Papers by Keyword: Manufacturing Cost

Abstract: A simple theoretical model linking surface micro geometry, friction and manufacturing cost is presented. Combining a basic geometrical relationship of plastic deformation of workpiece surface asperities by a hard tool with an assumption of adhesive friction, the friction coefficient of a soft, rough surface sliding against a hard, smooth tool surface can be calculated, linking surface roughness with friction coefficient. The simple model can also link the cost related to manufacturing with a surface characterized by a given friction coefficient value. Results are presented from tests carried out to verify the simple model. Several test pieces were manufactured by turning, or grooving, an aluminum alloy and brass using different feeds, tool nose radii, and tool nose angles, achieving different surface profiles. The surfaces were characterized using a stylus profilometer and a digital microscope. The static friction coefficient was determined in terms of angle of repose using a rotary table. The experimentally determined values of the friction coefficient were compared with those predicted from feed, tool radius, and asperity angle. The tests have shown a good reproducibility, and a clear determination of the friction coefficient was possible. However, due to the low normal loads involved in this set up, the influence from the surface roughness was not clear. Further investigations are therefore proposed.

Abstract: The mechanical systems consist of assembled parts, between which diverse interactions take place. Tolerance analysis purpose is to study the effects of part geometric deviations on assembly functional requirements. In the current approaches from this field, the part geometrical deviations are toleranced without considering the evolution of the geometrical deviations during product exploitation. As consequence, between two parts identical as type but with different values of their geometrical features, inside the designed tolerance zones, any difference is made despite they might have significantly different life cycles or manufacturing costs. This paper presents a new conceptual approach concerning parts tolerance design, based on a new criterion, namely the dimensional quality, defined by two important features: life cycle and manufacturing cost. The main issue of this approach is the optimal relation between the manufacturing tolerance zones and the acceptable functional deviation domain. The new concept implementation is sampled in the case of an articulated arm.

Abstract: With the constraints on manufacturing capacity, the satisfaction of product performance and the cost of manufacture are contradictory, the problem between high-performance and low-cost must be solved at the period of design and manufacture for product. To solve this problem, the product loss model has been analyzed, the parameterized and non-parameterized model of anticipant losses has been researched, with concurrent design, in connection with the product with multiple correlated assembly functional dimensions, the relation function between quality loss and process dimension tolerance has been provided, the concurrent tolerance design mathematical model based on lowest-cost and quality loss has been established. The applied case shows that this method has important guiding significance for engineering application.

Abstract: Enterprise management mode is being changed by a single enterprise management mode into supply chain management. The development of economy calls for the needs of the application of cost management in the supply chain, which is one of the most important trends in the field of cost management. However, the weak basis for cost management of small and medium enterprises (SMEs) and the lack of funds and personnel various resources make most of the current cost management methods and technologies in supply chain cannot be applied into SMEs’ management. All of these give practitioners in SMEs and researchers in the field of cost research an important research topic-the unique management mode of cost management for SMEs in the supply chain environment.

Abstract: Single-row facility layout is widely used in manufacturing system. It has a very important effect on the performance of manufacturing system. The single-row facility layout, including linear, U-shape, and semi-circular layout are introduced firstly. Based on the lower selling price of customers’ demand, the components of manufacturing cost are analyzed secondly. Then the relationship between the manufacturing cost and objectives of single-row layout are described. Meanwhile, the mathematical and simulation models related to several parts of manufacturing cost of single-row layout are set up respectively. Finally, the simulation of these models for single-row layout is running in QUEST. After analyzing the simulation results, conclusions are obtained: (1) material handling cost of semi-circular layout is the lowest among the three types of single-row facility layout; (2) area utilization rate of U-shape layout is higher than others; (3) equipment and labor utilization of U-shape layout is the higher than others in the same moment. This research results will

Abstract: Tolerance allocation have significant influence on the manufacturing cost and quality loss cost. In order to obtain optimal tolerance, Lagrange multiplier method is used to minimize the summation of manufacturing cost and quality loss cost subject to constraints on product functional requirement. The reciprocal power cost-tolerance model with different functional constraints is considered, and closed-form optimal tolerances are obtained. Using the model proposed in this paper, the optimal tolerance can be obtained quickly and accurately. One example is used to illustrate the method proposed in this paper.

Abstract: Manufacturing cost is the major factor that affects the profit of any industry or any product. Manufacturing Cost involves material, labor, equipment & tooling, quality, maintenance etc. Sheet metal forming is one of the major manufacturing processes and used for most of the products. The Die is the tooling used in the sheet metal forming. The proper design of die is important in sheet metal forming processes. This article discusses how the Combination Die can reduce the manufacturing cost, particularly the labor cost and material handling cost. For this study, a product U Clamp is considered. The Product requires piercing, bending and parting off operations. The Combination Die is designed and fabricated for the product and tested. Data on operation time, material handling time, die fabrication cost are collected, analyzed and discussed.

Abstract: All companies strive towards lowering their manufacturing costs. Few companies do however succeed in continuously improving their production after the launch of a new production process. This article introduces a method for companies having an established technology to optimize their production in terms of part cost without disrupting the normal, day-to-day production. By incrementally chancing the process parameters such as for example cutting data as a function of the originally selected values, it is possible to optimize the production process. This is closely related to the lean production philosophy and long term sustainability which strives towards efficient use of resources and involvement of all employees in improving the production process. In the case study presented in this article it was found that by adding extra sulfur to the cutting fluid it was possible to decrease the part cost. By using the proposed method the company was able to decrease the part cost when manufacturing a specific part with approximately 5 %.

Abstract: This essay is the subject of national eleventh five support schemes: The analysis of key technology on emission reduction and comprehension utilization of solid waste from large iron ore mine (Number:2008BAB32B14).For the concrete with ultra-fine iron tailings the research on the new special cement has been successfully prepared by means of using a low dosage of crystal-core-element named CCE for short (which has an excellent capability to accelerate the hydration speed and develop the strength of the cement)and high percentage of blast furnace slag and other several industrial residue. Compared to the ordinary Portland cement grade 42.5, the new cement has several outstanding virtues such as lower use level of cement clinker, higher level usage of industrial residue and lower cost. According to the cement standard GB175-2007, strength of special cement sample NO.3 is same as the ordinary Portland cement grade 42.5 with the standard sand. When with ultra-fine iron tailings, the new special cement has higher strength after 28days than the OPC. That shows the special cement has an excellent long-term performance of concretion. The manufacturing cost of the new special cement sample NO.3 is decreased by 20.76% than the ordinary Portland cement grade 42.5, that will bring a great environment and economic effect.

Abstract: In a gear box design, it is quite difficult for a designer to quickly find an optimum solution, while the space restriction is given and the weight is to be minimized. Also the manufacturing cost, total power loss and other relevant factors have to be considered. Solving such a problem is very time-consuming, if different variants of reducers have to be evaluated carefully. A new optimization tool, based on KISSsys software, permits to layout automatically a complete gearbox using functions for the layout of gear stages, shaft dimensions and bearings, if the required torque capacity, life time, safety factors and the total ratio are given. This tool is used to generate a complete set of different variants of gear reducers. The main results are displayed in 3D graphics, showing weight, costs and efficiency of the different variants. Another graph shows the casing dimensions of the variants in three dimensions in order to check the compliance with space restriction. The use of this tool in two typical engineering applications gives very good results; the potential for weight reduction is higher than expected, going up to 30%. Manufacturing price reduction is even higher, going up to 50%.