Thursday, April 29, 2021

Knowledge and Knowledge Management for Process Chart Based Industrial Engineering

 


Gilbreth - ASME Process Chart Activities


PROCESSING   -  INSPECTION  -  TRANSPORT  -  TEMPORARY DELAYS  -  STORAGE


The process chart based industrial engineering, that is industrial systems improvement starts with preparing the process chart. In a discrete manufacturing factory, manufacturing of each part is a process. The process starts with issuing the material from the raw material stores, moving it to the specified shop, keeping it in the shop inventory till it is loaded on a machine, inspecting it during processing or when processing is stopped. After the part is made, it is moved to the parts inspection station. It is inspected and sent to parts stores. There are transport activities between machine to machine.

Industrial systems engineering, that is design of the process also can use the same activities and develop processing, inspection, transport and storage elements. When we look at the steps in process chart today, we may think of including information activity also. It is based on a dispatching instruction, that activities are initiated. Also, there is provision of drawings, instruction sheets and oral communication from planners as well as shop supervisors. It is necessary to include information activities in the process chart.

Process chart based industrial engineering looks at the sequencing of various activities and examines the possibilities of rearranging them to increase productivity or to achieve good change. Once that exercise is done, the attention shifts to improving each activity or operation. The cost of each activity has to be reduced as part of industrial engineering study of the process. Hence industrial engineers need to be educated in each of the activities or operations and continuing education has to be there.

Operation improvement requires engineering and technology knowledge related to that operation.

Prof. Mikell Groover, Professor of Industrial Engineering, Lehigh University covered the technical details of each operation included in the process chart in more detail in his book, Automation, Production Systems, and Computer-Integrated Manufacturing, 5th edition.


                                                                        

Picture Source: https://engineering.lehigh.edu/ise/faculty/joint-emeriti-faculty

Professor Groover's book is a must reading for industrial engineers. It has to be further deepened by full books on manufacturing processes (authored by Groover himself), Inspection/metrology, mechanical handling and warehousing. The literature related to lean is the recommended reading for eliminating temporary delays.


Relevant Chapters from Automation, Production Systems, and Computer-Integrated Manufacturing, 5th edition.


                                                           


Source: https://www.pearson.com/store/p/automation-production-systems-and-computer-integrated-manufacturing/P100000251090/9780134605463?tab=table-of-contents

Processing - Manufacturing

PART IV MANUFACTURING SYSTEMS

Chapter 13 OVERVIEW OF MANUFACTURING SYSTEMS

13.1 Components of a Manufacturing System

13.2 Types of Manufacturing Systems

Chapter 14 SINGLE-STATION MANUFACTURING CELLS

14.1 Single-Station Manned Cells

14.2 Single-Station Automated Cells

14.3 Applications of Single-Station Cells

14.4 Analysis of Single-Station Cells

Chapter 15 MULTI-STATION MANUFACTURING SYSTEMS: MANUAL ASSEMBLY LINES

15.1 Fundamentals of Manual Assembly Lines

15.2 Analysis of Single-Model Assembly Lines

15.3 Line Balancing Algorithms

15.4 Workstation Details

15.5 Other Considerations in Assembly Line Design

15.6 Alternative Assembly Systems

Appendix 15A Batch-Model and Mixed-Model Lines

Chapter 16 MULTI-STATION MANUFACTURING SYSTEMS: AUTOMATED PRODUCTION LINES

16.1 Fundamentals of Automated Production Lines

16.2 Applications of Automated Production Lines

16.3 Analysis of Transfer Lines

Appendix 16A Transfer Lines with Internal Storage

Chapter 17 AUTOMATED ASSEMBLY SYSTEMS

17.1 Fundamentals of Automated Assembly Systems

17.2 Analysis of Automated Assembly Systems

Chapter 18 GROUP TECHNOLOGY AND CELLULAR MANUFACTURING

18.1 Part Families and Machine Groups

18.2 Cellular Manufacturing

18.3 Applications of Group Technology

18.4 Analysis of Cellular Manufacturing

Appendix 18A Opitz Parts Classification and Coding System

Chapter 19 MULTI-STATION MANUFACTURING SYSTEMS: AUTOMATED FOR FLEXIBILITY

19.1 Manufacturing Flexibility Defined

19.2 Components of an FM

19.3 Analysis of Flexible Manufacturing Systems

19.4 Alternative Approaches to Flexible Manufacturing


Inspection

Chapter 21 INSPECTION PRINCIPLES AND PRACTICES

21.1 Inspection Fundamentals

21.2 Sampling versus 100% Inspection

21.3 Automated Inspection

21.4 When and Where to Inspect

21.5 Analysis of Inspection Systems

Chapter 22 INSPECTION TECHNOLOGIES

22.1 Inspection Metrology

22.2 Conventional Measuring and Gaging Techniques

22.3 Coordinate Measuring Machines

22.4 Surface Measurement

22.5 Machine Vision

22.6 Other Optical Inspection Methods

22.7 Noncontact Nonoptical Inspection Techniques

Appendix 22A Geometric Feature Construction

For More Detailed Reading

BOSCH.A., Editor, Coordinate Measuring Machines and Systems, Marcel Dekker, Inc., New York, 1995.

BROWN & SHARPE, Handbook of Metrology,  North Kingston, Rhode Island. 1992.

 Transport

Chapter 10 MATERIAL TRANSPORT SYSTEMS

10.1 Overview of Material Handling

10.2 Material Transport Equipment

10.3 Analysis of Material Transport Systems


KULWIEC, R. A., Editor, Material Handling Handbook, 2nd Edition, John Wiley & Sons, Inc., NewYork,1985

MULCAHY, D. E., Materials Handling Handbook, McGraw-Hili, New York. 1999

TOMPKINS, J. A., J. A. WHITE. Y. A. BOZER, E. H. FRAZELLE, J. M. TANCHOCO, and J. Travino, Faciliiies Planning, Second Edition,John Wiley & Sons. Inc., New York, 1996.


Permanent Storage or Storage/Warehousing

Chapter 11 STORAGE SYSTEMS

11.1 Overview to Storage Systems

11.2 Conventional Storage Methods and Equipment

11.3 Automated Storage Systems

11.4 Analysis of Storage Systems

Chapter 12 AUTOMATIC IDENTIFICATION AND DATA CAPTURE

12.1 Overview of Automatic Identification Methods

12.2 Bar Code Technology


Material Handling Institute, AS/RS In the Automated Factory, Pittsburgh, Pennsylvania, 1983

Material Handling Institute, Consideration for Planning and installing an Automated Storage/Retrieval System, Pittsburgh, Pennsylvania, 1977


Temporary Delays - Analysis

Chapter 26 JUST-IN-TIME AND LEAN PRODUCTION

26.1 Lean Production and Waste in Manufacturing

26.2 Just-in-Time Production Systems

26.3 Autonomation

26.4 Worker Involvement


Knowledge Management

New engineering and technical developments in each operation are to be monitored, acquired and properly filed and indexed by the industrial engineering department. Digital databases can be created or acquired. Each new technical development must be assessed for its utility in the processes of the organization and remarks are to be written against each new technical development.

Suggestions of various persons in the organization regarding new or existing technologies are also to be recorded as part of the knowledge base.

Information regarding utilization of the new technology also has to be acquired and filed.

Industrial engineering department must invite all technology related vendor to come and make presentations to them.


Knowledge Management Tools

https://www.apo-tokyo.org/publications/ebooks/knowledge-management-tools-and-techniques-manual/

More detailed articles on the chapters of Prof. Groover's book will be posted in due course.


Knowledge Base for Process Productivity Improvement - News - Information for



Process Industrial Engineering - Course Lessons


Introduction to Process Industrial Engineering Module

News - Information for Value-Adding Operation Analysis
Flow Process Chart - Value-Adding Operation - Inspection - Transport - Temporary Delay - Storage - Information


45

IE Research by Taylor Part 1 - Productivity of Machining

News - Information for Inspection Operation Analysis


46

Part 2 - IE Research by Taylor - Productivity of Machining

News - Information for Material Handling and Transport Operation Analysis

47

Part 3 - IE Research by Taylor - Productivity of Machining.

News - Information for Analysis of Delays in Processes

48

Part 4 - IE Research by Taylor - Productivity of Machining
https://nraoiekc.blogspot.com/2020/07/part-4-ie-research-by-taylor.html

News - Information for Storage/Warehousing Operation Analysis
https://nraoiekc.blogspot.com/2020/07/news-information-for-storagewarehousing.html

49

Part 5 - IE Research by Taylor - Productivity of Machining
https://nraoiekc.blogspot.com/2020/07/part-5-ie-research-by-taylor.html

News - Information for Information Generation & Transmission - Operation Analysis
https://nraoiekc.blogspot.com/2020/07/news-information-for-information.html


Information on Metal Cutting Processes for Industrial Engineers


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Metal Cutting Processes - Industrial Engineering and Productivity Aspects
https://nraoiekc.blogspot.com/2020/07/metal-cutting-processes-industrial.html

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Machine Tools - Industrial Engineering and Productivity Aspects

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Machining Cutting Tools - Industrial Engineering and Productivity Aspects

53

Machine Tool Toolholders - Industrial Engineering and Productivity Aspects

54

Metal Cutting Temperatures - Industrial Engineering and Productivity Aspects

55

Machining Process Simulation - Industrial Engineering and Productivity Analysis

56

Cutting Tool Wear and Tool Life Analysis - Industrial Engineering and Productivity Aspects

57

Surface Finish - Industrial Engineering and Productivity Aspects

58

Work Material - Machinability - Industrial Engineering and Productivity Aspects

59

Machine Rigidity - Industrial Engineering and Productivity Aspects

60

Machining Time Reduction - Machining Cost Reduction - Industrial Engineering of Machining Operations

61

Machine Tool Cutting Fluids - Industrial Engineering and Productivity Aspects


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High Speed Machining - Industrial Engineering and Productivity Aspects

63

Design for Machining - Industrial Engineering and Productivity Aspects






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