Process Improvement - Productivity Analysis and Productivity Engineering.
Industrial engineer analyzes each process into its ultimate, simple elements, and compares each of these simplest steps or processes with an ideal or perfect condition and modifies the element appropriately. - F.W. Taylor - Hugo Diemer.
Prof. Hugo Diemer - Taylor's Industrial Engineering
https://nraoiekc.blogspot.com/2020/05/prof-hugo-diemer-taylors-industrial.html
Productivity Analysis - Comparison of Current Process to Ideal or the Best Process has to be done from System level up to Element level.
Operator Work Study - Machine Work Study - Interaction Study
In ILO Work Study Book, in page 349-350, it is written, "When seeking to improve the method the work study person follows two main approaches."
First, he or she tries to "push the handle down into the pump" — that is, to arrange for some of the manual elements which are being performed outside the machine-controlled time to be carried out as inside work, thus shortening the work cycle.
Second, close attention is given to "shrinking the pump" — making the machine-controlled time as short as possible by ensuring that the machine is being used to the best advantage, to the correct speeds and feeds, and using cutting tools which are correctly ground and made of the best type of cutting steel for the sort of work in hand, so that the machine-running time is minimum with the best conditions maintained always. (This is what Taylor said, favorable circumstances.)
The first one is interaction improvement. The second is machine work improvement. The third which is not mentioned in this paragraph is operator work improvement. All three need to be done to improve machine-man work systems.
Part of Main Topic: Analysis of Items in Operation Information Sheet
Productivity Analysis of Metal Cutting Parameters
Machining productivity improvement was started by F.W. Taylor with investigation into variables that allow maximum cutting speed to be used in turning and boring machines to remove material in less time and cost. From that time onward, it is an area with abundant research. Industrial engineers have to keep abreast of this productivity improvement research and adopt the best practice in their operation.
They need to develop the maximum speed, feed and depth of cut that can be utilized in similar operations and experiment with this values in their operation to see the feasibility. They can use six sigma or design of experiments approach to find the best combination of cutting parameters that give the maximum productivity. Each time the operation analysis, is attempted on metal cutting operations, analysis of cutting parameters is the final step that gives increased productivity and confirms the productivity improvement achieved by doing various changes in the different elements of the process.
Industrial engineers have to monitor developments into machinability research to know the maximum cutting speed, feed and depth of cut found feasible in laboratory conditions for each work material - tool material combination. I observe number of research papers on machining of hard materials in engineering journals. For materials in use for number of years, the number of research papers in any year may be less. But continuous monitoring of research papers and articles in production related magazines will bring out the highest values of cutting parameters. But to implement these parameters, supporting machine related capability, work holder capability and tool holder capability may be required. Industrial engineers have to calculated the required supporting parameters and experiment first to validate their feasibility in the facilities available in their plants and supply chain.
Optimization requires inputs of engineering parameters and engineers have to study current developments in engineers and upgrade their facilities before doing mathematical optimization. It does not mean that the benefit of mathematical optimization has to be delayed by a day. But mathematical optimization does not mean that the best system is in place. Unless the best engineering configuration is being used in the production system, the mathematical calculation gives only suboptimal solution.
The analysis has to compare the best possible cutting parameters with the currently used parameters to identify the productivity improvement opportunity.
(C) Narayana Rao K.V.S.S. 2020
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Productivity Science of Machining - Taylor to Current Times
Updated on 27.8.2023, 30 August 2022,
First published 15 September 2020
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