Search results for: Lean Tool
Commenced in January 2007
Frequency: Monthly
Edition: International
Paper Count: 5000

Search results for: Lean Tool

4910 Lean Thinking and E-Commerce as New Opportunities to Improve Partnership in Supply Chain of Construction Industries

Authors: Kaustav Kundu, Alberto Portioli Staudacher

Abstract:

Construction industry plays a vital role in the economy of the world. But due to high uncertainty and variability in the industry, its performance is not as efficient in terms of quality, lead times, productivity and costs as of other industries. Moreover, there are continuous conflicts among the different actors in the construction supply chains in terms of profit sharing. Previous studies suggested partnership as an important approach to promote cooperation among the different actors in the construction supply chains and thereby it improves the overall performance. Construction practitioners tried to focus on partnership which can enhance the performance of construction supply chains but they are not fully aware of different approaches and techniques for improving partnership. In this research, a systematic review on partnership in relation to construction supply chains is carried out to understand different elements influencing the partnership. The research development of this domain is analyzed by reviewing selected articles published from 1996 to 2015. Based on the papers, three major elements influencing partnership in construction supply chains are identified: “Lean approach”, “Relationship building” and “E-commerce applications”. This study analyses the contributions in the areas within each element and provides suggestions for future developments of partnership in construction supply chains.

Keywords: partnership, construction, lean, SCM, supply chain management

Procedia PDF Downloads 396
4909 Influence of Machine Resistance Training on Selected Strength Variables among Two Categories of Body Composition

Authors: Hassan Almoslim

Abstract:

Background: The machine resistance training is an exercise that uses the equipment as loads to strengthen and condition the musculoskeletal system and improving muscle tone. The machine resistance training is easy to use, allow the individual to train with heavier weights without assistance, useful for beginners and elderly populations and specific muscle groups. Purpose: The purpose of this study was to examine the impact of nine weeks of machine resistance training on maximum strength among lean and normal weight male college students. Method: Thirty-six male college students aged between 19 and 21 years from King Fahd University of petroleum & minerals participated in the study. The subjects were divided into two an equal groups called Lean Group (LG, n = 18) and Normal Weight Group (NWG, n = 18). The subjects whose body mass index (BMI) is less than 18.5 kg / m2 is considered lean and who is between 18.5 to 24.9 kg / m2 is normal weight. Both groups performed machine resistance training nine weeks, twice per week for 40 min per training session. The strength measurements, chest press, leg press and abdomen exercises were performed before and after the training period. 1RM test was used to determine the maximum strength of all subjects. The training program consisted of several resistance machines such as leg press, abdomen, chest press, pulldown, seated row, calf raises, leg extension, leg curls and back extension. The data were analyzed using independent t-test (to compare mean differences) and paired t-test. The level of significance was set at 0.05. Results: No change was (P ˃ 0.05) observed in all body composition variables between groups after training. In chest press, the NWG recorded a significantly greater mean different value than the LG (19.33 ± 7.78 vs. 13.88 ± 5.77 kg, respectively, P ˂ 0.023). In leg press and abdomen exercises, both groups revealed similar mean different values (P ˃ 0.05). When the post-test was compared with the pre-test, the NWG showed significant increases in the chest press by 47% (from 41.16 ± 12.41 to 60.49 ± 11.58 kg, P ˂ 001), abdomen by 34% (from 45.46 ± 6.97 to 61.06 ± 6.45 kg, P ˂ 0.001) and leg press by 23.6% (from 85.27 ± 15.94 to 105.48 ± 21.59 kg, P ˂ 0.001). The LG also illustrated significant increases by 42.6% in the chest press (from 32.58 ± 7.36 to 46.47 ± 8.93 kg, P ˂ 0.001), the abdomen by 28.5% (from 38.50 ± 7.84 to 49.50 ± 7.88 kg, P ˂ 0.001) and the leg press by 30.8% (from 70.2 ± 20.57 to 92.01 ± 22.83 kg, P ˂ 0.001). Conclusion: It was concluded that the lean and the normal weight male college students can benefit from the machine resistance-training program remarkably.

Keywords: body composition, lean, machine resistance training, normal weight

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4908 The Applications of Toyota Production System to Reduce Wastes in Agricultural Products Packing Process: A Study of Onion Packing Plant

Authors: P. Larpsomboonchai

Abstract:

Agro-industry is one of major industries that has strong impacts on national economic incomes, growth, stability, and sustainable development. Moreover, this industry also has strong influences on social, cultural and political issues. Furthermore, this industry, as producing primary and secondary products, is facing challenges from such diverse factors such as demand inconsistency, intense international competition, technological advancements and new competitors. In order to maintain and to improve industry’s competitiveness in both domestics and international markets, science and technology are key factors. Besides hard sciences and technologies, modern industrial engineering concepts such as Just in Time (JIT) Total Quality Management (TQM), Quick Response (QR), Supply Chain Management (SCM) and Lean can be very effective to supportant to increase efficiency and effectiveness of these agricultural products on world stage. Onion is one of Thailand’s major export products which brings back national incomes. But, it also facing challenges in many ways. This paper focused its interests in onion packing process and its related activities such as storage and shipment from one of major packing plant and storage in Mae Wang District, Chiang Mai, Thailand, by applying Toyota Production System (TPS) or Lean concepts, to improve process capability throughout the entire packing and distribution process which will be profitable for the whole onion supply chain. And it will be beneficial to other related agricultural products in Thailand and other ASEAN countries.

Keywords: packing process, Toyota Production System (TPS), lean concepts, waste reduction, lean in agro-industries activities

Procedia PDF Downloads 230
4907 Various Models of Quality Management Systems

Authors: Mehrnoosh Askarizadeh

Abstract:

People, process and IT are the most important assets of any organization. Optimal utilization of these resources has been the question of research in business for many decades. The business world have responded by inventing various methodologies that can be used for addressing problems of quality improvement, efficiency of processes, continuous improvement, reduction of waste, automation, strategy alignments etc. Some of these methodologies can be commonly called as Business Process Quality Management methodologies (BPQM). In essence, the first references to the process management can be traced back to Frederick Taylor and scientific management. Time and motion study was addressed to improvement of manufacturing process efficiency. The ideas of scientific management were in use for quite a long period until more advanced quality management techniques were developed in Japan and USA. One of the first prominent methods had been Total Quality Management (TQM) which evolved during 1980’s. About the same time, Six Sigma (SS) originated at Motorola as a separate method. SS spread and evolved; and later joined with ideas of Lean manufacturing to form Lean Six Sigma. In 1990’s due to emerging IT technologies, beginning of globalization, and strengthening of competition, companies recognized the need for better process and quality management. Business Process Management (BPM) emerged as a novel methodology that has taken all this into account and helped to align IT technologies with business processes and quality management. In this article we will study various aspects of above mentioned methods and identified their relations.

Keywords: e-process, quality, TQM, BPM, lean, six sigma, CPI, information technology, management

Procedia PDF Downloads 394
4906 Sexually Dimorphic Effects of Chronic Exercise and Myocytic Androgen Receptor Overexpression on Body Composition in Sprague dawley Rats

Authors: Sabrina Barsky, Ashley Monks

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In humans, exercise improves symptoms of various pathological states, although exercise adaptations seem to differ in response to sex. Skeletal muscle anabolism is thought to be regulated by androgen receptor (AR) through poorly specified mechanisms. Interactions of AR and exercise on muscle phenotype remain inconclusive in males, and undetermined in females. We hypothesized that sex differences in exercise adaptations are regulated by the androgenic system and the type of exercise performed. Here we examined interactions between a muscle-specific AR overexpression transgene (HSA-AR) and forced aerobic exercise paradigm on muscle and adipose exercise adaptation in male and female rats. We used dual-energy X-ray absorptiometry (DXA) to examine body composition adaptations post 9-week exercise protocol. We replicated the effects of HSA-AR on body composition, with males only having increased % lean mass and reduced % fat mass (P<0.05). Aerobic exercise improved lean body phenotype significantly, with lesser indices of total and % fat mass (P<0.01) in both sexes. Sex-specific effects of exercise included decreased total body mass (P<0.01) in males and increased lean mass % (P<0.001) in females. Surprisingly, neither AR manipulation nor exercise affected bone parameters in either sex. This varied response in total mass and lean mass according to exercise presents a sexually dimorphic response to exercise. Neither sex showed an interaction between HSA-AR and forced aerobic exercise on body composition. Future work is proposed to examine the effects of exercise type (aerobic versus resistance) and the role of gonadal androgens in sexually dimorphic exercise-mediated mitochondrial adaptations. This work implicates the development of sex-specific exercise therapies.

Keywords: androgen receptor, forced exercise, muscle physiology, sexual dimorphism

Procedia PDF Downloads 83
4905 Developing a Knowledge-Based Lean Six Sigma Model to Improve Healthcare Leadership Performance

Authors: Yousuf N. Al Khamisi, Eduardo M. Hernandez, Khurshid M. Khan

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Purpose: This paper presents a model of a Knowledge-Based (KB) using Lean Six Sigma (L6σ) principles to enhance the performance of healthcare leadership. Design/methodology/approach: Using L6σ principles to enhance healthcare leaders’ performance needs a pre-assessment of the healthcare organisation’s capabilities. The model will be developed using a rule-based approach of KB system. Thus, KB system embeds Gauging Absence of Pre-requisite (GAP) for benchmarking and Analytical Hierarchy Process (AHP) for prioritization. A comprehensive literature review will be covered for the main contents of the model with a typical output of GAP analysis and AHP. Findings: The proposed KB system benchmarks the current position of healthcare leadership with the ideal benchmark one (resulting from extensive evaluation by the KB/GAP/AHP system of international leadership concepts in healthcare environments). Research limitations/implications: Future work includes validating the implementation model in healthcare environments around the world. Originality/value: This paper presents a novel application of a hybrid KB combines of GAP and AHP methodology. It implements L6σ principles to enhance healthcare performance. This approach assists healthcare leaders’ decision making to reach performance improvement against a best practice benchmark.

Keywords: Lean Six Sigma (L6σ), Knowledge-Based System (KBS), healthcare leadership, Gauge Absence Prerequisites (GAP), Analytical Hierarchy Process (AHP)

Procedia PDF Downloads 129
4904 Analysis of Supply Chain Risk Management Strategies: Case Study of Supply Chain Disruptions

Authors: Marcelo Dias Carvalho, Leticia Ishikawa

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Supply Chain Risk Management refers to a set of strategies used by companies to avoid supply chain disruption caused by damage at production facilities, natural disasters, capacity issues, inventory problems, incorrect forecasts, and delays. Many companies use the techniques of the Toyota Production System, which in a way goes against a better management of supply chain risks. This paper studies key events in some multinationals to analyze the trade-off between the best supply chain risk management techniques and management policies designed to create lean enterprises. The result of a good balance of these actions is the reduction of losses, increased customer trust in the company and better preparedness to face the general risks of a supply chain.

Keywords: just in time, lean manufacturing, supply chain disruptions, supply chain management

Procedia PDF Downloads 302
4903 Study of Tool Shape during Electrical Discharge Machining of AISI 52100 Steel

Authors: Arminder Singh Walia, Vineet Srivastava, Vivek Jain

Abstract:

In Electrical Discharge Machining (EDM) operations, the workpiece confers to the shape of the tool. Further, the cost of the tool contributes the maximum effect on total operation cost. Therefore, the shape and profile of the tool become highly significant. Thus, in this work, an attempt has been made to study the effect of process parameters on the shape of the tool. Copper has been used as the tool material for the machining of AISI 52100 die steel. The shape of the tool has been evaluated by determining the difference in out of roundness of tool before and after machining. Statistical model has been developed and significant process parameters have been identified which affect the shape of the tool. Optimum process parameters have been identified which minimizes the shape distortion.

Keywords: discharge current, flushing pressure, pulse-on time, pulse-off time, out of roundness, electrical discharge machining

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4902 Production of Pig Iron by Smelting of Blended Pre-Reduced Titaniferous Magnetite Ore and Hematite Ore Using Lean Grade Coal

Authors: Bitan Kumar Sarkar, Akashdeep Agarwal, Rajib Dey, Gopes Chandra Das

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The rapid depletion of high-grade iron ore (Fe2O3) has gained attention on the use of other sources of iron ore. Titaniferous magnetite ore (TMO) is a special type of magnetite ore having high titania content (23.23% TiO2 present in this case). Due to high TiO2 content and high density, TMO cannot be treated by the conventional smelting reduction. In this present work, the TMO has been collected from high-grade metamorphic terrain of the Precambrian Chotanagpur gneissic complex situated in the eastern part of India (Shaltora area, Bankura district, West Bengal) and the hematite ore has been collected from Visakhapatnam Steel Plant (VSP), Visakhapatnam. At VSP, iron ore is received from Bailadila mines, Chattisgarh of M/s. National Mineral Development Corporation. The preliminary characterization of TMO and hematite ore (HMO) has been investigated by WDXRF, XRD and FESEM analyses. Similarly, good quality of coal (mainly coking coal) is also getting depleted fast. The basic purpose of this work is to find how lean grade coal can be utilised along with TMO for smelting to produce pig iron. Lean grade coal has been characterised by using TG/DTA, proximate and ultimate analyses. The boiler grade coal has been found to contain 28.08% of fixed carbon and 28.31% of volatile matter. TMO fines (below 75 μm) and HMO fines (below 75 μm) have been separately agglomerated with lean grade coal fines (below 75 μm) in the form of briquettes using binders like bentonite and molasses. These green briquettes are dried first in oven at 423 K for 30 min and then reduced isothermally in tube furnace over the temperature range of 1323 K, 1373 K and 1423 K for 30 min & 60 min. After reduction, the reduced briquettes are characterized by XRD and FESEM analyses. The best reduced TMO and HMO samples are taken and blended in three different weight percentage ratios of 1:4, 1:8 and 1:12 of TMO:HMO. The chemical analysis of three blended samples is carried out and degree of metallisation of iron is found to contain 89.38%, 92.12% and 93.12%, respectively. These three blended samples are briquetted using binder like bentonite and lime. Thereafter these blended briquettes are separately smelted in raising hearth furnace at 1773 K for 30 min. The pig iron formed is characterized using XRD, microscopic analysis. It can be concluded that 90% yield of pig iron can be achieved when the blend ratio of TMO:HMO is 1:4.5. This means for 90% yield, the maximum TMO that could be used in the blend is about 18%.

Keywords: briquetting reduction, lean grade coal, smelting reduction, TMO

Procedia PDF Downloads 280
4901 Comparative Assessment of MRR, TWR, and Surface Integrity in Rotary and Stationary Tool EDM for Machining AISI D3 Tool Steel

Authors: Anand Prakash Dwivedi, Sounak Kumar Choudhury

Abstract:

Electric Discharge Machining (EDM) is a well-established and one of the most primitive unconventional manufacturing processes, that is used world-wide for the machining of geometrically complex or hard and electrically conductive materials which are extremely difficult to cut by any other conventional machining process. One of the major flaws, over all its advantages, is its very slow Material Removal Rate (MRR). In order to eradicate this slow machining rate, various researchers have proposed various methods like; providing rotational motion to the tool or work-piece or to both, mixing of conducting additives (such as SiC, Cr, Al, graphite etc) powders in the dielectric, providing vibrations to the tool or work-piece or to both etc. Present work is a comparative study of Rotational and Stationary Tool EDM, which deals with providing rotational motion to the copper tool for the machining of AISI D3 Tool Steel and the results have been compared with stationary tool EDM. It has been found that the tool rotation substantially increases the MRR up to 28%. The average surface finish increases around 9-10% by using the rotational tool EDM. The average tool wear increment is observed to be around 19% due to the tool rotation. Apart from this, the present work also focusses on the recast layer analysis, which are being re-deposited on the work-piece surface during the operation. The recast layer thickness is less in case of Rotational EDM and more for Stationary Tool EDM. Moreover, the cracking on the re-casted surface is also more for stationary tool EDM as compared with the rotational EDM.

Keywords: EDM, MRR, Ra, TWR

Procedia PDF Downloads 283
4900 Flame Volume Prediction and Validation for Lean Blowout of Gas Turbine Combustor

Authors: Ejaz Ahmed, Huang Yong

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The operation of aero engines has a critical importance in the vicinity of lean blowout (LBO) limits. Lefebvre’s model of LBO based on empirical correlation has been extended to flame volume concept by the authors. The flame volume takes into account the effects of geometric configuration, the complex spatial interaction of mixing, turbulence, heat transfer and combustion processes inside the gas turbine combustion chamber. For these reasons, flame volume based LBO predictions are more accurate. Although LBO prediction accuracy has improved, it poses a challenge associated with Vf estimation in real gas turbine combustors. This work extends the approach of flame volume prediction previously based on fuel iterative approximation with cold flow simulations to reactive flow simulations. Flame volume for 11 combustor configurations has been simulated and validated against experimental data. To make prediction methodology robust as required in the preliminary design stage, reactive flow simulations were carried out with the combination of probability density function (PDF) and discrete phase model (DPM) in FLUENT 15.0. The criterion for flame identification was defined. Two important parameters i.e. critical injection diameter (Dp,crit) and critical temperature (Tcrit) were identified, and their influence on reactive flow simulation was studied for Vf estimation. Obtained results exhibit ±15% error in Vf estimation with experimental data.

Keywords: CFD, combustion, gas turbine combustor, lean blowout

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4899 Using Single Decision Tree to Assess the Impact of Cutting Conditions on Vibration

Authors: S. Ghorbani, N. I. Polushin

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Vibration during machining process is crucial since it affects cutting tool, machine, and workpiece leading to a tool wear, tool breakage, and an unacceptable surface roughness. This paper applies a nonparametric statistical method, single decision tree (SDT), to identify factors affecting on vibration in machining process. Workpiece material (AISI 1045 Steel, AA2024 Aluminum alloy, A48-class30 Gray Cast Iron), cutting tool (conventional, cutting tool with holes in toolholder, cutting tool filled up with epoxy-granite), tool overhang (41-65 mm), spindle speed (630-1000 rpm), feed rate (0.05-0.075 mm/rev) and depth of cut (0.05-0.15 mm) were used as input variables, while vibration was the output parameter. It is concluded that workpiece material is the most important parameters for natural frequency followed by cutting tool and overhang.

Keywords: cutting condition, vibration, natural frequency, decision tree, CART algorithm

Procedia PDF Downloads 294
4898 Analysis of Rectangular Concrete-Filled Double Skin Tubular Short Columns with External Stainless Steel Tubes

Authors: Omnia F. Kharoob, Nashwa M. Yossef

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Concrete-filled double skin steel tubular (CFDST) columns could be utilized in structures such as bridges, high-rise buildings, viaducts, and electricity transmission towers due to its great structural performance. Alternatively, lean duplex stainless steel has recently gained significant interest for its high structural performance, similar corrosion resistance and lower cost compared to the austenitic steel grade. Hence, this paper presents the nonlinear finite element (FE) analysis, behaviour and design of rectangular outer lean duplex stainless steel (EN 1.4162) CFDST short columns under compression. All classes of the outer rectangular hollow section according to the depth-to-thickness (D/t) ratios were considered. The results showed that the axial ultimate strength of rectangular CFDST short columns increased linearly by increasing the concrete compressive strength, while it does not influence when changing the hollow ratios. Finally, the axial capacities were compared with the available design methods, and recommendations were conducted for the design strength of this type of column.

Keywords: concrete-filled double skin columns, compressive strength, finite element analysis, lean duplex stainless steel, ultimate axial strength, short columns

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4897 Pre-Eliminary Design Adjustable Workstation for Piston Assembly Line Considering Anthropometric for Indonesian People

Authors: T. Yuri M. Zagloel, Inaki M. Hakim, Syarafi A. M.

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Manufacturing process has been considered as one of the most important activity in business process. It correlates with productivity and quality of the product so industries could fulfill customer’s demand. With the increasing demand from customer, industries must improve their manufacturing ability such as shorten lead time and reduce wastes on their process. Lean manufacturing has been considered as one of the tools to waste elimination in manufacturing or service industri. Workforce development is one practice in lean manufacturing that can reduce waste generated from operator such as waste of unnecessary motion. Anthropometric approach is proposed to determine the recommended measurement in operator’s work area. The method will get some dimensions from Indonesia people that related to piston workstation. The result from this research can be obtained new design for the workarea considering ergonomic aspect.

Keywords: adjustable, anthropometric, ergonomic, waste

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4896 Life Prediction of Cutting Tool by the Workpiece Cutting Condition

Authors: Noemia Gomes de Mattos de Mesquita, José Eduardo Ferreira de Oliveira, Arimatea Quaresma Ferraz

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Stops to exchange cutting tool, to set up again the tool in a turning operation with CNC or to measure the workpiece dimensions have a direct influence on production. The premature removal of the cutting tool results in high cost of machining since the parcel relating to the cost of the cutting tool increases. On the other hand, the late exchange of cutting tool also increases the cost of production because getting parts out of the preset tolerances may require rework for its use when it does not cause bigger problems such as breaking of cutting tools or the loss of the part. Therefore, the right time to exchange the tool should be well defined when wanted to minimize production costs. When the flank wear is the limiting tool life, the time predetermination that a cutting tool must be used for the machining occurs within the limits of tolerance can be done without difficulty. This paper aims to show how the life of the cutting tool can be calculated taking into account the cutting parameters (cutting speed, feed and depth of cut), workpiece material, power of the machine, the dimensional tolerance of the part, the finishing surface, the geometry of the cutting tool and operating conditions of the machine tool, once known the parameters of Taylor algebraic structure. These parameters were raised for the ABNT 1038 steel machined with cutting tools of hard metal.

Keywords: machining, productions, cutting condition, design, manufacturing, measurement

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4895 Process Improvement and Redesign of the Immuno Histology (IHC) Lab at MSKCC: A Lean and Ergonomic Study

Authors: Samantha Meyerholz

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MSKCC offers patients cutting edge cancer care with the highest quality standards. However, many patients and industry members do not realize that the operations of the Immunology Histology Lab (IHC) are the backbone for carrying out this mission. The IHC lab manufactures blocks and slides containing critical tissue samples that will be read by a Pathologist to diagnose and dictate a patient’s treatment course. The lab processes 200 requests daily, leading to the generation of approximately 2,000 slides and 1,100 blocks each day. Lab material is transported through labeling, cutting, staining and sorting manufacturing stations, while being managed by multiple techs throughout the space. The quality of the stain as well as wait times associated with processing requests, is directly associated with patients receiving rapid treatments and having a wider range of care options. This project aims to improve slide request turnaround time for rush and non-rush cases, while increasing the quality of each request filled (no missing slides or poorly stained items). Rush cases are to be filled in less than 24 hours, while standard cases are allotted a 48 hour time period. Reducing turnaround times enable patients to communicate sooner with their clinical team regarding their diagnosis, ultimately leading faster treatments and potentially better outcomes. Additional project goals included streamlining tech and material workflow, while reducing waste and increasing efficiency. This project followed a DMAIC structure with emphasis on lean and ergonomic principles that could be integrated into an evolving lab culture. Load times and batching processes were analyzed using process mapping, FMEA analysis, waste analysis, engineering observation, 5S and spaghetti diagramming. Reduction of lab technician movement as well as their body position at each workstation was of top concern to pathology leadership. With new equipment being brought into the lab to carry out workflow improvements, screen and tool placement was discussed with the techs in focus groups, to reduce variation and increase comfort throughout the workspace. 5S analysis was completed in two phases in the IHC lab, helping to drive solutions that reduced rework and tech motion. The IHC lab plans to continue utilizing these techniques to further reduce the time gap between tissue analysis and cancer care.

Keywords: engineering, ergonomics, healthcare, lean

Procedia PDF Downloads 187
4894 Tool Damage and Adhesion Effects in Turning and Drilling of Hardened Steels

Authors: Chris M. Taylor, Ian Cook, Raul Alegre, Pedro Arrazola, Phil Spiers

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Noteworthy results have been obtained in the turning and drilling of hardened high-strength steels using tungsten carbide based cutting tools. In a finish turning process, it was seen that surface roughness and tool flank wear followed very different trends against cutting time. The suggested explanation for this behaviour is that the profile cut into the workpiece surface is determined by the tool’s cutting edge profile. It is shown that the profile appearing on the cut surface changes rapidly over time, so the profile of the tool cutting edge should also be changing rapidly. Workpiece material adhered onto the cutting tool, which is also known as a built-up edge, is a phenomenon which could explain the observations made. In terms of tool damage modes, workpiece material adhesion is believed to have contributed to tool wear in examples provided from finish turning, thread turning and drilling. Additionally, evidence of tool fracture and tool abrasion were recorded.

Keywords: turning, drilling, adhesion, wear, hard steels

Procedia PDF Downloads 299
4893 Application of Lean Six Sigma Tools to Minimize Time and Cost in Furniture Packaging

Authors: Suleiman Obeidat, Nabeel Mandahawi

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In this work, the packaging process for a move is improved. The customers of this move need their household stuff to be moved from their current house to the new one with minimum damage, in an organized manner, on time and with the minimum cost. Our goal was to improve the process between 10% and 20% time efficiency, 90% reduction in damaged parts and an acceptable improvement in the cost of the total move process. The expected ROI was 833%. Many improvement techniques have been used in terms of the way the boxes are prepared, their preparation cost, packing the goods, labeling them and moving them to a place for moving out. DMAIC technique is used in this work: SIPOC diagram, value stream map of “As Is” process, Root Cause Analysis, Maps of “Future State” and “Ideal State” and an Improvement Plan. A value of ROI=624% is obtained which is lower than the expected value of 833%. The work explains the techniques of improvement and the deficiencies in the old process.

Keywords: packaging, lean tools, six sigma, DMAIC methodology, SIPOC

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4892 Development of the Independent Building Permit System to Improve Productivity and Quality Service

Authors: Hartomo Soewardi, Bachtiar Jouhari

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Ineffectiveness and inefficiency of the building permit process in Indonesia still becomes a major problems for people to apply. Long time of service, the complicated administration process, and an expensive fees are a process that causing a dissatisfaction and discomfort for applicant. Therefore, it is critical to improve the quality of service of building permit system. Objectives of this research is to develop a better process of the system to improve productivity and quality service. Lean six sigma concept by using DMAIC procedures was used to analyze the existing system. Moreover, improvement of the system was conducted by using the Axiomatic Design method. Verification test was done to test the hypothesis of the proposed system design. Result of this research shows that proposed system can produce increasing 61.8% of efficiency on service time, and more effective and easier.

Keywords: axiomatic design, bbuilding permit system, DMAIC, Lean Six Sigma

Procedia PDF Downloads 297
4891 Effect of the Drawbar Force on the Dynamic Characteristics of a Spindle-Tool Holder System

Authors: Jui-Pui Hung, Yu-Sheng Lai, Tzuo-Liang Luo, Kung-Da Wu, Yun-Ji Zhan

Abstract:

This study presented the investigation of the influence of the tool holder interface stiffness on the dynamic characteristics of a spindle tool system. The interface stiffness was produced by drawbar force on the tool holder, which tends to affect the spindle dynamics. In order to assess the influence of interface stiffness on the vibration characteristic of spindle unit, we first created a three dimensional finite element model of a high speed spindle system integrated with tool holder. The key point for the creation of FEM model is the modeling of the rolling interface within the angular contact bearings and the tool holder interface. The former can be simulated by a introducing a series of spring elements between inner and outer rings. The contact stiffness was calculated according to Hertz contact theory and the preload applied on the bearings. The interface stiffness of the tool holder was identified through the experimental measurement and finite element modal analysis. Current results show that the dynamic stiffness was greatly influenced by the tool holder system. In addition, variations of modal damping, static stiffness and dynamic stiffness of the spindle tool system were greatly determined by the interface stiffness of the tool holder which was in turn dependent on the draw bar force applied on the tool holder. Overall, this study demonstrates that identification of the interface characteristics of spindle tool holder is of very importance for the refinement of the spindle tooling system to achieve the optimum machining performance.

Keywords: dynamic stiffness, spindle-tool holder, interface stiffness, drawbar force

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4890 Cutting Tool-Life Test of Ceramic Insert for Engine Sleeve

Authors: Adam Janásek, Marek Pagáč

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The article is looking for an experimental determination of tool life tests for ceramic cutting inserts. Mentioned experimental determination should provide an added information about cutting process. The mechanism of tool wear, cutting temperature in machining, quality machined surface and machining process itself is the information, which are important for whole manufacturing process. Mainly, the roughness plays very important role in determining how a real object will interact with its environment. The main aim was to determine the number of machined inserts, tool life and micro-geometry, as well. On the basis of previous tests the tool-wear was measured at constant cutting parameter which is more typical for high volume manufacturing processes.

Keywords: ceramic, insert, machining, surface roughness, tool-life, tool-wear

Procedia PDF Downloads 452
4889 Time Compression in Engineer-to-Order Industry: A Case Study of a Norwegian Shipbuilding Industry

Authors: Tarek Fatouh, Chehab Elbelehy, Alaa Abdelsalam, Eman Elakkad, Alaa Abdelshafie

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This paper aims to explore the possibility of time compression in Engineer to Order production networks. A case study research method is used in a Norwegian shipbuilding project by implementing a value stream mapping lean tool with total cycle time as a unit of analysis. The analysis resulted in demonstrating the time deviations for the planned tasks in one of the processes in the shipbuilding project. So, authors developed a future state map by removing time wastes from value stream process.

Keywords: engineer to order, total cycle time, value stream mapping, shipbuilding

Procedia PDF Downloads 116
4888 Qualitative Evaluation of the Morris Collection Conservation Project at the Sainsbury Centre of Visual Arts in the Context of Agile, Lean and Hybrid Project Management Approaches

Authors: Maria Ledinskaya

Abstract:

This paper examines the Morris Collection Conservation Project at the Sainsbury Centre for Visual Arts in the context of Agile, Lean, and Hybrid project management. It is part case study and part literature review. To date, relatively little has been written about non-traditional project management approaches in heritage conservation. This paper seeks to introduce Agile, Lean, and Hybrid project management concepts from business, software development, and manufacturing fields to museum conservation, by referencing their practical application on a recent museum-based conservation project. The Morris Collection Conservation Project was carried out in 2019-2021 in Norwich, UK, and concerned the remedial conservation of around 150 Abstract Constructivist artworks bequeathed to the Sainsbury Centre for Visual Arts by private collectors Michael and Joyce Morris. The first part introduces the chronological timeline and key elements of the project. It describes a medium-size conservation project of moderate complexity, which was planned and delivered in an environment with multiple known unknowns – unresearched collection, unknown condition and materials, unconfirmed budget. The project was also impacted by the unknown unknowns of the COVID-19 pandemic, such as indeterminate lockdowns, and the need to accommodate social distancing and remote communications. The author, a staff conservator at the Sainsbury Centre who acted as project manager on the Morris Collection Conservation Project, presents an incremental, iterative, and value-based approach to managing a conservation project in an uncertain environment. Subsequent sections examine the project from the point of view of Traditional, Agile, Lean, and Hybrid project management. The author argues that most academic writing on project management in conservation has focussed on a Traditional plan-driven approach – also known as Waterfall project management – which has significant drawbacks in today’s museum environment, due to its over-reliance on prediction-based planning and its low tolerance to change. In the last 20 years, alternative Agile, Lean and Hybrid approaches to project management have been widely adopted in software development, manufacturing, and other industries, although their recognition in the museum sector has been slow. Using examples from the Morris Collection Conservation Project, the author introduces key principles and tools of Agile, Lean, and Hybrid project management and presents a series of arguments on the effectiveness of these alternative methodologies in museum conservation, as well as the ethical and practical challenges to their implementation. These project management approaches are discussed in the context of consequentialist, relativist, and utilitarian developments in contemporary conservation ethics, particularly with respect to change management, bespoke ethics, shared decision-making, and value-based cost-benefit conservation strategy. The author concludes that the Morris Collection Conservation Project had multiple Agile and Lean features which were instrumental to the successful delivery of the project. These key features are identified as distributed decision making, a co-located cross-disciplinary team, servant leadership, focus on value-added work, flexible planning done in shorter sprint cycles, light documentation, and emphasis on reducing procedural, financial, and logistical waste. Overall, the author’s findings point largely in favour of a Hybrid model which combines traditional and alternative project processes and tools to suit the specific needs of the project.

Keywords: project management, conservation, waterfall, agile, lean, hybrid

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4887 Taguchi Robust Design for Optimal Setting of Process Wastes Parameters in an Automotive Parts Manufacturing Company

Authors: Charles Chikwendu Okpala, Christopher Chukwutoo Ihueze

Abstract:

As a technique that reduces variation in a product by lessening the sensitivity of the design to sources of variation, rather than by controlling their sources, Taguchi Robust Design entails the designing of ideal goods, by developing a product that has minimal variance in its characteristics and also meets the desired exact performance. This paper examined the concept of the manufacturing approach and its application to brake pad product of an automotive parts manufacturing company. Although the firm claimed that only defects, excess inventory, and over-production were the few wastes that grossly affect their productivity and profitability, a careful study and analysis of their manufacturing processes with the application of Single Minute Exchange of Dies (SMED) tool showed that the waste of waiting is the fourth waste that bedevils the firm. The selection of the Taguchi L9 orthogonal array which is based on the four parameters and the three levels of variation for each parameter revealed that with a range of 2.17, that waiting is the major waste that the company must reduce in order to continue to be viable. Also, to enhance the company’s throughput and profitability, the wastes of over-production, excess inventory, and defects with ranges of 2.01, 1.46, and 0.82, ranking second, third, and fourth respectively must also be reduced to the barest minimum. After proposing -33.84 as the highest optimum Signal-to-Noise ratio to be maintained for the waste of waiting, the paper advocated for the adoption of all the tools and techniques of Lean Production System (LPS), and Continuous Improvement (CI), and concluded by recommending SMED in order to drastically reduce set up time which leads to unnecessary waiting.

Keywords: lean production system, single minute exchange of dies, signal to noise ratio, Taguchi robust design, waste

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4886 Handling Patient's Supply during Inpatient Stay: Using Lean Six Sigma Techniques to Implement a Comprehensive Medication Handling Program

Authors: Erika Duggan

Abstract:

A Major Hospital had identified that there was no standard process for handling a patient’s medication that they brought with them to the hospital. It was also identified that each floor was handling the patient’s medication differently and storing it in multiple locations. Based on this disconnect many patients were leaving the hospital without their medication. The project team was tasked with creating a cohesive process to send a patient’s unneeded medication home on admission, storing any of the patient’s medication that could not be sent home, storing any of the patient’s medication for inpatient administration, and sending all of the patient’s medication home on discharge. The project team consisted of pharmacists, RNs, LPNs, members from nursing informatics and a project engineer and followed a DMAIC framework. Working together observations were performed to identify what was working and not working on the different floors which resulted in process maps. Using the multidisciplinary team, brainstorming, including affinity diagramming and other lean six sigma techniques, the best process for receiving, storing, and returning the medication was created. It was highlighted that being able to track the medication throughout the patient’s stay would be beneficial and would help make sure the medication left with the patient on discharge. Using an automated medications dispensing system would help store, and track patient’s medications. Also, the use of a specific order that would show up on the discharge instructions would assist the front line staff in retrieving the medication from a set location and sending it home with the patient. This new process will effectively streamline the admission and discharge process for patients who brought their medication with them as well as effectively tracking the medication during the patient’s stay. As well as increasing patient safety as it relates to medication administration.

Keywords: lean six sigma, medication dispensing, process improvement, process mapping

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4885 Simulation of Particle Damping in Boring Tool Using Combined Particles

Authors: S. Chockalingam, U. Natarajan, D. M. Santhoshsarang

Abstract:

Particle damping is a promising vibration attenuating technique in boring tool than other type of damping with minimal effect on the strength, rigidity and stiffness ratio of the machine tool structure. Due to the cantilever nature of boring tool holder in operations, it suffers chatter when the slenderness ratio of the tool gets increased. In this study, Copper-Stainless steel (SS) particles were packed inside the boring tool which acts as a damper. Damper suppresses chatter generated during machining and also improves the machining efficiency of the tool with better slenderness ratio. In the first approach of particle damping, combined Cu-SS particles were packed inside the vibrating tool, whereas Copper and Stainless steel particles were selected separately and packed inside another tool and their effectiveness was analysed in this simulation. This study reveals that the efficiency of finite element simulation of the boring tools when equipped with particles such as copper, stainless steel and a combination of both. In this study, the newly modified boring tool holder with particle damping was simulated using ANSYS12.0 with and without particles. The aim of this study is to enhance the structural rigidity through particle damping thus avoiding the occurrence of resonance in the boring tool during machining.

Keywords: boring bar, copper-stainless steel, chatter, particle damping

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4884 Designing a Tool for Software Maintenance

Authors: Amir Ngah, Masita Abdul Jalil, Zailani Abdullah

Abstract:

The aim of software maintenance is to maintain the software system in accordance with advancement in software and hardware technology. One of the early works on software maintenance is to extract information at higher level of abstraction. In this paper, we present the process of how to design an information extraction tool for software maintenance. The tool can extract the basic information from old program such as about variables, based classes, derived classes, objects of classes, and functions. The tool have two main part; the lexical analyzer module that can read the input file character by character, and the searching module which is user can get the basic information from existing program. We implemented this tool for a patterned sub-C++ language as an input file.

Keywords: extraction tool, software maintenance, reverse engineering, C++

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4883 Modular Data and Calculation Framework for a Technology-based Mapping of the Manufacturing Process According to the Value Stream Management Approach

Authors: Tim Wollert, Fabian Behrendt

Abstract:

Value Stream Management (VSM) is a widely used methodology in the context of Lean Management for improving end-to-end material and information flows from a supplier to a customer from a company’s perspective. Whereas the design principles, e.g. Pull, value-adding, customer-orientation and further ones are still valid against the background of an increasing digitalized and dynamic environment, the methodology itself for mapping a value stream is characterized as time- and resource-intensive due to the high degree of manual activities. The digitalization of processes in the context of Industry 4.0 enables new opportunities to reduce these manual efforts and make the VSM approach more agile. The paper at hand aims at providing a modular data and calculation framework, utilizing the available business data, provided by information and communication technologies for automizing the value stream mapping process with focus on the manufacturing process.

Keywords: lean management 4.0, value stream management (VSM) 4.0, dynamic value stream mapping, enterprise resource planning (ERP)

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4882 A Neural Network System for Predicting the Hardness of Titanium Aluminum Nitrite (TiAlN) Coatings

Authors: Omar M. Elmabrouk

Abstract:

The cutting tool, in the high-speed machining process, is consistently dealing with high localized stress at the tool tip, tip temperature exceeds 800°C and the chip slides along the rake face. These conditions are affecting the tool wear, the cutting tool performances, the quality of the produced parts and the tool life. Therefore, a thin film coating on the cutting tool should be considered to improve the tool surface properties while maintaining its bulks properties. One of the general coating processes in applying thin film for hard coating purpose is PVD magnetron sputtering. In this paper, the prediction of the effects of PVD magnetron sputtering coating process parameters, sputter power in the range of (4.81-7.19 kW), bias voltage in the range of (50.00-300.00 Volts) and substrate temperature in the range of (281.08-600.00 °C), were studied using artificial neural network (ANN). The results were compared with previously published results using RSM model. It was found that the ANN is more accurate in prediction of tool hardness, and hence, it will not only improve the tool life of the tool but also significantly enhances the efficiency of the machining processes.

Keywords: artificial neural network, hardness, prediction, titanium aluminium nitrate coating

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4881 Study on Dynamic Stiffness Matching and Optimization Design Method of a Machine Tool

Authors: Lu Xi, Li Pan, Wen Mengmeng

Abstract:

The stiffness of each component has different influences on the stiffness of the machine tool. Taking the five-axis gantry machining center as an example, we made the modal analysis of the machine tool, followed by raising and lowering the stiffness of the pillar, slide plate, beam, ram and saddle so as to study the stiffness matching among these components on the standard of whether the stiffness of the modified machine tool changes more than 50% relative to the stiffness of the original machine tool. The structural optimization of the machine tool can be realized by changing the stiffness of the components whose stiffness is mismatched. For example, the stiffness of the beam is mismatching. The natural frequencies of the first six orders of the beam increased by 7.70%, 0.38%, 6.82%, 7.96%, 18.72% and 23.13%, with the weight increased by 28Kg, leading to the natural frequencies of several orders which had a great influence on the dynamic performance of the whole machine increased by 1.44%, 0.43%, 0.065%, which verified the correctness of the optimization method based on stiffness matching proposed in this paper.

Keywords: machine tool, optimization, modal analysis, stiffness matching

Procedia PDF Downloads 50