Applied Mechanics and Materials Vols. 592-594

Abstract: In regular electrical upsetting process, the process parameters were determined by the experience. During working, these parameters were constant and could not be controlled online. In this paper a new proportionate valve and various velocity top anvils, electrical upsetting system is introduced. Based on the bulb temperature measured at the time of operation proportionate valve will vary the upset pressure to obtain the bulb without crack or fold. The control strategy includes two key parts: sensing the temperature and controlling it by varying the power intensity in the circuit through controlling the upset pressure. And the different anvil position and anvil velocity will be used to change the bulb shape based on the valve profile. This control strategy also includes two key parts: Velocity of anvil is directly proportional to height of bulb, in various positions various velocity will be used to form a different shape of bulb without defects.

Abstract: Value Stream Mapping has the reputation of uncovering waste in manufacturing, production and business processes by identifying and removing or streamlining value-added steps and eliminating non-value-added steps. The various process times for manufacturing a mono block pump were obtained from a pump manufacturing industry. The flow diagram showing the process is drawn to reflect the current state of the operation. The non-value actions are identified in each step and between each step by their waste of time and resources. The process is analyzed for opportunity to drastically reduce and simplify it to the fewest actions necessary. By reducing waste the proportion of value adding time in the whole process rises and the process throughput speed is increased. This makes the redesigned process more effective (the right things are being done) and more efficient (needing fewer resources). The reengineered process is flow charted in its future state with process steps and information flows redesigned, simplified and made less expensive. This paper addresses the application of lean manufacturing concepts to the pump manufacturing industry.

Abstract: Managing the products at the end of its intended use and recovery of such used products from the market is gaining significant importance these days due to global environmental concerns, resource reduction, government regulations and economic factors. Reverse logistics networks serve the same. The handling of products, components and materials during the recovery process can be called reverse logistics. Due to the increasing number of heavy vehicles in the country like India, large quantities of used tires are generated every year, and proper disposal of these used tires creates problem in the day-to-day life. Hence recover the value from these used tires in the form of material recovery is gaining importance. The implementation of such recycling system usually requires an appropriate reverse logistics network for choosing the physical locations, facilities, and transportation links to convey the used products from the end customers to the recycling facility. A case study was conducted and traditional reverse logistics networks involved in the used tires focusing quality characteristics has been analyzed in the paper and a new network has been suggested focusing the quality characteristics of material recovered out of used tires through laboratory work and at the same time without compromising the cost factor involved in it. Finally a mathematical model has been developed and optimization of cost subjected to quantity, and time has been done and validated for the decision makers involved in the reverse logistics activities of used tires recycling.

Abstract: Continuous improvement is a vital component of an effective performance management system. Simply measuring performance will not result in system improvements. Getting improvement in any service requires an educational strategy for linking performance measurement to the implementation of the specific system improvements. The aim of the paper is to identify the effectiveness and implementation of the kaizen programme in an electronics manufacturing company. Customers focus on product quality, delivery time and cost. Because of this a company should introduce a quality system to improve and increase both quality and productivity continuously. Kaizen is a methodology that aims to increase the availability of the existing equipment hence reducing the need for further capital investment. This paper identifies role of maintenance in reducing production cost and increasing plant profit with the implementation of kaizen. Use of the Timed-PDCA concept makes it possible to pursue productivity improvement in the current works including nurturing motivations to workers concurrently by arranging kaizen theme.

Abstract: TPM is implemented in industry for improving production efficiency with an ultimate aim of attaining zero breakdowns, zero losses and zero defects. The purpose of this paper is to demonstrate the implementation of TPM initiatives and particularly the most contributing Kobestu-Kaizen (Focused improvement) Pillar in a process industry. The practical aspects and comprehensive approach for the deployment of Kobestu-Kaizen Pillar are presented as a case study. KK pillar helps to attain zero losses and to improve Overall Equipment Efficiency(OEE) of the processes and the plant. The benefits of TPM remained very encouraging and the company decided to continue with second phase of TPM implementation to achieve higher operational excellence.

Abstract: The objective of this paper is to develop a spreadsheet-based simulation methodology to evaluate the performance of a serial supply chain under different inventory position based ((r, Q) and (r, S)) and non-inventory position based (Fixed Order Quantity (FOQ) and Demand Flow Strategy (DFS)) periodic review inventory policies. The performance measures comprises of Fill Rate, Risk of Shortage, Bullwhip Effect and Total Cost of Supply Chain. An experimental study with four scenarios are carried out for two customer demand distributions under information sharing and no information sharing scenarios to determine performance measures in lost sales environment. The best performing inventory control policy for each scenario is found by conducting Grey Relational Analysis and the analysis show that one of non-inventory position based policy, FOQ is the better policy compared to other three policies.

Abstract: For many years,companies have focussed on quality and productivity of their products. Globalization, competition and information technology development have forced the industries to manufacture the products with low cost, good quality, availability in the market. Integration of all business entities will promote the value of above said criteria. Supply chain management is an integrated activity, which can meet this critical challenge. Supplier, customer and manufacturer are the entities of the supply chain, which are associated with more uncertainty. Therefore, the supply chain requires an effective rescheduling strategy to manage the disruption and uncertainty by updating and revising the existing schedule. However, the literature survey on rescheduling activity is very limited. The present literature review attempts to analyze the rescheduling activity due to the disruption from the supplier, manufacturer and customer. Literatures on the rescheduling environment, rescheduling factors, and rescheduling algorithm are reviewed to get over all focus. Finally, the review suggests that, to meet the delivery schedule with least makespan and without any disruptions the following factors viz (i) delivery capability (ii) machine utilization rate and (iii) stock level are to be considered. Keywords: Rescheduling, supply chain, disruption, uncertainty, performance measure

Abstract: A developing country like India depends on Micro, Small and Medium Enterprises (MSMEs) for its economical development. But the sector is not attractive now for the entrepreneurs, since the return for investment is very small. These organisations have to practice the habit of innovation for their survival. The present study focused on the extent of innovations in steel re-rolling MSMEs in Kerala state, India. Also, the barriers for innovation are identified so that the same can be overcome by the planned efforts. The data collection is through a field survey based on a questionnaire prepared. The study shows that level of innovation is very low in MSME sector and proper steps are to be taken to overcome this issue.

Abstract: The replacement problems are concerned with the situation that arises on decrease in the efficiency of the item, failure or breakdown. The problem of replacement is to identify the best policy to determine the ideal replacement time which is most economical. Group replacement model is applicable to the items that fail completely on usage and the result is group replacement age for the entire group of items in the system irrespective of whether they are functioning or not. The present paper proposes intermediate states i.e., minor repair and major repair states in between functioning and irreparable breakdown states. In addition, higher order Markov chains are used in generating the probabilities of items which are falling in different states. In order to consider money value, macro-economic variable, inflation is considered in this model. In the present model, real interest rates are calculated using forecasted inflation for future periods. Future period values of inflation are predicted by using the forecasting technique and a regression model with trigonometric function. These methods are used to accommodate cyclical fluctuation in the prices of items/inflation. The optimal replacement age is the time bucket in which the average cost of the individual replacement, repair and the cost of the items is minimum.

Abstract: Isomorphism identification is a difficult problem in kinematic chains. There is number of method given by many researchers to detect the isomorphism and inversion of kinematic chain but each has its own shortcomings. Purpose of this paper is to give an efficient and reliable method. An attempt has been made to provide satisfactory solution to detection of isomorphism by using hamming method. The method is implemented on sewing machine, break drum; straight line motion mechanisms have six links kinematic chain.