through cloud computing, and accurate
infrastructure was found to have a moderately strong and decisions can be made continuously and autonomously
positive association with the product design (r ¼ 0.465). with little or no human intervention.
Intelligent devices were found to have a strong positive Moreover, the results of semi-structured interviews
association with the intelligent processes, intelligent revealed that most of the respondents stressed that intelli-
employees, intelligent connectivity and intelligent infra- gent devices have an effective impact on product design
structure (r ¼ 0.582, r ¼ 0.571, r ¼ 0.553, r ¼ 0.519), towards reducing production waste in their companies. For
respectively. Intelligent employees were found to have a example, AR2, BR1 and CR1 referred that
moderately strong and positive association with intelligent
connectivity, intelligent infrastructure and intelligent pro- the intelligent devices and equipment have an effective role in
cesses (r ¼ 0.484, r ¼ 0.464, r ¼ 0.439). Moreover, the improving product design and thus walk the manufacturing
intelligent processes were found to have a strong positive processes more safely and smoothly towards the production
association with the intelligent connectivity and intelligent of defect-free products, which in turn, lead to improving the
infrastructure (r ¼ 0.552, r ¼ 0.539), respectively. As well, efficiency of manufacturing resources and significantly
it found that intelligent connectivity had a strong positive reducing manufacturing waste. Respondent AR3 and CR2
association with intelligent infrastructure (r ¼ 0.537, noted that the intelligent devices not only improve the design
p < 0.01). Once association was established between vari- of the products in the factory but also assisted to reduce the
ables, regression analysis using multiple regression tech- errors that can occur in the production process of products,
nique was conducted and their findings integrated with the which in turn lead to reduce the percentage of defective prod-
results of the content analysis of the interviews, which were ucts significantly and raise the level of customer satisfaction
used to triangulate the results of a qualitative study (inter- on the products of the factory in terms of quality in particular.
views) with the results of the quantitative analysis (regres-
sion analysis). The results of the regression analysis are Thus, the results of the regression analysis along with
shown in the following section of the current study. the results of interviews for the IME model–product design
provide support for the first hypothesis; therefore, hypoth-
esis 1 was accepted.
Regression analysis for IMEs and product design The regression findings revealed that the intelligent
To check the impact of the IMEs on product design with the employees (b ¼ 0.379, p < 0.05) have an influence on
aim to reduce production waste, the multiple regression improving the product design towards reducing production
analysis was performed for the elements of intelligent man- waste in industrial organizations. It means that the intelli-
ufacturing and product design. The regression has been gent employees who have abundant production experience
performed to make sure which of the elements are most will have the ability to make product design processes and
influential on product design towards reducing production manufacture faster and more flexible to cope with the fluc-
waste in the three plants under study. Table 4 displays the tuations in product production requirements that can occur
findings of the multiple regression analysis. in the global markets, thus increasing the efficiency of
The regression results indicated that intelligent devices manufacturing resources and reducing production waste.12
(b ¼ 0.534, p < 0.05) have a strong influence on the product Moreover, intelligent employees are very important to
design towards reducing production waste in industrial the success and effectiveness of an organization. They are
organizations under study. It means that intelligent devices often ambitious and want to make an extra effort to achieve
would have an influence of 53.4% on improving the prod- the organization’s goals. They also have creative ideas that
uct design, which will, in turn, lead to effective use of make the organization’s processes, whether productive or
10 International Journal of Engineering Business Management

Table 4. Multiple simultaneous regression analysis for dimensions of IME–PD model.a

Model R R2 Adjusted R2 F Significant b t p


0.617 0.394 0.380 25.310 0.000
Intelligent devices 0.534 7.825 0.000
Intelligent employees 0.379 5.161 0.028
Intelligent processes 0.521 7.719 0.000
Intelligent connectivity 0.497 6.806 0.016
Intelligent infrastructure 0.182 4.301 0.039

Source: Organized by the researcher depending on the data of multiple regression analysis for dimensions of IME–PD model.
a
Predictors: (constant) intelligent devices, intelligent employees, intelligent processes, intelligent connectivity, and intelligent infrastructure; dependent
variable: product design.

service, more capable and efficient to face any changes Similarly, the regression findings pointed out that intel-
that may occur in the markets in which these organiza- ligent processes also have a significant role in product
tions operate. All these, in turn, will assist to improve the design. This means that intelligent processes would have
competitiveness of these organizations. Accordingly, the a significant influence (52.1%) on improving products
management of the organizations must motivate such design efficiency, minimizing manufacturing waste, the
employees and provide them with the necessary safety of the working environment and improving the quality
support.26 of the products in the industrial organizations.12 All these
Further, Chen33 referred that one of the key character- will, in turn, lead to radically enhanced efficiency of those
istics of human intelligence is the capability to learn. Thus, organizations, increased worker performance, reduction of
it should follow the strategy of ML, which refers to the operational risks,34 and then increasing their confidence in
capability to understand and learn the inside of a physical the face of volatile market requirements and thereby enhan-
system by the intelligent people for computing algorithms cing their economic value and competitiveness.
based on data. For manufacturing systems, the implemen- Grigori et al.44 mentioned that the intelligent manufac-
tation of an ML algorithm by intelligent employees makes turing processes for any organization in order to be smarter,
it feasible for a machine or other device to learn its baseline this organization needs to follow the technology that can
and working conditions automatically. It is also feasible to offer ML and predictive analytics tailored to the unique
create and upgrade a knowledge base throughout the man- processes. Thus, with a foundation of operational insights,
ufacturing process.43 real-time analytics and the ability to quickly generate
In addition, the results of the interviews revealed that reports to support intelligent manufacturing processes, this
most respondents pointed out that there is a remarkable role makes the organizations be more determined to own the
for intelligent employees in making the stages and pro- technology referred to above; this is in order to be more
cesses of PD and manufacture more efficient in terms of prosperous in their insights and analysis and make their
the use of available resources to suit the requirements of intelligent manufacturing smarter.
the volatile customers in the current markets. For example, Moreover, the findings of semi-structured interviews
AR2, BR1, CR2 and CR3 said that showed that all respondents were positive about the effec-
tive role of intelligent processes in improving product
‘the intelligent employee is the employee who has the confi- design, where the respondents AR3, BR2 and CR1 referred
dence of himself. A confident employee is also more willing to that
take risks or go for challenges that an uncertain counterpart
would shy away from. Great outcomes come from people who the intelligent processes not only help to improve product
have faith in their abilities and talents. Thus, such employees design and reducing the manufacturing waste but also help
will be more efficient in dealing with precision devices and to reduce downtime and speed up product production in gen-
equipment as well as production processes, and thus produce eral, as well as speed to adapt these processes to any changes
products with more economical designs in terms of price, more that can occur in specification and characteristics of products
efficient in terms of quality and less waste in terms of produc- to keep pace with changes in market requirements. In addition,
tion. This is what most business organizations are looking for intelligent processes assist in making the working environment
in the face of intense competition today’. [sic] safer by removing repetitive, replicable and routine tasks in the
factory.
Based on the foregoing, it can be observed that the
results of regression analysis along with the results of inter- Thus, the results of the regression analysis along with
views for the model of the IMEs–product design indicate the results of interviews for the IME model–product design
support for the second hypothesis; therefore, hypothesis 2 indicate that their results support the third hypothesis;
has been accepted. therefore, hypothesis 3 was accepted.
Hama Kareem 11

In addition, the regression results showed that the intel- Table 5. Results of the study hypotheses.
ligent connectivity (b ¼ 0. 497, p < 0.05) has an effect on
Hypotheses Results
improving the product design towards reducing production
waste in industrial organizations under study. This means H1 Intelligent devices have an influential Hypothesis
that the intelligent connectivity (IoT) in the industrial orga- impact on product design towards supported
nizations can assist in allowing for the sharing of data and reducing production waste in
industrial companies.
information between these devices, systems and then the
H2 Intelligent employees influence the Hypothesis
business integration.12,31 This leads to the possibility of product design towards reducing supported
producing designs for higher quality and more economical production waste in industrial
products in terms of the manufacturing waste, which ulti- companies.
mately makes these products, in the end, have a higher H3 Intelligent processes would have a Hypothesis
value in the market.3 strong impact on product design supported
Furthermore, the results of interviews indicated that towards reducing production
waste in industrial companies.
intelligent connectivity has a positive effect on the produc-
H4 Intelligent connectivity would have a Hypothesis
tive process of the factory as a whole, where the respon- strong impact on product design supported
dents AR3 and CR2 mentioned that towards reducing production
waste in industrial companies.
the intelligent connectivity among the devices and equipment H5 Intelligent infrastructure would have Hypothesis
of the factory has a large role in the speed and accuracy of data a strong impact on product design supported
towards reducing production
transfer between these devices and equipment; this is what
waste in industrial companies.
helps to extract the designs for more useful products that are
less harmful in terms of production. Intelligent connectivity Source: Organized by the researcher depending on the results of data
allows for the rapid ability to make any change requiring prod- analysis.
uct specifications in line with the requirements of volatile
customers. All this, in turn, can significantly improve effi- whole to improve the use of smart devices and equipment to
ciency and business growth in the factory, thereby enhancing
design and manufacture products more efficiently and which
the factory’s economic and competitive position.
are less harmful in terms of production. This is accomplished
by the plant-floor OT and business-level IT, which are char-
Based on the foregoing, it can be observed that the acteristics of intelligent infrastructure.
results of regression analysis along with the results of inter- Moreover, the above result was confirmed by a number
views for the model of the IME–product design indicate of respondents such as AR1, AR2, BR3 and CR2 inter-
support for the fourth hypothesis; therefore, hypothesis 4 viewed in the current study. Based on the results of the
has been accepted. regression analysis and the results of the interviews,
However, the regression results displayed that the intel- hypothesis 5 was accepted.
ligent infrastructure (b ¼ 0. 182, p < 0.05) has an effect, but
is somewhat weak on the product design in industrial fac-
tories under study. This is mainly due to the fact that build- Summary of the findings
ing a complete intelligent infrastructure, especially in the This section provides the summary of findings. The present
third world countries, requires large capital. This is because study was conducted to investigate the impact of the set of
this element (intelligent infrastructure) is needed to build IMEs on the product design in reducing production waste.
advanced IT such as Satellite link, Ethernet connectivity, The data were collected using mixed methods represented
Fibre optic link and other technologies.36,37 Due to the in a questionnaire survey and semi-structured interviews.
inability of many business organizations, including the The study hypotheses were tested using parametric tests
organizations under study, to provide sufficient capital for such as Pearson correlation for establishing the association
the establishment of such technology, the result of the pres- between the major variables of the study. To investigate the
ent study indicates that the intelligent infrastructure has a influence of independent variables (IMEs) on product
slight impact on the product design. design with the aim to reduce production waste, the multi-
Nevertheless, intelligent infrastructure is essential to ple regression analysis was performed. Table 5 displays the
improve the efficiency of product design and manufacture results of the study hypotheses.
and thus maintain the high quality in many industrial organi-
zations.39,40 This means that smart infrastructure, whether in
The practical implications of the current
organizations under study or other business organizations that
seek to improve the design of the product towards reducing study
the manufacturing waste, should provide sufficient capital for The findings of the current study showed that implement-
its establishment (smart infrastructure) in a manner that helps ing IMS successfully by the industrial organizations toward
to create favourable circumstances in the organization as a improve the production lines effectiveness, the safety at the
12 International Journal of Engineering Business Management

work environment and attain the desired competitive advan- customer requirements in the market, business organiza-
tage in terms of the high ability to meet the needs of the tions are working closely to modernize the industrial base
market volatile depends on providing and implementing by using the common intelligence of people, processes and
properly for the set of IMEs which were addressed in the machines in one system called IMS. This is done with the
current study. Thus, the practical implications of the current aim of influencing the macroeconomics of manufacturing
study which would help the three factories’ management by improving product design towards improving manufac-
under study to improve the implementation of the IMS and turing resources, improving business value, increasing
getting the desired results are represented in the following: safety, reducing waste while meeting customer require-
ments for delivery and quality, and thereby improving the
1. Diagnose the IMEs that are most influential on market share of the organization and keeping it in the fore-
product design towards reducing production waste front of competition.
in the three plants under study. Thus, the results of the study showed that there are
2. Diagnose the obstacles that prevent the improving several elements of intelligent manufacturing that have an
of implementing the elements of intelligent manu- important effect on improving product design towards
facturing properly (such as intelligent infrastruc- improving manufacturing resources and reducing manufac-
ture) in the factories under study. This would turing waste. These results revealed that each intelligent
assist the factories’ management to take the neces- device and intelligent process of IMEs had had a strong
sary measures to address these obstacles and impact on improving product design, leading to the opti-
thereby getting the desired results of implementing mum use of manufacturing resources and reducing manu-
the IMS as much as possible. facturing waste in the industrial organizations. All these are
3. The results of the study were revealed that the fac- mainly due to the fact that intelligent devices are capable of
tories managements need to take more attention changing their behaviour towards making any changes in
with the intelligent devices in terms of providing product design in response to changes in situations and
these devices and using them effectively. This market requirements. Intelligent processes also have the
mainly due to the high ability of these devices on ability to reduce the downtime of factory devices and
improving the design of the products and reducing equipment in general, thereby accelerating product produc-
the errors that can occur in the production process, tion. In addition, the speed of adaptation of these processes
which in turn, can lead to reduce the percentage of in response to any changes that can occur in the specifica-
defective products significantly and raise the level tions and characteristics of products enables companies to
of customer satisfaction on the factory products in keep pace with changes in market requirements.
terms of quality in particular. The findings of the study revealed that both intelligent
4. The study findings revealed that IEs have also an connectivity and intelligent employees have played a sig-
influence on improving the product design towards nificant role in improving product design and improving
reducing the production waste in industrial organi- the efficiency of manufacturing resources to reduce man-
zations. Therefore, the factories’ management ufacturing waste. This is because intelligent connectivity
should give those employees the necessary empow- (IoT) in the industrial organizations can assist in allowing
erment and autonomy to implement their tasks well. for the sharing of data and information between these
5. The study results revealed the need to pay attention devices, systems and then the business integration, and
by the factories’ management with smart processes thereby the ability to produce designs for more quality
and provide all that is necessary to make them and more economical products in terms of the manufac-
more efficient in improving products design, mini- turing waste, which ultimately makes these products have
mizing manufacturing waste, safety of working higher value in the market. Intelligent employees also
environment and improving the quality of the have the confidence in themselves and thus they are more
products in plants. efficient in dealing with precision devices and equipment
6. The factories managements should give attention as well as production processes, and thus produce prod-
with the intelligent connectivity, this because of its ucts with more economical designs in terms of price, more
big role in the speed and accuracy of data transfer efficient in terms of quality and less waste in terms of
between the factory devices and equipment, which production. This is what most business organizations are
in turn, will help to extract the designs for the more looking for in the face of intense competition today. How-
useful products and the less harmful in terms of ever, the study results displayed that the intelligent infra-
production. structure had a somewhat weak product design towards
reducing manufacturing waste. This is mainly due to the
fact that providing intelligent infrastructure for all busi-
Conclusion and future research directions ness organizations, including the organizations under
In light of the globalization of the world economy and the study, requires large capital. This is because this element
growth of competition, as well as rapidly changing (intelligent infrastructure) requires advanced IT such as
Hama Kareem 13

Satellite link, Ethernet connectivity, Fibre optic link and the current study conducted it in terms of the state of IMS
other technologies, which require considerable financial implementing.
capacity.
Although this study yielded interesting results, the Declaration of Conflicting Interests
study is not without limitations. The foremost being the The author(s) declared no potential conflicts of interest with
sample size. Only three organizations were selected and respect to the research, authorship and/or publication of this
respondents to the survey belonged to these three article.
selected organizations. Increasing sample size and the
number of organizations may affect the results of the Funding
study. Further, doing a comparative study of organiza-
The author(s) received no financial support for the research,
tions that have implemented and organizations that are authorship and/or publication of this article.
in the process of implementing IMS would definitely
reveal results that could provide more insights into the
ORCID iD
successful implementation of this system. In addition,
the researcher faced many difficulties (limitations) dur- Jamal Ahmed Hama Kareem https://orcid.org/0000-0002-
9971-5596
ing the current study. These difficulties are as follows:
(1) The difficulty of determining the date for interviews
with department managers (especially production depart- References
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