Papers by Keyword: Cycle Time

Abstract: Objective of the paper is to present the latest applications of GISS technology, a little more than six years since the launch in the die casting industry. Industrial applicability and robustness of the solution have been the main targets of GISSCO development which is focussed on providing a technology appliable to mass production with short lead time and cost effectiveness. Based on the concepts of viscosity control and feeding compensation the GISS technology can lead to reduction of production costs (energy, lubrication, waste disposal, die life extension) as well as increase of the casting quality. Life Cycle Inventory and Carbon Footprint calculation of a case study are presented.

Abstract: In this paper we consider the Multi-Aisle Automated Storage and Retrieval Systems where only one Storage/Retrieval machine (crane) is used, which has the advantage of decreasing the system costs but at the same time has the disadvantage of reducing the system throughput. This important performance evaluation parameter is highly related to another equally important one i.e. the cycle time of the crane. Because of its repercussions on the whole system performances, we are interested here in the modeling of this average cycle time, knowing that it could bring positive and significant advantages in terms of efficiency and accuracy, and consequently throughput and productivity. For that, the system to be studied is considered as Discrete Events System. To model it, we use a dedicated graphical tool known under the name Timed Petri Nets in the purpose to explore the theory used to evaluate the performances of these systems.

Abstract: In order to reduce CO2 emissions, for the automotive industry, the most promising area of research is lightweight construction. Next to weight reduction, lightweight materials like fiber reinforced thermoplastic composites (FRTC) may also improve mechanical properties of vehicle body parts. FRTCs, so-called organic sheets, have the potential for large scale series production and they can be back moulded due to the thermoplastic matrix. On the other hand high production cycle times and a poor surface quality are limiting their potential. Therefore, ITA’s current research approaches these problems in two ways. Nanomodified materials and a new tool concept for heat pressing are going hand in hand and may lead to the technology’s breakthrough.To reduce the cycle times of the production of FRTCs innovative and modified matrix systems are investigated. The goal of the public founded project “VarioOrgano” is to analyze the potential of these modified yarns and the tool system during the FRTC production. Moreover, the capability of these composites in visible parts in automotive applications is investigated. Therefore, the whole process chain from compounding, to melt spinning, commingling and consolidation with a heat press is investigated.This paper shows the production steps along the process chain to produce these FRTCs with focus on hybrid yarn development and production.

Abstract: In recent times, lean manufacturing applications have become essential for manufacturers all over the globe. The manufacturers have gradually shifted from mass production to flexible manufacturing and customers are looking for customized and unique products. Productivity becomes a very important element with multiple product need. Passenger vehicle seat manufacturing industry is found to be poorly affected by manufacturing problems due to more cycle time, unbalanced workload and improper layout. The main aim of this paper is to study the existing system of a seat manufacturing industry and to improve productivity using lean methodology without much affecting current working systems. The critical non value added activities are identified and chances required for improvement has been recognized. The total lead time was reduced from 2.55 days to 2.438 days after implementation of applications of VSM. Using spaghetti diagram the current layout was optimized and the total cycle time was reduced by about 26.28% after implementing the proposed layout to meet the customer demand.

Abstract: Nowadays, Lean manufacturing application is reported for manufacturers in global level.Those reports have exposed that this application has enabled the companies to become competitivethrough the elimination of wastes while producing products and offering services. Various tools like5S, Poka Yoke, Kaizen, Kanban, JIT, etc have been used while implementing lean manufacturingmodel in various types of organization. Recently, both researchers and practitioners have found thatValue Stream Mapping (VSM) technique serves as a powerful vehicle in enabling organizations toimplement lean manufacturing model. Meanwhile, it is found that lean manufacturing model is yet tobe applied in the case of certain manufacturing products. One among those products is gear shaft. Inthis background the theoretical proposition of implementing lean manufacturing model in the case ofmanufacturing a gear shaft has been investigated in this article.

Abstract: In lean manufacturing environment Value Stream Mapping (VSM) & SMED are one of the renewed industrial engineering technique used worldwide. VSM is used for visualizing the system of manufacturing and many other relevant processes and helps in great extend to understand to system itself effectively. Single Minute Exchange of Dies (SMED) helps to reduce the setup time of process. A valve manufacturing company was being selected for Case study. First we draw the current state value stream map. From the current data analysis find out the problems and give some recommendations to improve the production lead time and provide a future state value stream map, we reduced the lead time through VSM, from 46.63 days to 43.03 day. Second we applied SMED techniques & reduced the setup time from 21 min to 16 min in bonnet machining operation of valve.

Abstract: This research objective is to improve the productivity of cookware assembly line by means of time and distance reductions. The motion study and line balancing techniques were applied to the entire assembly operations. A bottle neck was identified to where the operation with inadequate machine layout and workplace organization, including the unbalanced workloads. The new workplace layout and new working method for operators were designed and implemented as well as balancing the assembly line. Specifically, the conveyor speed and duration between the consecutive workpieces in the production line were adjusted to 0.10 m/s and 50 cm, respectively. The number of operators needed in the process can be reduced from 14 persons to 11 persons. The cycle time for assembling process is decreased from 12 to 5 second.

Abstract: Quality control is important aspect of manufacturing process. The quality of product in injection moulding is influenced by injection moulding process parameter. A study of the influence of process parameters on the injection moulding process is presented. Statistically based model approach were studied. In this the process parameter that affect the injection moulding process are like injection time, injection pressure, packing pressure, packing time, cooling time, coolant temperature mold temperature, melt temperature are studied and compared. This paper deals with design of experiment approach to fine out optimal parameter setting. The comparison shows effect of parameters on injection moulding process.Key words: Plastic injection moulding, Orthogonal array, Cycle time

Abstract: An assembly system consists of work stations where specific tasks are carried in such a way that last station gives the complete product. An assembly line balancing Problem (ALBP) involves optimally assigning tasks among workstations with respect to some performance objective. ALBP problems are of NP hard nature and in literature; many efforts are there to solve the problem efficiently through heuristics. This paper proposes a heuristic algorithm for solving type 2 ALBP for single objective optimization. The proposed algorithm assigns tasks to a fixed no of stations with objective of minimizing cycle time. In literature, type 2 ALBP is mostly solved through Type 1 problem. However, this paper proposes a direct approach to Type 2 ALBP. The effectiveness is tested through application on Gunther problem of 35 tasks with forty five precedence constraints. The task assignment for six stations is computed and it shows competitive performance. The number of fixed stations is varied and corresponding cycle times are computed. The algorithm is also tested on a real industrial problem of 24 tasks. The experimental testing indicates tendency of the proposed algorithm to give effective optimal results.

Abstract: Metal casting is a process of metallurgical forming by liquidize of material up to certain high temperature to achieve perfect chemical reaction and high level quality products. Auto pour means pouring the metal liquid into the mould not by manual operation but more than automatically done by a set of machine without any human intervention. This paper aims to describe the process of automation for brake drums where several parameters are compare with manual process. The standard time, cycle time, rejection rate, dimension, chemical composition and product quality have been analyzed. The results shows that the standard time reduce to 40%, rejection rate less 5%, tensile strength 3% higher because of better pouring process. The other parameters are the same for both manual or automatic pouring process. The conclusion of this research is that the auto pour provides better results in term of productivity and quality.