Friday, January 31, 2014

Productivity Councils in Various Cities and States in India

Dr. S. Rajagopala Reddi
Hony. Secretary
Andhra Pradesh Productivity Council
‘Productivity House’
Plot No. 87, Road No. 2, Banjara Hills
Hyderabad-500 033

Phone : 040-23545232, 23545102
Fax :     040-23542827

Shri B.P. Bakshi, Chairman
Shri B.K. Agarwal, Hon.Gen.Secretary
Assam Productivity Council
Lions Sewa Kendra Complex
Makum Road, Udyog Nagar
Tinsukia – 786 146 (Assam)

Phone  :  0374-2352405
Fax:        0374-2352565


Shri Vipinchandra R. Patel, President /
Shri P. Das, Executive Director
Baroda Productivity Council
Productivity House
Alkapuri, P.B. No. 3727
Baroda – 390 007

Phone  : 0265- 2312431,2312432,       2312433
Fax:       0265-2338664
   Email :

Shri Chandraprakash Singh, President /
Shri S.K. Sinha, Hony. Secretary
Bihar State Productivity Council
Bihar Industries Association Premises
Sinha Library Road
Patna-800 001

Phone :  0612-2239244/2222100
Fax:       0612-2226642

Dr.Ram Narayan Barot, Vice President
Shri Dorai Swamy, Executive Secretary
Shri Vijay Kewal Ramani, Hon.Sec.
Bombay Productivity Council          
39, Apurva Industrial Estate
Makwana Road, Marol, Andheri (E)
Mumbai – 400 059

Phone : 022-65776771/ 65776762
Fax:      022-28501111
E-mail :

Shri S. Ramamurthy
Hony. Secretary
Coimbatore Productivity Council
“Vyshnav Building” (3rd Floor)
Opp. K.G. Theatre,
 95-A, Race Course
Coimbatore - 641 018  (Tamilnadu)

Phone  : 0422- 2215727/4393727/2213762
Fax:  (0422) 2214724
E-mail :

Shri Sudarshan Sareen
Delhi Productivity Council
IE/10, Swami Ram Tirath Nagar
New Delhi – 110 055.
Phone :  23522835, 23527803,
Fax:   91-11-23553605/23542440

Shri J.P. Tripathi
Haryana State Productivity Council
Plot No. 521 – A,  Sector – 17
Faridabad – 121 002.

Phone  : 0129-22282205
Fax :      0129-22233983
E-mail :
Shri A.D. Wadhwa
Hony. Secretary
Jharkhand State Productivity Council
501, Saptarishi Apartments
82, Burdwan Compound
Ranchi-834 001.

Phone: 0651-2365208
9431107515, 9204515110 (M)
Shri Yadupati Singhania, President
Shri M. Umar, Dy.Director Incharge
Kanpur Productivity Council
81-B, Cooperative Industrial Estate
Udyog Nagar (Dada Nagar)

Phone : 0512-208022
Fax:      0512-297236

Shri  K.V. Ramachandran, Chairman /
Shri C.K. Krishnan. Hony. Secretary
Kerala State Productivity Council
Productivity House
P.B. No. 8, HMT Road

Phone : 0484-2555526 / 2555367
Fax:      0484-2532107
E-mail :
Shri M.R. Nangare,
Executive Officer
 Kolhapur Productivity Council
1243/46-47-E, Kolhapur Engg. Asso. Building,
 Shivaji, Udyam Nagar
Kolhapur-416 008 (Maharashtra)

Phone :  0231-2656347
Fax :      0231-2654652
E-mail :

Shri Manhar G. Majithia
Hony. Secretary
Kutch-Saurashtra Productivity Council
6,  Rajput Para

Phone/Fax : 0281-2226935
Mob:  9824444603
Shri K.E. Krishnamurthy
Exeuctive Secretary
Madras Productivity Council
110, Nelson Manickam Road

(044) 23740728/23743694
E-mail :

Shri  R. Subbiah, President
Shri V. Pathervellai, Vice President
Shri G. Subramanian, Hon. Secretary
Laisalle Towers-2nd Floor,
52,TB Road(opp to ESI Hospital) and nearby LovelyCards Showroom

Phone:  0452-2346112, 4383080
Fax:      0452-2743410
E-mail :, Website :

Dr. C. R. Mohapatra, President
Shri S. Jagdev, Hon.Secretary
Shri Laxmidhara Dash, Executive Secretary
Orissa Productivity Council
N-6, IRC Village
Ground floor, UCCI Bldg.
Nayapalli, Bhubaneshwar -  751015

Phone:  0674-2552616
Fax:      0674-2552616

Dr. P.C. Shejwalkar, President /
Dr. B.R. Sabade, Hony. Secretary
Poona Divnl. Productivity Council
Ashirwad, Plot No. 2
Akshay Co-Op. Housing Society
Shahu College Road, Parvati

Phone:  020-422554/4212458/4226918
Fax :   020 -  4225541
E-mail  :
Dr. K.L. Jain, President /
Shri U.C. Jain, Hony. Secretary General
Rajasthan State Productivity Council
Basement, Rajasthan Chamber Bhawan
M.I. Road

Phone:  0141-2577427
Fax:      0141-2561419/2562610

Website :
Shri K. Mariappan, President
Shri M. Ilangovan, Hon.Secretary
Salem Productivity Council
1 Park Street, Fairlands
Salem-636 016. (Tamilnadu)

Phone  :  0427- 4042959
Fax         0427-2447295

Shri Pravin Nanavati, President /
Shri Tushar Shah, Hony. Secretary
South Gujarat Productivity Council
B-303, Tirupati Plaza
Near Collectorate, Nanpura

Phone: 0261-2463399
Fax:     0261-2463400

Prof. Raja Mutthirulani
Hony. Secretary General
Tiruchirapalli Productivity Council
S.M. Higher Secondary School Campus
24-A, Nachiar Kovil Road, WORIUR
Tiruchirapalli-620 003.

Phone:  0431-2762320
Fax:      0431 2762320

Shri S. Sundaresan
Tirunelveli Productivity Council
Fibroflex India (P) Ltd.
Industrial Estate, Pettai
Tirunelveli-627 010. (TN)

Phone: 0462-2300352/2627357
Fax:      0462-2300113
The Hony. Secretary
Vidarbha Productivity Council
C/o Pratap Steel Rolling Mills
35, MIDC Area, Hingna Road

Phone:    07104-237369
Telefax : 07104-237369
E-mail :
Shri S.R. Das
State Productivity Council-West Bengal
9, Syed Amir Ali Avenue, 2nd Floor
Kolkata– 700 017.
Phone: 033-22873889, 6994/22830183
Fax:     033-22873889

Industrial Engineer - Job Descriptions

Manufacturing Engineer
Country of service: China
State: Shanghai
City: Shanghai
Company name: Shanghai Bolaite Compressor Co., Ltd
Last date to apply: 2014-02-16

Job description:
Follow the Safety First rule during the process and operation design of assembly line, focus on the health and environment protect in assembly line.Lean principle implement in production line.Line verification list for the compressor assembly to optimize the assembly quality, implement the improve for quality in assembly line.Establish and optimize the manufacturing process of the assemble line for high productivity.Standard Operation Procedure/Routing sequence document preparation for assembly line.Design the packing of Parts with suppliers.Tooling definition and management in assembly linePacking of the FGDesign and install layout for efficient working of assembly line.Design and maintain the KanBan stock control system for assembly line base on the request and layout.Co-ordinate with suppliers for development of assembly tooling & fixture and container for the parts.Make the time study and AVIX analyze for assembly lineOrganize the flow process of assembly line according to the standard working time, define the workstation in assembly line, balance the working time on each workstation.Implement the Design Notification release by Engineering for assembly line, setting the effective date for Design Notification.Train workers to use new equipment/procedure.Negative stock follow up relate to the parameter setting in BPCS.

As manufacturing engineer you are responsible for the design the working process of assembly line in order to guarantee safe operations and customer satisfaction by delivering qualified products on time.

Experience requirements:
Experience of flow management concept, Planning, Manufacturing flow process.

nowledge of Layout & Infrastructure Management. Good process knowledge and Quality consciousness.ERP system (BPCS) usage.Fluent in Microsoft Office Application (VBA of excel as plus).

Educational requirements:
Bachelor’s degree in Mechanical/Production/Industrial Engineering.Good command of English and Mandarin (both oral and written)





NATIONAL DISTRIBUTION FIRM.  FAST PACED 3PL currently interviewing for an Industrial Engineer with 2-5 years experience in time/motion studies, space layout and design, managing, mentoring and reporting of associate bonus plan based on metrics for success.

The successful candidate will currently be living in the S. Indianapolis area   or in the process of moving to the area.  No relocation will be considered at this time.

This position is an autonomous position within the DC reporting to the Sr. Industrial Engineer in another city.  The IE will report onsite to the SVP/GM with interface to the management team.  Evaluation and research of  new equipment, processes and methology to drive efficiency.
 Focus on and Implement process improvements within the operation.

Maintain accurate drawings of all facilities in the best software (CAD, Visio, etc.) most compatible with our material handling vendors

Analyze and challenge existing procedures in all departments throughout the facilities making recommendations and working with the DC management to integrate solutions.

Develop Standard Operating Procedures and process flow charts for all departments.

Analyze space needs and demands on consistent basis, publish weekly report, develop and implement solutions.

Develop Activity Based Costing; make recommendation on labor staffing and costs for some of the labor “insourcing" we are currently doing.

Partner with all of the Distribution/ Returns Center Managers.  Work closely with project management team.

Build working  relationshipswith hourly associates to enable involving them in any experiments.

Oversee slotting process in DCs in order to achieve the goals:

Reduce walk time between hits (lines not units)

Minimize replenishment (increase “weeks in pick" – a function of SKU size and velocity.

Create a “Visual Factory"


Four Year degree in Industrial Engineering.  minimum of 2 years experience as an IE in a distribution facility or manufacturing facility with distribution responsibility.

Strong process improvement, time motion , layout design and top people skills.

Industrial Engineer
Rexnord - Auburn, AL

Brief Description

The Industrial Engineer will be part of the Manufacturing Department and provide industrial engineering support to plant issues that are impacting production. In this role the industrial engineer will be charged with seeking out areas of inefficiency & improve processes regarding people, machines, or processes.


Evaluates and executes time-study techniques to establish labor standards, and implement tools to monitor performance to these standards on a daily and hourly basis.Develops labor cost analysis, evaluates worker productivity and implements improvements to the process.Develops and improves workplace design. Initiates and evaluates plant project requests through cost justification analysis. Evaluates opportunities for efficient utility utilization and cost reduction.Determine worker functions and responsibilities by studying operations sequence, material flow and part function Execute labor analysis and achieve line balance for initial implementation and support improvement activities targeted at improving utilization and efficiency Design and implement layout (new and take over business) of equipment, materials, workspace and packaging to deliver maximum efficiency Develop manufacturing methods, labor utilization standards, and cost analysis systems to reduce waste and improve performance Estimate production cost and effect of product design changes for management review, action, and

control Participate/lead in CAR developments as needed


1. Bachelor's Degree in Engineering or Engineering Technology required
2. Analytical problem solving skills with proven mechanical aptitude
3. Good understanding of Lean manufacturing principles (e.g waste reduction, 1- piece flow etc.)
4. Experience with time studies, line balancing and labor standards development
5. Experience with AutoCAD or other programs for development of plant and work cell layouts
6. Use of spreadsheet tools for line balancing, labor analysis, inventory analysis etc.
7. Ability to work directly with manufacturing staff to troubleshoot and solve problems
8. Understands process stability and demonstrates system thinking
9. Willingness to learn and coachable
10. Demonstrates high initiative and proactive thinking

Thursday, January 30, 2014

Value Engineering - Expanded

Low cost alternative materials
Low cost alternative processes
Low cost alternative suppliers
Low cost alternative design of components
Low cost alternative design of assembly
Low cost alternative assembly process

Design optimization
Material optimization

Variant reduction
Weight reduction

Design Optimization News

30 January 2014

Frugal Engineering: The Mantra To Design Resource-efficient Embedded Systems and Chips
Optimization in designing embedded systems

Optimization of components of frame assemblies used across vehicle variants

Productivity and IE in Motorcycle and Scooter Manufacturing

1000th post  created

Single-Pass Bore Finishing from Engis Revs Up Productivity for Motorcycle Gear Supplier

Tight tolerances are extremely important in gear manufacturing; even more so when those gears are used in performance motorcycle transmissions. Just as important is the ability to manufacture as competitively as possible. This was the position a motorcycle component manufacturer faced recently when they contacted Engis Corp. about single-pass bore finishing.

Motorcycle Manufacturer Increases Productivity with Multiple
Pentalift Application Designed Hydraulic Lift Tables

Revving Up Productivity With A Pallet Changer

Optimising and simulating the assembly line balancing problem in a motorcycle manufacturing company: a case study
Pablo Cortés, Luis Onieva, José Guadix
International Journal of Production Research (Impact Factor: 1.46). 06/2010; 48:3637-3656.

Nano costs less than Ford T in Inflation Adjusted Terms

The Model-T (the first cheap car)  was sold at  $850 in 1908. When you adjust for inflation, that is about $22000 now.

However, the price of that got reduced to  $260 by 1920 (about $3500 now).

Tata Nano can be termed as a car similar to Ford T and it costs $2000.

Production Method - Technology Efficiency Engineering

Production technology or method has to be effective and efficient.
A technology is effective when it is able to produce a product with quality acceptable to the customer, that means it is as per the specification agreed to by the producer and customer.

A technology is efficient when it uses the lowest amount of resources to the produce the quality product. Efficiency can be measured only when the process produces acceptable quality products.

Production technology efficiency engineering is proposed by H.B. Maynard in Industrial Engineering discipline as Operation Analysis.

He gave nine areas of technology or production method for efficiency analysis.

They are:

1. Purpose of operation.

2. Complete survey of all operations performed on part.

3. Inspection requirements.

4. Material.

5. Material handling.

6. Setup and tool equipment.

7. Common possibilities for job improvement.

8. Working conditions.

9. Method.

As mentioned above the first focus of technology development is effectiveness or production of the item with acceptable quality. This effective method of production is normally composed of number of operations using different equipments.

The first question is whether each of the specified operations is rational?

The second analytical issue the sequence of operation. Is there any benefit by a combination of operations or rearrangement of operations.

The third area of analysis is the tolerances specified for each dimension that is inspected. Tighter tolerance result in higher costs.

The fourth aspect of analysis is material. In production method analysis, the examination of the material is done from the point of view manufacturing optimization. In value engineering or product design efficiency engineering, the material aspect is analysis must more rigorously with respect to alternative low cost materials.

The fifth aspect is material handling. How the material is moved between operations. To do this, the industrial engineer must have good knowledge of alternative material handling methods and their costs.

The sixth aspect is given as setup, tool and equipment. A radical redesign of the production method can call for replacement of the existing equipment or proposed equipment with more economically efficient equipment. Industrial engineer needs to have knowledge equipment alternatives and their costs in the area of technology being analysed. In number of cases, the efficiency analysis is more focused on using the existing equipment more efficiently. In this case, the industrial engineer must know the efficiency aspect of the existing machines in relation to various jobs being done in the organization.

Cutting tools, coolants, jigs and fixtures, chip removal methods are various aspects of the production method related to the equipment which need to be analyzed. The industrial engineer needs to have an updated knowledge about each of these aspects to do efficiency analysis and improvement of the production methods.

H.C.Starck Newton Facility - Productivity Improvement

H.C. Starck's Newton, MA site has been awarded Industry Week's 2013 Best Plants. The award demonstrates H.C. Starck's manufacturing excellence and its outstanding team who delivered extraordinary results in the face of strong global competition, cost reduction directives and increased customer demand.

The implementation of a world-class manufacturing program with 5S, Six Sigma and Lean techniques yielded significant improvements in Newton's manufacturing operations. Through these programs the facility hit the bulls-eye with its operational strategy, improved production practices and performance. Major gains were seen in customer satisfaction, product quality, and on-time delivery.

“There are many ways to measure the benefits of the work done at our plant,” says Lee Sallade, Vice President and General Manager.  “For me, the best measure is the overall increase in productivity. Over the last two years, this new focus has helped us see significant improvements in productivity as measured in tons produced and dollars sold per full time equivalent employee.”

                                                          2008                   2010      % Improvement
Tons Produced/FTE                            2.04                    2.95           45%
Thousands of Dollars Sold/FTE             748                  1,068           43%

"These improvements in output have helped us reduce costs and improved profitability,” adds Sallade. “A number of our competitors have plants in countries with low cost labor. But our productivity improvements have allowed us to maintain our competitiveness and our market share!”

Real time inline inspection in tantalum line in H.C. Starck - 2004

Wednesday, January 29, 2014

Robots - Engineering Economic Analysis

Economic Analysis of Robots Employment in Building
Abraham Vvarszawski and Yehiel Rosenfeld
Faculty of Civil Engineering and National Building Research Institute
Technion - Israel Institute of Technology
Haifa 32000, ISRAEL

Tuesday, January 28, 2014

Value Engineering of Ventilator


OneBreath ventilator will be priced at $3000

Omdiyar of EBay is funding OneBreath for manufacture of portable ventilators.


Ventilators cost hospitals from $3,000 up to $40,000

Matthew Callaghan they just push air around. It isn't complicated engineering. You don't need all the bells and whistles." That thought was the impetus behind the OneBreath, the ventilator Callaghan invented with a small team of fellow Stanford biodesign students. The device is just a fraction of the cost of a low-end conventional ventilator, runs on a 12-volt battery for six to 12 hours at a time, and is smaller than a toolbox so it can be easily deployed wherever needed.

Callaghan started from scratch with a basic pressure sensor, typically used in devices like blood-pressure meters, that cost about $10.

Another Design for Manufacturing cost of $200

Productivity and IE in Stock and Commodity Exchange Trading

Monday, January 27, 2014

Productivity and IE in Industrial Gas Manufacturing

The improved ammonia process utilizing pressure swing adsorption will help reduce energy consumption and costs. The estimated energy savings by 2030 are in excess of 7 trillion Btu. At power plants and other
facilities that use ammonia in their SCR and SNCR systems, the scaleable, on-demand
process will also eliminate the need to transport and store large amounts of ammonia, helping
to improve worker and plant safety.
Feb 2009

Hydrogen Production

Green Process for producing Hydrogren - Cost Effectiveness

Hydrogen is abundant element, but is generally bound to oxygen in water (H2O) or to carbon in methane (CH4), the primary component in natural gas. At present, industrial hydrogen is produced from natural gas using a process that consumes a great deal of energy while also releasing carbon into the atmosphere, thus contributing to global carbon emissions.

Using electrolysis, wherein the electrode serves as a catalyst, a material that can spur one reaction after another without ever being used up, hydrogen can be made. Platinum is the best catalyst for electrolysis. If cost were no object, platinum might be used to produce hydrogen from water today.

But money matters. The world consumes about 55 billion kilograms of hydrogen per year. It now costs about $1 to $2 per kilogram to produce hydrogen from methane.

Researchers have come out with a cheaper alternative. Researchers synthesized nanoclusters of  special moly sulfide. These nanoclusters were deposited onto a sheet of graphite, a material that conducts electricity. The graphite and moly sulfide form a cheap electrode. It is a substitute for platinum, the ideal but expensive catalyst for electrolysis. The experimenters found that their cheap, moly sulfide catalyst had the potential to liberate hydrogen from water on something approaching the efficiency of a system based on prohibitively expensive platinum.

The larger questions were: could this technology scale to an industrial level plant? And what will be the finished cost per kilogram?

Last year, Thomas Jaramillo, an assistant professor of chemical engineering at Stanford and a dozen co-authors studied four factory-scale production schemes and published  an article for The Royal Society of Chemistry's journal of Energy and Environmental Science. They concluded that it could be feasible to produce hydrogen in factory-scale electrolysis facilities at costs ranging from $1.60 and $10.40 per kilogram. The lower end is  competitive with current practices based on methane. Therefore developing this process further means the world can move  from carbon-intensive resources to renewable, sustainable technologies to produce hydrogen.  2013 paper
Technical and economic feasibility of centralized facilities for solar hydrogen production via photocatalysis and photoelectrochemistry!divAbstract

Over view of technology options
2009 report

Efficient, Highly Productive Hydrogen Production from Glucose
The long-term objective of this research is to enable the widespread deployment of a new technology that converts sugars derived from cellulosic biomass into hydrogen, with energy conversion yields greater than 90% and fuel value conversions at volumetric productivities at least 10-fold higher than current U.S. biomass-to-ethanol technologies. The process for accomplishing this will use inexpensive bacterial cell extracts to convert glucose, xylose and water into hydrogen and CO2. A kinetic and thermodynamic model for a novel, cell-free enzymatic pathway will be developed, providing new scientific insights.

Sunday, January 26, 2014

Productivity and IE in Soap and Other Detergent Manufacturing

Innovation and Productivity: What’s the Relationship and How
Does They Happen?
Nov 2011

Maximizing Soap and Detergents Manufacturing
Processes with the Proper Pump

Use of supercomputers by Proctor and Gamble

• Saves $309,000 annually
The installation and configuration of a Programmable Logic Control (PLC)-based network controls
package with Management Information System (MIS) capability. The new control system was
linked to additional airflow and dew point measuring devices that could provide it with real-time
data to better help it determine when to bring compressors on or offline.
The project has substantially reduced energy consumption by the original, seven-compressor system,
yielding annual energy savings of 7.6 million kWh and $304,000. The mill saved an additional
$5,000 on maintenance by taking a 450-hp unit offline. Together, these savings total $309,000.
Because the project cost was $545,000, the simple payback is 1.75 years

The Power of Productivity
Wealth, Poverty, and the Threat to Global Stability
William W. Lewis

Productivity and IE in Paint, Coating, and Adhesive Manufacturing

ABB paint industry solutions for optimization
Using its process expertise and experience in paint and coating production, ABB has
developed innovative and optimized solutions to each specific constraint encountered
in paint production phases: dispersing, grinding, tinting, filtration, cleaning, transfer,
pigging system, powder handling, pneumatic transfer, control system, scheduling.$file/paint_coatings_final.pdf

Energy Conservation for a Paint Company Using Lean Manufacturing Technique
Sobia Shahid1,*, Sibi Chacko1 , C M Shukla2
1 School of Engineering and Physical Sciences Faculty, Heriot Watt University Dubai Campus, 294345, Dubai, United Arab Emirates 2 Quality Control Manager, Jotun Paints, 3671, Dubai, United Arab Emirates

Improving accurarcy of paint delivery

In the beginning of 2006, Nippon Paint started to make some simple changes by implementing an Intermec barcoding system to its operations in Singapore, with the support from Intermec’s partner MuRho. Nippon Paint’s goal was to improve the accuracy of paint delivery, while reducing administrative work.
Using Intermec’s MobileLAN WA22 wireless LAN access point, with Intermec 730 and Intermec 730 i-Safe handheld mobile computers, Nippon Paint redesigned the 5-stage work process with the use of technology; manufacturing, item movement from production to logistics, stock-taking, selection and loading.
The process is now barcoded and automatically integrated from where packing begins, and ending when the goods leave the factory premises.

The system has increased the worker’s efficiency and improved the productivity of the company. The system also reduces time required to train new staff, and ensures more consistent work processes regardless of staff experience. With the success of this system, Nippon Paint may propagate this to other facilities in the future.

Godwin, Harold Chukwuemeka and Achara, Okechukwu Michael

Productivity and IE in Pesticide and Other Agricultural Chemical Manufacturing

Productivity in Life Science Industries - Statewise Data - USA

Productivity and IE in Plastics Material and Resin Manufacturing

Polymer Pumps for Resin Plants & for Plastic Processing - Productivity Improvements

Energy Consumption by Chemical Industries

Opportunities for Energy Efficiency in Hydrocarbon Resin Manufacturing Facilities

This paper summarizes the results of a plant-wide assessment of Neville Chemical
plants in Anaheim, CA and Pittsburgh, PA. US DOE cosponsored the assessments (Ganji, et
al. 2002).

Detailed plant-wide assessment of two hydrocarbon resin manufacturing facilities of
Neville Chemical revealed significant opportunities for energy efficiency, and consequently
air emissions and green house gas reduction in such facilities. The energy efficiency
opportunities (EEOs) in the Anaheim plant, the smaller of the two facilities, could save 27%
of the facility’s annual electrical energy usage, and 36% of its annual natural gas energy
usage. The cost savings is estimated at about 20% of this facility’s annual energy costs, with
an overall simple payback of 1.6 years. The EEOs identified in the Pittsburgh plant, a much
larger facility, could save 9% of the facility’s annual electrical energy usage, and 54% of its
annual natural gas usage. The total annual energy cost savings would represent about 30% of
the facility’s annual energy costs with an overall payback of 0.9 year. Significant non-energy
benefits including waste reduction and productivity improvement measures were also

Vacuum Forming

Vacuum thermoforming is a plastic manufacturing process in which a 2 dimensional thermoplastic sheet is heated to a forming optimal temperature and, using vacuum and pressure, is formed into a 3 dimensional part.

Materials Commonly Used in Vacuum Forming
ABS - Broad spectrum of resins used across a number of applications. Can be formulated to meet UL flammability standards.
PC/ABS - Alloy delivers UL approval in addition to high impact performance.
HDPE - Cost effective material for industrial applications requiring high impact strength.
TPO - High impact material delivering performance in cold and high heat applications.
HIPS - Low cost resin used in many POP applications requiring excellent forming characteristics.
PVC/Acrylic - Widely used resin in micro-processor based equipment housings. Meets most stringent UL standards for flammability and can be made in wide range of colors and textures.

Plastics Manufacturing Systems Engineering
David O. Kazmer
Hanser, 2009 - Kunststoffverarbeitung - 502 pages

"Plastics manufacturing is a highly interdisciplinary endeavor requiring knowledge related to materials science, physics, engineering, and management. This book was written to educate and support plastics processing engineers, but is also highly useful to others involved with plastics manufacturing who are performing process development, research, and even machinery design"--Provided by publisher.

Productivity and IE in Basic Organic Chemical Manufacturing

Water Benchmarking to improve productivity in basic organic chemical manufacturing

Basic organic chemical manufacturing sector water use benchmarks
Performance measures Benchmark kL per tonne
Minimum 0.10
Mean 1.94
Maximum 4.0

Productivity Performance of Indian Chemical Sector: 2012

Chemical Process Simplification: Improving Productivity and Sustainability
Girish K. Malhotra
ISBN: 978-0-470-48754-9
282 pages
December 2010

Table of Contents
Preface xiii
1 Process Simplification: Basic Guidelines 1

2 Process Solutions 9

3 Commonalities of Businesses 53

4 Laboratory Process Development 77

5 Mass and Heat Balance 95

6 Reaction Kinetics 111

7 Physical Properties 123

8 Combination of Heat, Mass Balance, and Physical Properties 135

9 Cross-Fertilization of Technologies 159

10 Scale-up to Commercialization 171

Frugal Reengineering

Frugal Reengineering - Definition

Frugal Reengineering is a structured, sustainable process of continually redesigning products to cut costs. Cost-effective continual re-engineering (or continuous improvement in manufacturing parlance) of a product is the essence of frugal re-engineering.

Frugal re-engineering builds on the concepts of value analysis and engineering.
Frugal re-engineering has the potential to drive year-on-year cost savings of between 7 and 12 percent.

Knowledge Base and Knowledge Management for Frugal Reengineering

Are substitute low cost materials available?

Commodity prices are always rising and but low cost substitutes are being invented and developed.  The low cost substitutes material properties are also being further developed. Recently, an Indian automaker that projected the rising cost of nickel generated significant savings by substituting components that contained nickel with non-nickel-based components. Another firm cut costs by 5 percent and weight by 10 percent by judiciously substituting composite materials, which are less expensive than steel for low-volume applications.

Have manufacturing advances occurred offering low cost substitute processes?

Manufacturing technology and process innovations offer further opportunities to cut costs by reducing input material requirements. New process technologies such as near-net forging and flow forming—technologies with implications in many discrete manufacturing companies—can dramatically cut costs.

Have design engineering advances occurred providing opportunities for low cost designs?

The company must develop a knowledge management system that is able to create a database of relevant development in the external environment and ideas generated by internal members in this regard and make them available for the team doing a frugal reengineering project on a product, sub-assembly or component.

Reengineering Medical Technology

Saturday, January 25, 2014

Industrial Engineering For Efficient Energy Use


Failing to accurately account for the cost of energy in manufacturing can be a recipe for failure.!

3.11. 2013
Energy Efficiency - ABB

The Knol is being updated after one and half years. The motivation for the update is an article published in the Industrial Engineering Magazine (IIE Magazine) July 2011 with the title Energizing Continuous Improvement by John Preston,
John Preston is a corporate industrial engineer and president of IIE’s Greater Detroit Chapter. He is employed by Dura Automotive Systems in Rochester Hills, Mich.
He gave ideas on improving energy efficiency. I am summarizing the article in another knol.

20 December 2009


Industrial Engineering and Energy

Industrial engineering profession decided to evaluate and improve the efficiency of energy use and hence included energy in its definition. It also added information to its definition with the same objective.
But has industrial engineering developed any methodologies for evaluating and improving energy use efficiency? This knol is an attempt to collect material relating to efficient energy use.

Industrial Engineering in the field of Energy and Environmental Engineering

Münster/Steinfurt (23 February 2007)

Sales, management or controlling - only a few other degree programmes give graduates access to such a wide range of professional opportunities as that in Industrial Engineering.

This is why Münster University of Applied Sciences has now added Industrial Engineering to its range of courses.

"By popular demand, we have decided to offer a degree programme in Industrial Engineering in the field of Energy and Environmental Engineering", Prof. Dr.-Ing. Christof Wetter, Dean of the Faculty of Energy · Building · Environment, underlined.


Third International Conference on Production Research – Americas’ Region 2006 (ICPR ICPR-AM06)

Data center energy efficiency assessment by IBM services

IBM report: cutting energy costs for a powerful competitive advantage
IBM Data Center and Facilities Strategy Services – data center energy efficiency assessment measures the energy usage of your cooling, electrical and building systems, compares your energy efficiency to an industry standard and identifies opportunities to improve. It helps create business-case financial justification to help prioritize improvements for energy savings, giving you a framework to make infrastructure decisions.

The Cisco Data Center Energy Efficiency Assessment Service

Increase the Energy Efficiency of Your Physical Design
The Cisco Data Center Energy Efficiency Assessment Service helps you to benchmark the power, cooling, and facilities infrastructure of your data center so you can increase its energy efficiency.
The service includes five activities:
● Inspect physical infrastructure
● Benchmark energy efficiency
● Project efficiency effects of changes
● Model air flow and temperature distribution
● Assess electrical efficiency
The Knol is being updated after one and half years. The motivation for the update is an article published in the Industrial Engineering Magazine (IIE Magazine) July 2011 with the title Energizing Continuous Improvement by John Preston,
John Preston is a corporate industrial engineer and president of IIE’s Greater Detroit Chapter. He is employed by Dura Automotive Systems in Rochester Hills, Mich.
He gave ideas on improving energy efficiency. I am summarizing the article in another knol.
Original knol - 2061

Productivity and IE in Synthetic Dye and Pigment Manufacturing

Absolute.Za depth filters provide unmatched per-formance for the chemical process industries. Z.Plex* technology has been used to create a depth filter, which has absolute filtration (99.9% efficiency at the rated micron) and long life. This combination delivers the lowest total operating cost for the most demanding applications in the chemical process industries. A leading manufacturer of ink jet dyes trialed Absolute.Za in their manufacturing process. The company was looking for improved productivity, faster processing and lower total operating cost, while maintaining their customers’ quality require-ments. The manufacturing process was a batch operation, which included over 350 different ink dye formulations. Organic solvents used were primarily ketones. Absolute filtration at 0.5 micron was re-quired for ink quality.
Production and purchas-ing management viewed the performance and cost savings of switching to the Absolute.Za as an "easy decision," and initiated the required steps to imple-ment its use.
2012 GE power and water case study


Dintex Dyechem Green Productivity Case Study
This resulted in savings of over Rs.16 million (US$ 357,136) a year — from an initial investment of some
Rs 17 million (US$379,457).

Dye Manufacturing Technologies and pollution
1998 paper

Productivity and IE in Photographic Film, Paper, Plate, and Chemical Manufacturing


Debuting at PRINT'13, XMF Workflow v5.5 enhances the J Press 540W

Fuji Ceasing Motion Picture Film Production

Display Film and Paper



Low Cost Suppliers for Industrial Engineering - Value Engineering - 2014 - Information

Low cost supplier - Google link -page 4

World Industrial Reporter
Information for Industrial Buyers and Sellers Worldwide

Low-Cost Country Sourcing Procurement Solutions from GEP Procurement Consultants
More Value, Less Time
Research says best-in-class procurement organizations source at least 20% of their enterprise spend from low-cost countries. GEP can help you achieve more value more rapidly. On average, GEP delivers incremental savings of 25% to 30% when sourcing from low-cost country sources, instead of domestic suppliers.

Choosing the right overseas supplier for your business is a lengthy process that requires
time, research, experience and strategy if you want to negotiate fair terms and secure the
best available pricing.

 Product Sourcing in Low-Cost Countries - Learning from Bangladesh



Cheaper Chinese Solar Panels - Analysis
Industry-validated figures from the first half of 2012, estimate of an MSP is $1.19 per Watt for US solar panels, compared to $0.91 per Watt for Chinese solar panels, and it represents  a price advantage of 23 per cent for a China-based manufacturer.
The dominant reason behind it is primarily the scale of solar panel manufacturing in the region, enabled by a less restrictive business and regulatory environment. The study shows that the density of production and the cost-benefit of using local suppliers give a China-based manufacturer access to cheaper materials and machinery. These scale and supply-chain advantages provide a China-based solar panel factory with a significant MSP advantage of $0.28 per Watt.

Low-Cost Chinese Suppliers Threaten Shakeup in Pneumatic Components Market
The global market for pneumatic valves and actuators, estimated to be worth nearly $8 billion in 2012,
The market is dominated by a handful of large manufacturers, led by SMC from Japan and Festo from Germany, which together accounted for slightly more than 45 percent of the worldwide revenue in 2012.

Mexico Replaces China as U.S. Low Cost Supplier

Wednesday, January 22, 2014

National Conference on Industrial Engineering - NITIE - 2014

Conference Time: 29-31, October, 2014 at NITIE, Mumbai

Call for Papers

Important Dates


1. Prof. K.V.S.S. Narayana Rao

2. Prof. Sachin Kamble

Case Studies and Research Papers are invited:
Abstract submission: Last Date 30 April 2014.

Conference Tracks

Case Studies and Research Papers Invited
Case studies from Industry executives and PG students based on their summer projects and field projects.

Industrial Engineering Principles & Techniques

Value Analysis and Engineering
Methods Efficiency Engineering
Motion Economy Studies
Work Measurement
Facility Location & Layout Design
Engineering Optimization
Applied Operation Research / Optimization
Applied Statistics
Six Sigma
Engineering Economics
Production Economics
Engineering Ergonomics
Systems Dynamics and Modelling

Application of Industrial Engineering in Technical Processes

Manufacturing Systems
Material Handling Systems
Quality and Inspection Systems
Storage and Warehouse Systems
Supply Chain Systems
Logistics Systems
Information Systems
Pollution Control Systems
Energy Engineering
Reliability Engineering and Maintenance

Applications of Industrial Engineering in Business Processes

Marketing and Selling Processes
Accounting Processes
Customer Service Processes
Human Resource Recruitment Processes
Purchase Processes

Industrial Engineering & Managerial Effectiveness

Manpower Planning
Inventory Control and Materials Planning
Production Planning and Control
Project Planning and Control
Budgeting and Budgetary Control

More Detailed List of Proposed Conference Tracks

Monday, January 20, 2014

Productivity and IE in Petrochemical Manufacturing

Quintiq's intelligent supply chain planning & optimization software enables petrochemical companies to increase throughput and yield, reduce the consumption of energy, reduce inventory and improve customer service throughout the petrochemical supply chain realities of your business.


Productivity and IE in Petroleum Refineries

Productivity Growth in Indian Oil Refineries: Efficiency Improvement or Technical Improvement
IOSR Journal Of Humanities And Social Science (IOSR-JHSS)
Volume 9, Issue 2 (Mar. - Apr. 2013), PP 103-114
The selected companies includes in the present study are: Indian Oil Corporation Ltd(IOCL), Bharat Petroleum Corporation Ltd(BPCL), Hindustan Petroleum Corporation Ltd(HPCL), Mangalore Refinery and Petrochemicals Ltd(MRPL), Essar Oil Ltd(EOL), Chennai Petroleum Corporation Ltd(CPCL) and Reliance Industries Ltd(RIL). The period from 1996-97 to 2010-11 is selected for the study of selected Indian oil refineries.

Enhancing productivity and energy efficiency of oil refineries, terminals and downstream complexes
ABB Note 2011$file/Refining%20and%20PetroChem_lo.pdf

Benchmarking to improve productivity in Petroleum Refining and petroleum Fuel manufacturing
Petroleum refining and petroleum fuel manufacturing sector water use benchmarks

Performance measures
Benchmark kL per tonne
Minimum 0.20
Mean 16.97
Maximum 96.54

Sandvik puts focus on oil refinery productivity

By launching a new microsite Sandvik demonstrates its capabilties in helping oil refineries increase uptime in critical heat exchangers. The microsite provides examples showing how Sandvik's heat exchanger tubing in advanced stainless steels can contribute significantly to reduced maintenance and increased productivity.

Productivity and IE in Printing industry

Impact of Lean Practices on Printing Companies
Jenna Bodolay
Graphic Communication Department, June 2010

Lean manufacturing is just the latest catch phrase for maximizing production efficiency
in a printing plant by instituting process control procedures and measurement metrics.

Print Productivity: A System Dynamics Approach
Area: Processes, Productivity, and Profitability
Document # PICRM-2008-05
The productivity of the printing industry in terms of real sales per employee has been growing at an annualized rate of 1.9% for more than a decade. The National Association for Printing Leadership (NAPL) reports that the industry is lagging when compared to the average productivity growth of 4% from the non-durable manufacturing industries (2004).

Waterless Printing - Productivity Improvement
Adopting waterless printing can result in significant improvement in printing productivity. The advantages of not using dampening solution can be felt immediately.
compared to conventional PS printing, waterless printing can realize an improvement in printing press utilization of as much as 16%.

Productivity and IE in Paper Manufacturing

FACTOR 5: Transforming the Global Economy through 80%
Improvements in Resource Productivity
Online Industry Sector Study – The Pulp and Paper Industry ..................................................... 2
1) The Potential for Factor 5 Improvements in Pulp and Paper Manufacture Resource
Productivity ............................................................................................................................................... 2
Best Practice Case Studies ................................................................................................................. 8
Catalyst Paper International – Powell River and Port Alberni Mills, Canada .................................................. 8
Visy Industries – Tumut Mill, Australia ........................................................................................................... 9
ChemRec - Black Liquor Gasification Combined Cycle ................................................................................. 9
2) A Whole System Approach to Factor 5 in the Pulp and Paper Sector ......................................... 11
IPCC Strategy One: Energy Efficiency Opportunities ....................................................................... 11
IPCC Strategy Two: Fuel Switching .................................................................................................. 11
IPCC Strategy Three: Heat and Power Recovery ............................................................................. 11
IPCC Strategy Four: Renewable Energy .......................................................................................... 12
IPCC Strategy Five: Feedstock Change ........................................................................................... 12
IPCC Strategy Seven: Material Efficiency (Water) ............................................................................ 13
2010 paper

Benchmarking to improve productivity in pulp, paper and paperboard manufacturing facilities

Pulp, paper and paperboard product manufacturing water use benchmarks 
Performance measures 
Benchmark kL / per tonne 
Minimum 0.53 
Mean 1.98 
Maximum 4.73 

Ashok Kumar Mishra
It is estimated that about 5 million tons of starch are currently used by the world paper industry, that is about 1.5% starch by weight including all grades of paper and paperboard. The use of modified starches is more common in the United States where modified starches are not only used to achieve higher productivity, but also higher paper quality. For example in 2004, of all the corn-based starch used by the paper industry in the United States, 76% was modified,
The advantages of modified starches over native starches are manifold.

Productivity and IE in Plywood Manufacturing

YouTube Video


WOOD RESEARCH  55 (4): 2010

Innovative lay-up system in plywood manufacturing process
Alberto Regattieri, Giacomo Bellomi
European Journal of Wood and Wood Products
February 2009, Volume 67, Issue 1, pp 55-62
In the traditional plywood manufacturing process, the lay-up stage absorbs approximately 24% of the total manufacturing costs. It usually requires a large amount of manpower and produces a significant amount of waste material. Interesting results of the innovative process include productivity increases of up to 20%, a decrease in lay-up costs of approximately 19% and a consumption of area reduced about 42%. Moreover, by reducing manpower requirements, the new system generates a significant reduction in the number of problems relating to product quality and operator safety.

Plywood Manufacturing Lines

Biele provides highly efficient solutions for the manufacture of plywood in a wide variety of wood and qualities. Proposals range from high productivity multidaylight presses and automation projects for construction and commodity boards to coating lines for fine wood boards for the furniture application.



Problems and Prospects of Plywood Industry: A Case Study from Assam (Google eBook)
Badal Kumar Sen
Mittal Publications, 1995 - Fiberboard industry - 208 pages
Google ebook with preview facility

Productivity and IE in Footwear Manufacturing

Double-figure increase in productivity of production line workers  (Footwear)
by Lukas Homol

Technology and Employment in Footwear Manufacturing: A Study Prepared for the International Labour Office Within the Framework of the World Employment Programme
Gerard K. Boon
BRILL, 1980 - Law - 216 pages
This book describes the law concerning temporary work in the European Community & in the EC Member Countries, with the exception of Luxembourg. The reports, prepared by national experts, most of them academics, were written on the basis of a common outline in order to guarantee, to a maximum, that each national report would contain the same & therefore comparable material. This has self-evidently not been possible for all countries, such as Greece, Italy & Spain where temporary work, in the sense of travail temporaire, is until now prohibited. On the basis of the EC -- & the national reports, a comparative report has been written, highlighting the convergencies & the divergencies in the regulations of temporary work as they emerge from the varying approaches in the different Member States. In doing so, one is again baffled by the enormous diversity which prevails in the Member States, although an interesting, positive & integrating approach can be discerned.
Google book link with preview

Farida Footwear - R&D  Projects for Students

Footware Industry in India

Saturday, January 18, 2014

Productivity Improvement Using Rapier Looms in Place of Shuttle Looms

The rapier looms offer unparalleled versatility when it comes to yarns. From the finest counts
of cotton to the thickest Industrial yarns and can handle anything thrown at its negative
rapier head. The soft-pick gear system enables smooth transition of even highly fancy yarns
like embroidery and slub. The rapier loom is upgrade from shuttle-looms to the world of
modern weaving system and shuttle-less weaving. Rapier looms has been designed to
replace the old shuttle looms without any major changes to the existing infrastructure.

2010  Engineering Economic Analysis for Rapier Loom

Productivity and IE in Coffee and Tea Manufacturing

World-Class Maximus Sets Quality Standards with Heavyweight APS Platform

Productivity and IE in Bread and Bakery Product Manufacturing

Handbook of Food Products Manufacturing, 2 Volume Set

Nirmal Sinha, Ph.D.
John Wiley and Sons, 27-Apr-2007 - Technology & Engineering - 2308 pages

The Handbook of Food Products Manufacturing is a definitive master reference, providing an overview of food manufacturing in general, and then covering the processing and manufacturing of more than 100 of the most common food products. With editors and contributors from 24 countries in North America, Europe, and Asia, this guide provides international expertise and a truly global perspective on food manufacturing

Optimal Production Mix for Bread Industries: A Case Study of Selected Bakery Industries in Eastern Nigeriamore.

Nutrilac® Natural Improvers from Arla Foods Ingredients:
greater productivity and cleaner labels in bakery

Productivity and IE in Ice Cream Manufacturing

A Verderflex Rapide R7S tube pump has delivered many benefits to the Hungarian ice cream manufacturer Magic Ice. Including substantially increased productivity because the pump can accommodate several pump heads allowing the company’s production to be doubled.

Currently Magic Ice has a twin head Verderflex Rapide R7S on their production line but the pump can easily be expanded up to four heads, providing the potential for easy future expansion. Each head delivers the same flow rate as they all run at the same speed from a single drive; a far more cost effective and compact option than running several independent pumps.

National Conference on Technology Management - NITIE - 2014

Call for Papers

Important Dates


1. Prof. K.V.S.S. Narayana Rao
    kvssnrao55 @

2. Prof. Sachin Kamble

Case Studies and Research Paper are invited:
Abstract submission: Last Date 30 April 2014.

Technology & Innovation Management

Economics of Innovation
Design based innovation models
Technology and Product Road-maps
Technology Nurturing & Incubation
High Technology Marketing and Product Acceptance
Decision Support Systems in Technology Management

Technology Development - Outsourcing vs. internal development
R&D/ Project management
Technology acquisition and Transfer models
Energy technologies - scenarios and acceptance models
Industrial Engineering & Technology Management Interface

Models of New Product Development
Technology Portfolio Management
S Curves and Technology Life cycle
Technology Forecasting
Diffusion and Adoption of Technologies
Application of IE in Technology Life Cycle
Issues in Technology Development

Social & Economic Impact of Technology Development
Issues & Strategies in Small and Medium Enterprises

Wednesday, January 15, 2014

Proposed Tracks and Themes for National Conference on Industrial Engineering - NITIE - 2014

Part of National Conference on Industrial Engineering and Technology Management (NCIETM) 2014
at NITIE, Mumbai, India during 29 to 31 October 2014

Conference Tracks

Case studies and Research Papers are invited under the following broad themes and areas.

1. Developments in Industrial Engineering Principles and Techniques

2. Challenges for Industrial Engineering Discipline and Profession in Emerging Economies

3. Role of Industrial Engineering in Technology Life Cycle

4. Industrial Engineering of Technical Processes

  Manufacturing Systems Industrial Engineering
  Material Handling Systems Industrial Engineering
Quality and Inspection Systems Industrial Engineering
Storage and Warehouse  Systems Industrial Engineering
Supply Chain Systems Industrial Engineering
Logistics Systems Industrial Engineering
  Information Systems Industrial Engineering
Lean Manufacturing Systems Industrial Engineering

5. Industrial Engineering of Business Processes

Marketing and Selling Processes  Industrial Engineering
Purchase Processes  Industrial Engineering
Accounting Processes  Industrial Engineering
Customer Service Processes  Industrial Engineering
Human Resource Recruitment  Process Industrial Engineering

6. Industrial Engineering of Managerial Processes

Manpower Planning
Inventory Control
Production Planning and Control
Project Planning and Control
Budgeting and Budgetary Control

7. Management of Industrial Engineering Studies and Projects

8. Total Industrial Engineering – Use of Industrial Engineering Methods and Techniques  by Managers, Engineers and Operators

9. Japanese Innovations in Industrial Engineering Theory and Practice

10. Design Phase Cost Reduction and Use of Industrial Engineering Techniques

Conference Website

Saturday, January 11, 2014

The Economics of Productivity - Bibliography

A BLS reader on productivity (Google eBook)
U.S. Department of Labor, Bureau of Labor Statistics, 01-Jun-1996 - Business & Economics - 202 pages
Free E-Book on Google Books - Has some cases or studies  on specific industries.
Only contents page

Productivity - Key concept in Economics

Journal of Productivity Analysis

Technological change, technical and allocative efficiency in chinese agriculture: The Case of Rice Production in Jiangsu, January 1999

Technical Efficiency Measurement by Data Envelopment Analysis: An Application in Transportation

X-inefficiency - Wikipedia entry

Productivity and IE in Cheese Manufacturing

Bosch and Mondelēz increase cheese line productivity
By Jenny EAGLE, 12-Sep-2013
Mondelēz International has partnered with Bosch Packaging Services to install five dosing units compatible with its existing four Bosch ML4 processing systems to produce and package cheese at its Namur factory in Belgium.

Automating processes in cheese manufacture can improve the productivity of the manufacturing plant to help meet increasing demand.

Productivity of industrial cheese making process, which is the mass of cheese extracted from unit volume of raw milk, is a key element in the profitability of this industry. This productivity depends, among other parameters, on the cutting time of the milk gel that is formed to produce cheese. The cutting allows the
whey to separate from the solid matter. The cutting step can happen at different moments depending on the kind of cheese under production. If the cutting is done too soon or too late, this will dramatically affect the productivity of the process and the quality of the final product. One of the challenges of the industry
is to standardize the cutting time in order to optimize productivity.

How to optimize the cutting time of milk gels?

Industrial Productivity in Processed Cheese

Productivity and IE in Chocolate and Confectionery Manufacturing

New Chocolate Molding Plant Increases Productivity, Decreases Downtime

Better, faster, longer lasting: Quality and productivity in confectionery production

Hershey Invests $300M To Modernize Chocolate Production

Productivity and IE in Sugar Manufacturing

A Study on Growth and Productivity of Indian Sugar Companies
, S.V.Revathi2
IOSR Journal of Business and Management (IOSR-JBM)
e-ISSN: 2278-487X, p-ISSN: 2319-7668. Volume 9, Issue 5 (Mar. - Apr. 2013), PP 01-10

Objectives Of The Study
1. To study the process of sugar industry.
2. To analyze the Growth and Trend of select sugar companies in India.
3. To study the productivity of select sugar companies in India.
4. To offer findings and suggestions for improving the sugar companies in India.

Thus the main objectives of the present study are:
1. To measure the rate of growth of TFP in Indian sugar industry for the pre (1982-1990) and post-reform (1991-1998)periods.
2. To measure the relative contribution of TFP in Indian sugar industry on value added for pre and post reform periods.
3. To measure the labor efficiency of Indian sugar industry.

Efficiency Dynamics of Sugar Industry of Pakistan

Sugar Technology Association of India
They organized a seminar on productivity in Feb 2013
Their Annual convention proceedings - 2012

Sometimes regulation decreases productivity. Example sugar industry in US

More interesting is the statement in the above article  that in US 90 percentile company has twice the productivity of 10 percentile company.
In India ratio is 7:1 and in China it is 5:1.

Productivity and IE in Breakfast Cereal Manufacturing

Improving Productivity in Canada’s Food Processing Sector through Greater Scale


Lombard provides £2m funding to boost productivity.
The investment in the new equipment cut  two days off the overall production process. ,
The increased automation of the plant has enabled Bokomo to reduce overheads by cutting down on agency manpower.

Increase in productivity of printing of packages in breakfast cereal mfg.

Wednesday, January 8, 2014

Six Sigma Articles, Books, Reports and Case Studies - Bibliography

Six Sigma For Quality and Productivity Promotion  

Asian Productivity Organization 2003
Author Sung H. Park Full book available for download

Six Sigma Process Improvements - 2005 report  

Six Sigma for the New Millennium: A CSSBB Guidebook

Kim H. Pries
ASQ Quality Press, 2009 -- 436 pages

"This book is designed to walk the reader through the ASQ Certified Six Sigma Black Belt (CSSBB) Body of Knowledge (BoK) at a medium level of detail. It follows the nine sections of the BoK exactly, from enterprise-wide deployment, organizational process management and measures, and team management, to detailed coverage of each stage of the DMAIC process. With more than 25 tables and 80 figures, the various concepts can not only be read about but "seen". The appendices include all the statistical tables that test-takers and also those in the field will need. New to this edition is material that shows the Black Belt candidate how to work through some standard statistical tests--just the kind he or she might expect to see on the certification exam."

Six Sigma

William T. Truscott, William Truscott
Routledge, 2003 -  250 pages

There are a number of distinctive features of this book that makes it different from other on Six Sigma.

It recognizes that there are two diametrically opposing views expressed on Six Sigma, those that are strongly in favour, and those that are not, for various reasons. The book deals, head on, with the principle reasons for such hostility. It cuts through the hype associated with the brand name. It proposes simple remedies for certain defined frailties in the standard approach, particularly those related to the Sigma Measure that provides the brand name for the Six Sigma breakthrough strategy.

The book is highly supportive of the Six Sigma continuous improvement process, provided it is tailored to the needs and expectations of a particular organization. The commitment and active participation of top management is emphasized, to ensure the necessary change in culture and priorities demanded, in most organizations.

Practical guidance is given in the setting up, operating and developing the project by project approach across an organisation. The book also covers how to equip a critical mass of members in an organization with the core workforce competencies required to get the desired results.

The book covers the realities of applying Six Sigma in a range of functions within an organization and also to various types of organizations from the manufacturing sector to commerce and public service. It demonstrates how statistical thinking, coupled with the application of technical and operational knowledge of processes and focus provided by Six Sigma, can considerably enhance quality, competitiveness, effectiveness and efficiency.

Statistical process control is a tool, which enables both manufacturers and suppliers to achieve control of product quality by means of the application of statistical methods in the controlling process. This book gives the foundations of good quality management and process control, including an explanation of what quality is, and control of conformance and consistency during production. The text offers clear guidance and help to those unfamiliar with either quality control or statistical applications and coves all the necessary theory and techniques in a practical and non-mathematical manner. This book will be essential reading for anyone wishing to understand or implement modern statistical process control techniques.

Leading Six Sigma: A Step-by-step Guide Based on Experience with GE and Other Six Sigma Companies

Ronald D. Snee, Roger Wesley Hoerl
FT Press, 2003 - Business & Economics - 279 pages

In Leading Six Sigma, two of the world's most experienced Six Sigma leaders offer a detailed, step-by-step strategy for leading Six Sigma initiatives in your company. Top Six Sigma consultant Dr. Ronald D. Snee and GE quality leader Dr. Roger W. Hoerl show how to deploy a Six Sigma plan that reflects your organization's unique needs and culture, while also leveraging key lessons learned by the world's most successful implementers. Snee and Hoerl share leadership techniques proven in companies both large and small, and in business functions ranging from R & D and manufacturing to finance. They also present a start-to-finish sample deployment plan encompassing strategy, goals, metrics, training, roles and responsibilities, reporting, rewards, and management review. Whether you're a CEO, line-of-business leader, or a project leader, Leading Six Sigma gives you the one thing other books on Six Sigma lack: a clear view from the top. * The right projects, the right people Identifying your company's most promising Six Sigma opportunities and leaders * How to hit the ground running Providing leadership, talent, and infrastructure for a successful launch * From launch to long-term success Implementing systems, processes, and budgets for ongoing Six Sigma projects * Getting the bottom-line results that matter most Measuring and maximizing the financial value of your Six Sigma initiative * Four detailed case studies: What works and what doesn't Avoiding the subtle mistakes that can make Six Sigma fall short. Proven techniques for leading successful quality initiatives. The Six Sigma guide designed specifically for business leaders Co-authored by Dr. Roger W. Hoerl, a leader in implementing Six Sigma at GE Draws on Six Sigma experiences at over 30 leading companies Covers the entire Six Sigma lifecycle, from planning onward Presents new solutions for overcoming the cultural resistance to Six Sigma initiatives Leading Six Sigma offers an insider's view of what it really takes to lead a successful Six Sigma initiative, drawing on the authors' experience at the top levels of the world's largest and most challenging organizations.Dr. Ronald D. Snee shares experiences drawn from executive-level consulting at over 30 major companies. Dr. Roger W. Hoerl teaches powerful lessons from his experience in pioneering Six Sigma throughout GE during the Jack Welch era. Together they offer unprecedented executive guidance on the issues most crucial to senior managers, covering every stage from planning through ongoingmanagement.Snee and Hoerl offer practical solutions for the cultural challenges and human resistance that face any executive seeking to initiate Six Sigma or improve an existing program. They even explain how and when to "wind down" initiatives, transitioning Six Sigma to a "fact of life" that doesn't require the support of a massive centralized infrastructure. " This is a truly insightful and well-researched book on Six Sigma by two of the leading experts in the field. Theirroadmap for successful deployment is supported by the experiences of major corporations, including GE and Honeywell. Itis extremely well presented in a step-by-step manner and backed up by real business-case examples.

Case Studies

Implementation of Six Sigma in a manufacturing process - 2009 case study

Six Sigma at GE

Six Sigma: Why GE do it
Steve Sargent - President and CEO - GE Australia & New Zealand
The Days at General Electric - Dr. Mikel Harry

Research Papers
Six Sigma: A Retrospective and Prospective Study
2009 POMS Conference paper

Motorola's second generation Six Sigma - 2002 article

Presentation on six sigma

Six Sigma - Originators - An article by Alan Ramias faculty at Motorola University in 1981