Monday, February 22, 2021

Ra to Rz - Industrial Engineers and Their Achievements - Productivity Improvement

 


Rahul Panchal 

Senior Process Engineer at Whirlpool Corporation

India


Experience

Whirlpool Corporation

Senior Process Engineer

Dates Employed: Since Jul 2019 

Education

Industrial Engineering

Vishwakarma Institute Of Technology

Graduation2016

https://www.linkedin.com/in/rahul-panchal-10103295/

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Aa to Az - Industrial Engineers and Their Achievements - Productivity Improvement

 

Alejandro Arroyo

Senior Industrial Engineer

Mexico 


Electrolux

Title: Senior Industrial Engineer

Dates Employed: From Sep 2017 

Location: Juarez, Chih. Mexico


Accountability of industrial engineering department in charge of three engineers, eight process technician and six welding technician.

Responsible of labor productivity, efficiency and utilization, budget, cost reduction projects and over time (KPI’s).

Head count calculation according to the customers demand to guarantee the safety, quality, cost and deliveries metrics.

Supporting the production lines where there are 600 direct labors and 4 lines call washer, dryer, fabrication and painting.

Following up and implementation of engineering change notice (ECN’s).

Working directly with maintenance, facilities, quality, materials, safety and production to solve problems in the production lines.

Equipment and machinery installation assistance and purchasing.

Knowledge and development of continuous improvement methodology and six sigma tools.


Industrial Engineer

Full-time

Dates Employed: Oct 2016 – Aug 2017

LocationJuarez Chihuahua Mexico

Support to the production line with 400 employees like an Industrial Engineer with two industrial technician and four welders in charge.

Responsible of the 3K metal cars and rack to maintenance in optimal condition to move the raw material.

Implemented & developed the lean manufacturing tools such as PDCA, 5 S’s, 7 wastes, standard work, visual factory, problem solving, 5D build in Quality, KPI’s, Data analysis, Line balance, SMED, PFEP, Process mapping, Leveling production system, KAIZEN workshop to continuously improve upon our own records.

Implemented & developed manufacturing tools such as time study, PFMEA, MOST, Poka yoke design, Flow Diagram, Ergonomic analysis, labor map, Poka Yokes design.

Production tooling purchasing order placing. Cost reduction projects leading. Pilot run & new models launch introduction.

Facility design as work station, static rack, dynamic rack, gravity conveyors, production lines, isolations areas and utility carts with Pipe Racking System.

https://www.linkedin.com/in/alejandro-arroyo-91b66256/

https://www.linkedin.com/in/mudassir-ali-57920217a/


https://www.linkedin.com/in/alan-reyes-869297163/


https://www.linkedin.com/in/amit-pangerkar-542b8810/


https://www.linkedin.com/in/avinash-gudmewar-1b97a596/

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Saturday, February 20, 2021

Drilling Machines - Specifications

 

AKN Hydraulic Automatic Deep Hole Drilling Machines

For mild steel or medium hard materials.

Brand AKN

Type of Drilling Machine Pillar

Motor HP 1-3 HP


Model H-90-150 H-70-150 H-60-150 H-50-100


Model                  H-50-100  

Max. Drilling Capacity Ø 10mm 

Spindle Travel  100mm

Spindle Speed (RPM)  3 speeds - 830.1670.2500 

https://www.aknindia.com/drilling-machines.html



Radial Drilling Machine - HMT

http://www.hmtmachinetools.com/product/108/radial-drilling-machine.htm


Specifications :

                      RM 62     RM 63         RM 65  

Drilling Capacity 


In Steel     mm                      dia 100 (At 60 rpm with 0.5 mm/rev.)

 


 In Cast Iron mm                dia.125 (at 60 rpm with 0.62 mm/rev)                              



Spindle speeds rpm 12:40-1800 32:10-1545

Spindle feeds no:mm/rev 6:0.125-1.25 18:0.075-4

Machine 1

http://www.hmtmachinetools.com/product/108/radial-drilling-machine.htm

Automatic drilling machine tool specifications

Description (All dimensions are in mm)

Model: P4/38

Drilling capacity in steel 38

Morse taper in spindle      4

Spindle traverse          178

Pillar diameter           139.7

Distance between center of spindle and column front 311

Maximum distance between spindle and Table 555

Maximum distance between spindle and base 1000

Table: Working surface 368 (Dia)

Base: Working surface 368*330

Number of spindle feeds 10

Number of power feeds 3

Range of feeds (mm/rev) 0.095, 0.190 and 0.285

Power of the spindle drive motor 2HP, 960 RPM, 400/440 volt A.C 3phase, 50 cycles

Space occupied (height*width*length) 2000*660*1110

Net weight of the machine 850 kg



Available spindle speeds

At MOTOR 720 RPM   MOTOR 1440 RPM

340                            680

245                            490

180                            360

125                            250

85                              170


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Machine Shop Cost Reduction News up to 2014 - Metal Working - Cost Reduction Opportunities

Machining Time Reduction - Productivity Improvement News


2014
Four Cost-Cutting Tips for CNC Machining
Daniel Clark
JUL 31, 2014
https://www.americanmachinist.com/shop-operations/article/21898592/four-costcutting-tips-for-cnc-machining


ORIGINAL ARTICLE
Published: 29 June 2014
Development of a smart machining system using self-optimizing control
Hong-Seok Park & Ngoc-Hien Tran 

2013

Productivity Technology in Metal Cutting - 2013

Manufacturing Systems Conference 2013 Papers - Bibliography

11. A study on the heating process for forging of an automotive
crankshaft in terms of energy efficiency
http://cms2013.ceni.pt/wp-content/uploads/2013/05/11_paper.pdf

42. An approach for a cloud-based machine tool control
http://cms2013.ceni.pt/wp-content/uploads/2013/05/42_paper.pdf

49. A Study of Automatic Determination of Cutting Conditions to
Minimize Machining Cost
http://cms2013.ceni.pt/wp-content/uploads/2013/05/49_paper.pdf

57. Beyond Lean and Six Sigma; Cross-Collaborative Improvement of  Tolerances and Process Variations - A Case Study
http://cms2013.ceni.pt/wp-content/uploads/2013/05/57_paper.pdf

62. Current State of Standardized Work in Automotive Industry in
Sweden
http://cms2013.ceni.pt/wp-content/uploads/2013/05/62_paper.pdf

64. Manufacturing of Twist-Free Surfaces by Hard Turning
http://cms2013.ceni.pt/wp-content/uploads/2013/05/64_paper.pdf


2012



30 November 2012
Complementarity and Cost Reduction - 1997 paper on Automobile Industry

Cost Effective Machining of Brass, Copper and Its Alloys

Cost Reduction of a Chassis and Cover by switching to Die Casting - Alexander Machine and Tool Company Cases - Cost reduction to $210 per piece frm $300

Emerging Titanium Cost Reduction Technologies

Impression Die Casting Projects - Cost Reduction Achievements - There is crank shaft case also.

Metal Injection Molding - Cost Reduction opportunities for small components with more than 10,000 parts per month and above

Ready for Six Sigma - 2006

Reduction in machining cost of crank shaft die by using a different tool

Setup Time Reduction in Machine Shop


Taking the pain out of  Machining ISO P25 Grade of Steel 
Multicapable insert tackles one of the toughest ISO classified turning areas.


JAN 26, 2006

2004
Richards Industries in Cincinnati, Ohio, - setup reduction
In January 2002, average setup time of CNC machines was 50 minutes. In two years, it was brought down to  average of 27 minutes.  The goal is 20 minutes, by the end of this year. The machine shop has  CNC lathes and mills, about 30 machines in all. In 2001, Richards Industries invited productivity consultants from TechSolve,  a Cincinnati-based firm to help them.
"setup reduction events" have four steps:

Document the current changeover.
Determine what setup steps can be done while the machine is still running.
Streamline setup steps that must be done while the machine is not running.
Put the basics in place for workplace organization and visual control.

The company set out to apply this process systematically, one machine at a time, starting with those machines that had the longest setups. Each "setup reduction event" took about a week. The first was held in February 2002.

As part of the exercise, an efficient workplace was created which has tools, parts etc. that are required in properly place positions so that there is no time waste in locating them.  

Shell Molding Process produces cost savings

Single piece design instead of 5 items - Forging

The Cost of Machine Tool Ownership

Tips on designing for cost effective machines parts

Use  Cold forming in place of machine - Reduce cost

Use continuous casting instead of machining

Use hard turning instead of grinding - Feb 2003


5-axis machining will reduce fixture costs and setup costs

Latest Trends in Machining - Full Book - Drishtikon Book


Machining cost reduction - Google Search Results

Operating A CNC Powered Machine Shop: Roadmap for Efficiency
http://home.earthlink.net/~cadcamcnc/data/Operating%20A%20CNC%20Powered%20Machine%20Shop.pdf


9/1/2001 
Boosting Multi-Spindle Productivity
Here's a look at some of the ways Delta Faucet is taking advantage of off-the-shelf technology to improve multi-spindle screw machining productivity.

















Updated on 19 August 2020
30 November 2012
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Friday, February 19, 2021

Drilling - Process and Machine - Evolution

Rotary cutting tool having PCD cutting tip

Abstract
A rotary cutting tool with an elongate body disposed about a longitudinal axis, the elongate body including a helical flute and a polycrystalline-diamond cutting tip. The cutting tip comprises an inner portion having an inner point angle and an outer portion having an outer point angle different from the inner point angle.
2019-06-25
Publication of US10328536B2
Inventor: L Karthik Sampath,  Armin Zimmerman, Steve George; Current Assignee: Kennametal Inc
https://patents.google.com/patent/US10328536B2/en

Deep hole drilling methods as well as tools for deep hole drilling machines

Abstract
The present invention relates to a deep hole drilling method for manufacturing a pipe having an inner profile having at least one recess spirally extending along the inside of the pipe, the deep hole drilling machine comprising: a basic body extending along a longitudinal axis And at least one cutting edge arranged on the outer periphery of the base body, wherein the tool is pulled through the interior of the pipe while the cutting edge is rotated around the longitudinal axis such that the cutting edge completes the cut along the spiral curry line on the inside of the pipe; Pushed.
2019-08-06
Publication of KR20190091438A
https://patents.google.com/patent/KR20190091438A/en


Drill head for a deep hole drilling tool for bta deep hole drilling, and deep hole drilling tool


A drill head (100) for a deep hole drilling tool for BTA / STS or ejector hole drilling, comprising a main body (101) of a drill head, a cutting edge (109), and guide pads (110, 111) (101) is rotatable about an axis of rotation (113) and has a hollow conduit (107) with a chip collection orifice (106) on the perforated side (160) and the perforated side (160) 109 are arranged on the upper side and have a ridge 114 of the main cutting edge and a ridge 115 of the minor cutting edge and the minor cutting edge is arranged on the outer side in the radial direction of the cutting edge,
2018-02-13
Publication of KR101829079B1
https://patents.google.com/patent/KR101829079B1/en


Drills: Science and Technology of Advanced Operations
Viktor P. Astakhov
CRC Press, 08-Apr-2014 - Science - 888 pages

In a presentation that balances theory and practice, Drills: Science and Technology of Advanced Operations details the basic concepts, terminology, and essentials of drilling. The book addresses important issues in drilling operations, and provides help with the design of such operations. It debunks many old notions and beliefs while introducing scientifically and technically sound concepts with detailed explanations.

The book presents a nine-step drilling tool failure analysis methodology that includes part autopsy and tool reconstruction procedure. A special feature of the book is the presentation of special mechanisms of carbide (e.g. cobalt leaching) and polycrystalline (PCD) tool wear and failure presented and correlated with the tool design, manufacturing, and implementation practice. The author also introduces the system approach to the design of the drilling system formulating the coherency law. Using this law as the guideline, he shows how to formulate the requirement to the components of such a system, pointing out that the drilling tool is the key component to be improved.

Teaching how to achieve this improvement, the book provides the comprehensive scientific and engineering foundations for drilling tool design, manufacturing, and applications of high-performance tools. It includes detailed explanations of the design features, tool manufacturing and implementation practices, metrology of drilling and drilling tools, and the tool failure analysis. It gives you the information needed for proper manufacturing and selection of a tool material for any given application.
https://books.google.co.in/books?id=3wwNAwAAQBAJ

Drills - Materials
https://books.google.co.in/books?id=3wwNAwAAQBAJ&pg=PA228#v=onepage&q&f=false



The invention also relates to a method of drilling composites by means of a ceramic drill bit of the type described above, in which method the drill bit has a peripheral cutting speed of between 600 and 1000 m/min.

Advantageously, the drill bit is advanced at between 0.05 and 0.20 mm/revolution.

Ceramic drill bit for high-speed drilling of composites


The ceramic drill bit has a particular geometry and is very advantageously applicable to the very high-speed drilling of parts made of a composite, especially a carbon-fiber composite having an epoxy resin matrix. The invention also relates to a method for the high-speed drilling of composites.

2009-01-29 Publication of US20090028654A1
2012-06-26 Application granted
2012-06-26 Publication of US8206067B2
Status Active
2031-04-26 Adjusted expiration
InventorL Claude Turrini; Current Assignee:  Safran Aircraft Engines SAS


6/15/1998 

The Fast Track To High Speed Drilling
Drill more productively by making a few strategic changes to the process. Those same changes may also let you drill dry.

Peter Zelinski, Editor-in-Chief, Modern Machine Shop


The Morse Twist Drill and Machine Co ...
[Catalogue]

Corporate Author: Morse Twist Drill & Machine Co., New Bedford, Mass.
Language(s): English
Published: New Bedford, 1912.
https://catalog.hathitrust.org/Record/100493266?type%5B%5D=title&lookfor%5B%5D=drilling%20machine&ft=

Modern drilling practice

A treatise on the use of various type of single- and multiple-spindle drilling machines, including their application to standard and special operations, the relation of speeds and feeds to intensive production, and the different types of tools and fixtures utilized in progressive machine shops for increasing the range and efficiency of machines of this class [by] Edward K. Hammond
Main Author: Hammond, Edward K., b. 1885.
Published: New York, The Industrial Press; [etc., etc.] 1919.
Edition: 1st ed.
https://babel.hathitrust.org/cgi/pt?id=uc2.ark:/13960/t06w97384&view=1up&seq=7


Suggested unit course in drill press work for beginners in machine shop practice ...
Corporate Author: New York (State).
Related Names: Witzel, Ewald L.
Language(s): English
Published: [Albany] : The University of the state of New York, the State education dept., Bureau of industrial and technical education, 1940.

https://catalog.hathitrust.org/Record/009211727?type%5B%5D=title&lookfor%5B%5D=drilling%20machine&ft=

Modern drilling practice, Hammond, Edward K

Published: New York, The Industrial Press; 1919.
Edition: 1st ed.
https://babel.hathitrust.org/cgi/pt?id=uc2.ark:/13960/t06w97384&view=1up&seq=7

Drilling machines which find the most general application in American manufacturing plants may be roughly divided into three general classes, as follows:
1. Vertical drilling machines. 2. Radial drilling machines. 3. Multiple-spindle drilling machines.

Each of these general classes is capable of further subdivision, so that drilling machines are finally classified under the following headings:

1. Vertical or " upright " drilling machines. 2. Vertical sensitive drilling machines. 3. Vertical high-duty drilling machines. 4. Radial drilling machines. 5. Multiple-spindle drilling machines of straight-line type. 6. Multiple-spindle drilling machines of cluster type. 7. Automatic drilling machines. 8. Turret-type drilling machines.

In addition to the eight preceding types of machines, a great deal of useful work is done by special machines built to meet the requirements of individual cases. Such machines are generally of the multiple-spindle type, but they are especially designed for specific classes of work.


Vertical or Upright Drilling Machines.


The vertical or up-right machine is the most commonly used type of " drill press " employed in the machine shop. It is usually equipped with power feed, and a tapping attachment is often provided, which may be engaged to provide for handling work in which holes have to be tapped. The term " sensitive " is applied to those types of light drilling machines which are equipped with hand feed, so that the opera tor is able to judge the amount of feed pressure with which the drill is being driven into the work. These machines are usually adapted for drills from the smallest sizes up to from f to J inch in diameter. They are used on a great variety of work, and for handling small parts in quick-acting jigs or fixtures they are capable of giving very satisfactory results. One advantage of the hand feed is that an experienced operator may use his judgment in releasing the feed pressure, if he finds that the drill has struck a hard spot in the work. This is the means of saving the breaking of drills. Machines of this type are now being built for operation at speeds which were unheard of a few years ago. For instance, some types of sensitive drilling machines are built for operation at speeds ranging from 10,000 to 15,000 revolutions per minute.

Vertical High-duty Drilling Machines.


As their name implies, high-duty drilling machines are adapted for the performance of heavy work, and they are commonly employed for using a range of drill sizes running from the maximum capacity of sensitive drilling machines up to the largest sizes in which drills are made. In addition to the performance of drilling operations, high-duty drilling machines are used for a great variety of other classes of work, including such operations as hollow-milling, spot-facing, facing, counterboring, threading, tapping, etc. In general, machines of this character may be employed to advantage wherever it is desired to use a rotating tool on stationary work under conditions where heavy cuts are to be taken. To meet the requirements of such severe service, the high-duty drilling machine is equipped with power-driven feed, and the rates of feed are commonly much greater than that employed on sensitive drilling machines, while the speed at which the drill is operated is correspondingly reduced, owing to the greater diameter of the drill. There are various forms of mechanisms used on these machines, but in all cases provision is made for obtaining any of a range of speed and feed changes suitable for the work on which the machine is engaged.


Radial Drilling Machines.


On the familiar type of radial drilling machine the spindle head is carried on an arm, which may be swung around the column of the machine, and the spindle head may also be moved back and forth along the arm. This combination of movements makes it possible to locate the spindle of a radial drilling machine at any desired point over work which comes within this range of movement. Radial drilling machines are commonly classified according to the length of arm, i.e., a 6-foot radial drill has an arm 6 feet in length. Sizes in which these machines are generally built run from about 2 to 6 feet. Obviously, the size of the work which can be handled with a machine of this type is governed by the length of arm and vertical adjustment of the arm on the machine column. Radial drilling machines are generally employed for handling those classes of work where there are a number of holes to be drilled and where the work is either too heavy or too large to be conveniently set up on multiple-spindle drilling machines.


Multiple-spindle Drilling Machines.


A great many parts that have to be drilled require holes of different diameters, and other operations, such as counterboring, reaming, or counter- sinking, are frequently necessary. When work of this class is done in a machine having one spindle, considerable time is wasted in removing one drill and replacing it with a different size or with some other kind of tool. For this reason, drilling machines having several spindles are often used when the work requires a number of successive operations. The advantage of the multiple spindle or " gang " type as applied to work of the class mentioned is that all the different tools necessary can be inserted in the various spindles, and the drilling is done by passing the work from one spindle to the next. Drilling machines of the multiple-spindle type are also commonly used for drilling a number of holes simultaneously. The arrangement of these machines is varied considerably to suit different kinds of work, but they may be divided into two general classes; namely, those having spindles which remain in the same plane but can be adjusted for varying the center-to- center distance, and those having spindles which can be grouped in a circular, square, or irregular formation. The first class referred to is used for drilling rows of bolt or rivet holes in steel plates, etc., and the second type is adapted to the drilling of cylinder flanges, valve flanges, or similar work.

CHAPTER IV

SPEEDS AND FEEDS FOR DRILLING


The proper speed at which a drilling operation should be performed is that speed at which the most desirable balance is obtained between cutting down of production through lowering the drilling speed and loss of time through the necessity of more frequently stopping the drilling machine to grind drills, where higher drilling speeds are employed. The following recommendations made by different authorities should prove of interest and practical value.

H. 'M. Norris, chief engineer of the Cindnnati-Bickf ord Tool Co.: occasionally a drill is found which is capable of standing up satisfactorily at a cutting speed of 150 feet per minute in either cast iron or steel, but it is seldom desirable to drive anything but very small drills at speeds in excess of 100 feet per minute. Under average conditions of operation, the best results will be obtained with a cutting speed of 80 feet per minute in cast iron, while, for steel, a speed of "7+76 feet per minute will give satisfactory results. Where this rule is used, the cutting speed will be decreased from 100 feet per minute for a |-inch drill to 80 feet per minute for a 3-inch drill. In explaining the rule, attention is called to the fact that, while cast iron is cut dry, a lubricant is required for drilling steel and a volume of lubricant sufficient to keep a J-inch drill cool at 100 feet per minute will only be sufficient to cool a 3-inch drill at 80 feet per minute.

Cleveland Twist Drill Co.:  It is well to start carbon steel twist drills under the following conditions of speed and feed until more definite data are available as to the maximum speed and feed which can properly be employed for the operation under consideration.

When drilling machine steel, use a peripheral speed of 30 feet per minute; for cast iron, use a speed of 35 feet per minute; and for brass, use a speed of 60 feet per minute. In each case, a feed of from 0.004 to 0.007 inch per revolution should be employed for drills up to i inch in diameter, while for larger sizes the feed should be from 0.005 ^^ ^-^^ 5 ^^^ P^^ revolution. In the case of high-speed steel drills, the preceding rates of speed should be increased from 100 to 125 per cent, while the same rates of feed are employed.

The Standard Tool Co. recommends starting high-speed steel drills at a peripheral speed of from 50 to 70 feet per minute for wrought iron or steel, and from 60 to 80 feet per minute for cast iron, or at 140 feet per minute for brass. The feeds recommended are 0.004 i^ch per revolution for a y^5-inch drill in wrought iron or steel, 0.005 inch per revolution for a J-inch drill, 0.008 inch per revolution for a ^-inch drill, o.oio inch per revolution for a i-inch drill, and 0.015 i^ch per revolution for a i^-inch drill.

Starting with any of the preceding speeds and feeds which have been recommended by different authorities, the operator carefully notes the condition of the drill after it has been working for some time. If the drill shows a tendency to wear away on the outside, it is running too fast, while if it breaks or chips on the cutting edges, the feed is probably too heavy for the work required. A little careful experimenting in this way, making changes gradually according to indications which are shown after working for some time, will usually result in securing a combination of speed and feed which will be the means of obtaining something approaching the maximum possible production.  It will, of course, be obvious that, to obtain a given peripheral cutting speed, the number of revolutions per minute must differ according to the size of the drill which is being used. This is the reason for running very small drills at extremely high speeds in order to have them working under conditions which approximate the required cutting speed for the material that is being machined. For the convenience of users of twist drills and other rotary cutting tools, tables are available which show the number of revolutions per minute at which a given size of drill should be run in order to obtain the required cutting speed. In Tables 1 and 2 the diameters of drills are given in the left-hand column, while peripheral cutting speeds in feet per minute are noted at the top of the table. By finding the intersection of horizontal and vertical lines through the given drill diameter and the required cutting speed, the number of revolutions per minute at which the drill must be run in order to obtain this speed will be found. Table 3 gives the decimal equivalents of nominal sizes of drills, and will be found useful when calculating the peripheral cutting speed of drills of various sizes; this table also shows the relation of the different sizes of drills, which are designated by letters and numbers, as compared to the fractional sized drills.

Critical Drilling Speeds. — In experimenting to determine the number of revolutions per minute at which a drill will have the greatest productive capacity, some interesting results are secured. Researches which were made at the plant of Baker Bros., with the view of securing data required in connection  with the design of their drilling machines, showed that there are certain critical speeds at which a twist drill will have a satisfactory rate of production, while there are other speeds — often lying between two rates of speed where the production is satisfactory — at which the drill will fail to give anything approaching satisfactory results. This condition is clearly shown by Fig. 3, which is plotted with data taken from original tests. These investigations were made several years ago, so that, while the condition shown by this set of curves is an established fact, the rates of speed and feed are lower than would be used in conducting similar tests at the present time. The point brought out by this diagram is the remarkable increase in production which can be secured by increasing the speed. The curves are plotted for the maximum feed at which the stock was successfully drilled without destroying the drill; at the next higher feed the drill would be destroyed. Curve No. 2 shows that the drill would give a far greater production without failing at 2CX) revolutions per minute than it would at 250 revolutions per minute, and also that it would give a much greater production if the speed were still further increased to 4cx) revolutions per minute.

Recently a well-known manufacturing establishment had an investigating committee working for over two years on the development of a table of speeds and feeds for use in connection with different sizes of drills working in various materials. The result of this investigation is presented in Tables 4 and 5, and although it is not claimed that the data presented can be followed without modification, it is claimed that the thousands of tests which were made during the period over which these data were secured have led to results which may safely be regarded as an average maximum of the rate of speed and feed under which a drilling machine may be operated. These tables are copyrighted by the Henry & Wright Mfg. Co., and the tests were made on a special drilling machine built by this company.


In starting to work on a new job the operator of the drilling machine will use the speed and feed shown in these tables, but should he find that the drill shows a tendency to wear around its periphery or that there is a considerable amount of chipping along the cutting edges of the drill, it indicates that the speed or feed is too heavy, and so the required adjustment of operating conditions must be made. In the plant where these data were obtained, the investigating committee reported that the installation of machines capable of operating under these conditions of speed and feed would represent a saving of $30,000 a year. The speeds recommended are rather high, and if twist drills are unable to stand them, the drill manufacturers should be notified, as it is claimed that any responsible maker can furnish suitable drills for use under these conditions if he is required to do so. The speeds are also too high for machines equipped with plain bearings, but properly constructed machines with ball bearings will easily stand up under such conditions of operations.

The best advice which can be given to the man who is trying to improve conditions in his drilling department is to adopt the method of experimenting with trial speeds and feeds — adopting those trial speeds and feeds recommended in the preceding discussion — until he has found the conditions
of speed and feed which give the most satisfactory results on his work.

High Speeds of Modem Drilling Machines. — Machine tool builders are now making drilling machines fully equipped with ball bearings so that they are adapted for operation at speeds which would have been utterly impossible of attainment a few years ago. For instance, the Leland-Gifford Co. builds a ma-
chine which is adapted for operation at speeds of from 11,000 to 15,000 revolutions per minute, and the same speeds are recommended for use on a bench drilling machine recently brought out by the Fenn Mfg. Co. Other machinery builders are making high-speed drilling machines. Driving twist drills at such
speeds means that the drilling operation is practically instantaneous; in fact, the speed at which holes may be drilled is often equal, if not in excess, of the speed at which the same work could be done on a power press. It is this constant increase in the speed of drilling, with the constant reduction of the ratio between " drilling time " and " setting-up time," which has emphasized the fact that, in order to approach the maximum rate of production, the user of high-speed drilling machines must design his work-holding fixtures in such a way that work may either be set up in indexing fixtures while the drilling operation is being performed, or, if this is not feasible, the clamping devices on fixtures must be so made that a minimum amount of time is consumed in securing the work in place ready to be drilled.

Several important advantages are secured through drilling at high speed, and this is particularly the case with small sized drills, which are likely to break, and also with high-speed steel drills. The reasons for this are as follows: In the case of small drills operated in sensitive drilling machines equipped with hand feed, running the drill at high speed makes it improbable that the operator will impose an excessive feed on the drill, because, in the case of a drill which is running at from 10,000 to 15,000 revolutions per minute, it would be necessary to pull the feed-lever down extremely fast in order that the feed for any one revolution of the drill would be sufficient to impose a stress in the steel which would be in excess of the maximum that the strength of the drill is capable of withstanding. A further explanation for the increased strength of a drill when running at high speed is that where an excessive amount of feed pressure tends to bend the drill slightly when running at high speed, the length of time that any set of fibers in the drill is subjected to stress is so short that the danger of breaking may be less than if the load remains on such fibers for a greater length of time. This is, of course, an unsettled question and is advanced in the form of a hypothesis rather than a statement of fact; in V any case, the question is an interesting one.

A series of tests was conducted on this machine by Paul Bedell Starr and John Millard Marsh to secure data for a thesis presented at the time these men took the degree of Bachelor of Science in mechanical engineering at the Case School of Applied Science. The object of this investigation was principally to determine the feed pressure required to drive different sizes of drills under various conditions of speed and feed. That very little reliable data were available on this subject was shown by the fact that, when the special drilling machine was first built by a firm of wide experience in the design and construction of equipment of this type, a pressure gage reading up to 3000 pounds was provided. At the first test, using a i-inch drill at a normal rate of feed, the range of this gage was shown to be entirely inadequate; therefore, a gage reading up to 15 tons was substituted, which proved suitable for the service required of it, this difference in gages showing conclusively that the knowledge concerning the magnitude of feed pressures was not at all definite.

Coolants and Lubricants used for Drilling. — For drilling operations, satisfactory results can usually be obtained through the use of one of the soluble oil coolants, for all classes of work where the length of chips produced is not very great; but in cases where long chips are formed, there is a rubbing action produced by the chips sliding over the lips of the drill, which produces a condition analogous to that of a machine bearing, thus making it necessary to apply a fluid which serves the combined purpose of lubricant and coolant. The following is an outline of lubricants and coolants recommended for drilling operations in various classes of material, and the lubricants used are recommended in the order in which they are named. In this list " cutting compound '' refers to any satisfactory brand of soluble oil mixed with water, in accordance with the manufacturer's instructions; and " mineral lard oil " is a mixture of lard oil and light petroleum oil. The proportions of this mixture vary according to the work, but one part of lard oil to two parts of petroleum gives a mixture that is well suited to the requirements of many average drilling operations. For drilling high-carbon or alloy steel, use mineral lard oil or turpentine; low-carbon steel, mineral lard oil or cutting compound; cast iron, dry or compressed air; wrought iron, cutting compound or mineral lard oil; malleable iron, cutting compound; brass, dry; bronze, cutting compound or dry; copper, mineral lard oil; aluminum, kerosene, beeswax, or tallow; monel metal, cutting compound; and glass, solution of camphor in turpentine.


Updated  19 Feb 2021
Published on 27 April 2020






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Resource Efficiency Industrial Engineering

 "Industrial Engineering is System Efficiency Engineering." - Narayana Rao

Industrial Engineering  = Engineering + Productivity Orientation (Productivity Science + Productivity Engineering + Productivity Management )


Who said it? First F.W. Taylor in his paper on Piece Rate System. It specifically mentions that the new system will increase productivity. What is the new system? Study of each element of the machine - man system with respect to time. How to reduce cutting time of machine tools? How to reduce manual or human effort time?

Reduce the time taken by technology or capital resources and human resources in industrial systems is the primary task of industrial engineering. It is engineering done with cost, time and productivity as measures of achievement or effectiveness.

The present environmental concern brought the issue of resource efficiency to the forefront. There is a demand for industrial engineering.



Integrated evaluation of resource efficiency and cost effectiveness in production systems


Michael Lieder

Licentiate thesis

KTH Royal Institute of Technology 

School of Industrial Engineering and Management 

Department of Production Engineering

Stockholm 2014

https://www.diva-portal.org/smash/get/diva2:712671/FULLTEXT01.pdf


On a global level multinational companies have launched numerous programs to improve their production systems and increase productivity (Netland, 2012).

The number of SMEs (1-250 employees) stands for 99% of all companies in Europe (European Commission, 2013)

Particularly when it comes to operational resources there is a lack of methods which enable accessing resource savings in a comprehensive way (Steinhilper, et al., 2011) leaving potentials for superior competitiveness untouched.

This research was partly originated from a European research project called ‘Methods for Efficiency - M4E’. The project has been initiated in order to develop a comprehensive concept to detect and tackle 
resource losses particularly in SMEs (Univerity of Bayreuth, u.d.).

Together with the University of Bayreuth, the Fraunhofer IPA and nine industrial partners the Department of Production Engineering at KTH developed a supporting tool for the consistent assessment of resource efficiency for SMEs (Lieder, 2011).  

Production systems can be described as people, equipment and procedures organized for the combination of materials and processes that constitutes the manufacturing operation (Groover, 2008).

Production system is a group of technical production facilities linked with each other for a certain type of production, which includes the existing reactions between them (International Institution for 
Production Engineering Research, 2004).

Synergetic behavior resulting from relationships between system parts is a significant characteristic.

Human and technical system together with energy and product material represent operational resources  in production systems.

The word resource has its origin in the French language and means “something that is a source of help” or “a means of supplying a deficiency or need” (Oxford University Press, 2013).

The term resource has perspectives as available money for operations in companies including patents, contracts or privileges (International Institution for Production Engineering Research, 2004),  as human and physical resources (Bernolak, 1997) and assets, humans, material, energy, equipment, 
machines, information, knowledge (Westkämper, 2006).

In this research work,  resources investigated are  labor from human and automated systems, energy, direct material for products, indirect material and handling of direct material during operation phases in production systems. (Handling is mentioned. Inspection also might have been mentioned).

I agree with this interpretation given in the thesis.

Effectiveness is mainly connected to an output oriented perspective and the creation of customer value of a transformation process.

Effectiveness is the first objective of systems design.

Efficiency is  associated with the utilization of resources to create effectiveness and a rather input oriented perspective of a transformation process. 

Green manufacturing is defined as “the creation of manufacturing products that use materials and processes that minimize negative environmental impacts, conserve energy and natural resources, are safe for employees, communities, and customers and are economically sound” and is labeled as first steps towards sustainability (Dornfeld, 2010).

Four levels of production system - single work unit, production lines, production plant and the natural environment. 

A single work station may for instance consist of an assembly station or a CNC machine.

Seeing time as a resource, the efficiency of equipment and manual operations can be evaluated by the time for which resources were used during the value added time. The idle time of material is measured by the inventory time in the process. (content in italics added by me)

Doctoral thesis

From resource efficiency to resource conservation Studies, developments and recommendations for industrial implementation of circular manufacturing systems

Michael Lieder

Doctoral thesis

KTH Royal Institute of Technology

School of Industrial Engineering and Management

Department of Production Engineering

Stockholm 2017

https://www.diva-portal.org/smash/get/diva2:1135859/FULLTEXT01.pdf












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Deep Hole Drilling - Technology and Productivity News and Developments

https://www.ctemag.com/   



Drilling - Process and Machine - Evolution

2011 - 2020 Drilling Operation Elements - News and Information for Industrial Engineering

2000-2010 Drilling Operation Elements - News and Information for Industrial Engineering

1991-2000 Drilling Operation Elements - News and Information for Industrial Engineering




Automotive components requiring deep hole drilling: 

Rackbars, Pinion Shafts, Cylinder Head, Engine Blocks, Valve Guides, Transmission Shafts, Connecting Rod, Input Shaft, Output Shaft, Gear Shaft, Camshaft, Crankshaft, Rocker Arm Shaft, Crank Case, Shock Absorbers, Piston Pin, Pump Barrel, Common Rail, and Nozzle.


Automotive deep hole applications - Available Solutions

Cam Shaft Deep Hole Drilling Solution

Engine Connection Rod Deep Hole Drilling Solution

Engine Valve Deep Hole Drilling Solution

Engine Valve Guide Drilling Solutions - Valve Guide Gundrilling

Fuel Injection Parts Deep Hole Drilling Machine

Gear Shaft Deep Hole Drilling Solutions

Oil pump injectors gun drilling machine

https://www.deepholemachines.com/special-purpose-deephole-machines/automotive-deep-hole-applications

______________________

https://www.youtube.com/watch?v=sN3F6W3J5Uc

_____________________


Deep hole drilling  - Fundamentals

_____________________


https://www.youtube.com/watch?v=1FmNqL_0dOE

_____________________

2021

https://www.americanmachinist.com/machining-cutting/media-gallery/21153554/customized-deephole-drilling-suhner-industrial-products

Search deep hole drilling - Interesting results


Widia TDMX indexable insert drilling line has been extended.

Deep hole drilling line extended

05.01.2021

1.5XD and 12XD drill bodies got added to the existing 3XD, 5XD and 8XD. 

The new 1.5XD addition will enhance the productivity, rigidity and stability when drilling shallow holes whereas the 12XD range will enable manufacturers to enjoy the benefit deep hole drilling. The TDMX drill body incorporates polished flutes, through coolant channels and margin lands on the entire body length to ensure straightness and increased hole quality.

2020

Going deep and cellular

Published December 8, 2020 

Deep-hole drilling systems, which can produce holes that exceed a 20-1 depth-to-diameter ratio, are a unique class of manufacturing equipment.

Unisig a multiple-spindle machine, the UNI25HD. It had the power and controls necessary to apply indexable gundrilling tools, significantly improving feed rates.

https://www.ctemag.com/news/articles/going-deep-and-cellular


BTA deep hole drilling machine

Patent
Publication of JP6746311B2: 2020-08-26

Drilling system and methods for deep hole drilling

Abstract

A deep hole drilling system and methods provide stability and cutting performance to produce deep holes having desired straightness. The system may include a replaceable cutting head provided with a center cutting member and first and second side cutting inserts. The tool provides a major diameter with the OD cutting margins on the replaceable side inserts, as well as possibly cutting margins on the center cutting member. Adjustment mechanisms are provided to adjust the center cutting member and/side cutting inserts.

2020-02-25: Publication of US10569347B2

Inventor: L Paul, W. Best, Salvatore D. Deluca, Lucas S. Dummermuth, David J. Carlisle, Current AssigneeL Allied Machine and Engineering Corp

https://patents.google.com/patent/US10569347B2/en



2018


Selection Of Deep Hole Drilling Parameters Under Cycle Time Requirement Based On Tool Wear Analysis And Life Estimation

Cong Liao, Haiyan Henry Zhang, and Yueen Li

Journal of Multidisciplinary Engineering Science and Technology (JMEST)

Vol. 5 Issue 10, October - 2018


Deep hole drilling process  investigated

9.9 mm diameter and 202 mm depth (the L/D ratio is more than 20). The tool is solid carbide twist drill bit coated with TiCrN and the workpiece is SAE1045.

Cutting parameters and conditions: 

SFM – 262(2570rpm), feed – 0.23mm/rev, 

coolant pressure – 725 psi, coolant concentration – 6~8%. 

Observed that the severe tool wear occurred at the periphery of the cutting edge in the early stage of  usage under the cutting condition of depth of 202 mm, diameter of 9.9mm, speed of 2570 rpm, and feed of 0.23 mm/rev. The surface speed at the outer spot of the cutting edge is estimated of 79.9 m/min.

Experiments reported

V (m/min)           f (mm/rev)                        tcycle (min) 

79.9                           0.23                              0.3149 

65.3                           0.27                              0.3563 

65.3                           0.225                            0.4276 

The paper gives the formula for calculating drilling time.

It also gives tool life formula for deep hole drilling in terms of cutting speed, feed and hole length.

2017

https://www.fabricatingandmetalworking.com/2017/12/deep-hole-drilling-of-diesel-engine-components-transmission-shafts-and-more/

2015

https://www.americanmachinist.com/machining-cutting/article/21898952/seven-axes-one-setup-for-deephole-drilling

https://www.americanmachinist.com/machining-cutting/media-gallery/21898953/automated-deephole-drilling-for-custom-shaft-production

2014


Going deep with holemaking

Christopher Tate

Published October 1, 2014


Uniform nomenclature for long/deep drills. Drill length is specified as a function of the diameter, it is common to see the drill length called out as 15D, 20D and so on. For example, 20D means the drill can produce a hole 20 diameters deep. Therefore, a ½ "-dia., 20D drill can produce a 10 "-deep hole.

2013

Effective Parameters For Improving Deep Hole Drilling Process By Conventional Method - A Review

L. Francis Xavier and D. Elangovan 


2008

Water-Cooled VW Performance Handbook: 3rd edition


Greg Raven, Chad Erickson

Motorbooks, 15-May-2011 - Transportation - 208 pages


Turn your VW into a high-performance machine. Chad Erickson explains everything from low-buck bolt-ons to CNC-machined mods. Learn how to choose, install, tune, and maintain performance equipment for Golfs, GTIs, Jettas, Passats, and more. This book will help improve your VW’s engine, transmission and clutch, ignition, carburetion/fuel injection, suspension and handling, brakes, body, and chassis. In its 3rd edition, Water-Cooled VW Performance Handbook is now updated to include new engines, body styles, and modifications for the 1986–2008 model years.

1999

Process for drilling oil-holes in crankshafts

Abstract

A process for drilling oil holes in a crankshaft at various positions lengthwise and widthwise about a longitudinal axis of the crankshaft, where the oil holes are perpendicular to and have angled directions with regards to the longitudinal axis. The process includes the sequential steps of placing the crankshaft in a horizontal position in a crankshaft holding unit and maintaining the crankshaft in a horizontal position through the drilling process. The holding unit is then rotated on a vertical axis until the crankshaft faces the drilling unit. The crankshaft is next rotated along the longitudinal axis of the crankshaft to position the crankshaft in a position for drilling a hole. The drill tool is then moved on a second and third axis until the drill tool is situated in order to drill the hole in the crankshaft.

Application US09/756,669 events 

1999-04-19

Priority to ES9900797

2002-11-26

Publication of US6485401B2

2019-07-23

Anticipated expiration

Status

Expired - Fee Related

https://patents.google.com/patent/US6485401B2/en


Updated 19 Feb 2021

Published on 15 Feb 2021



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Wednesday, February 17, 2021

Kubernetes - Cloud Computing - Cost Reduction and Cost Control

 

12 Feb 2021

Tame Kubernetes Costs with Percona Monitoring and Management and Prometheus Operator


More and more companies are adopting Kubernetes for cost benefit. But after some time they see an unexpected growth around cloud costs. Auto-scalers are set up, but the cloud bill is still growing.  Percona Monitoring and Management (PMM) can help you with monitoring Kubernetes and reducing the costs of the infrastructure.

https://www.percona.com/blog/2021/02/12/tame-kubernetes-costs-with-percona-monitoring-and-management-and-prometheus-operator











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Tuesday, February 16, 2021

Manufacturing Systems Design - Manufacturing Systems Engineering

 


Manufacturing systems engineering

Definition

Manufacturing systems engineering is the design and operation of factories. 

Product realisation process  is an integrated, iterative process that starts with the design of the product. The next step is the design of the process by which the product is made.

The design of the manufacturing system consists of three steps: the choice of the structure of the factory (the system architecture), the selection of the machines, and the design of the spaces to hold work-in-process inventory. 

The operating policy – the process by which decisions are made in the course of production – is chosen next. 

The factory design is evaluated. It can be done by simulation, by computation based on analytical methods, or by the experience of the designers. 

If the performance is predicted to be satisfactory, the design is accepted and the factory is built (or an existing factory is rebuilt). If not, the process is iterated starting at the required stage until the predicted performance is satisfactory.

The future of manufacturing systems engineering

Stanley B. Gershwin

International Journal of Production Research, 2018

Vol. 56, Nos. 1–2, 224–237, 



Design and Analysis of Integrated Manufacturing Systems

https://www.nap.edu/download/1100



Analysis and Modeling of Manufacturing Systems

Stanley B. Gershwin, Yves Dallery, Chrissoleon T. Papadopoulos, J. MacGregor Smith

Springer Science & Business Media, 06-Dec-2012 - Business & Economics - 429 pages

Analysis and Modeling of Manufacturing Systems is a set of papers on some of the newest research and applications of mathematical and computational techniques to manufacturing systems and supply chains. These papers deal with fundamental questions (how to predict factory performance: how to operate production systems) and explicitly treat the stochastic nature of failures, operation times, demand, and other important events.

Analysis and Modeling of Manufacturing Systems will be of interest to readers with a strong background in operations research, including researchers and mathematically sophisticated practitioners.

https://books.google.co.in/books?id=kZ7aBwAAQBAJ

Production Systems Engineering


Main Areas of Manufacturing

The informal definitions and classifications given below are subjective and based solely on the authors' experience and  understanding.

Manufacturing – the process of transforming raw materials into a useful product. Everything, which is done at or for the factory floor operations, we view as manufacturing.

Manufacturing matters. The wealth of a nation can be either taken from the ground (natural resources and agriculture) or manufactured (value added by processing materials). Thus, being one of just two ways of generating national wealth, manufacturing is of fundamental importance.

Manufacturing can be classified into two groups: continuous and discrete.

Quite informally, manufacturing can be classified into the following five areas:

Machine tools and material handling devices. The main problem here is: Given a desired material transformation and/or relocation, design, implement, and maintain a machine or a material handling device, which carries out its function in an efficient manner. This is a mature engineering field with numerous achievements to its credit.

Production systems. Main problem: Given machines and material handling devices, structure a production system so that it operates as efficiently as the machines in isolation. This can be achieved by maintaining smooth flow of parts throughout the system, so that mutual interference of the machines does not cause losses of production. The term "structure" is used here to include both design of new and improvement of existing production systems. To-date, this field lacks in rigorous quantitative methods and fundamental engineering knowledge.

Production planning and scheduling. Main problem: Given a production system and customer demand, calculate a production plan and schedule delivery of materials so that the demand is satisfied in an economically efficient manner. Numerous quantitative methods, often based on optimization, are available in this relatively mature field of manufacturing.

Quality assurance. Main problem: Structure and operate the production system so that parts produced are of the desired quality. To-date, statistical quality control is a major quantitative tool for maintaining product quality.

Work systems. Main problem: Organize personnel training and operation so that the production process is carried out safely and efficiently. This includes, in particular, designing wage and incentive systems so that the maximum of the utility function of an individual worker coincides with that of the manufacturing enterprise as a whole and, thus, self-interest of the worker leads to high efficiency of the manufacturing enterprise. At present, this field is still in its infancy.

In addition to the above classification, discrete part manufacturing can be subdivided into two groups: job-shop and large volume manufacturing. Job-shop is concerned with manufacturing "one-of-a-kind" products: unique instruments, highly specialized equipment, some aerospace systems, etc. Large volume manufacturing is intended to produce parts and products in multiple copies: cars, computers, refrigerators, and other items of wide use.

This textbook is devoted to one area of manufacturing production systems, although some structural issues of quality assurance are also addressed. While some methods included here might be useful for job-shops as well, the emphasis is on production systems in large volume manufacturing.



http://www.productionsystemsengineering.com/Booktoc_pseaa.html

Sample chapters
http://www.productionsystemsengineering.com/Booksamples_pseaa.html

For Industrial Audience
http://www.productionsystemsengineering.com/home_pseia.html


PSE IA Textbook Preface

Managers of production systems are well aware that to ensure high productivity they must:

Identify, protect, and improve bottlenecks;
Ensure leanness of work-in-process, raw materials, and finished goods inventory;
Guarantee desired level of customer demand satisfaction in quantity and quality of products shipped.

This book provides a simple and practical answer to this question and to offers software that facilitates applications. Methods described here use traditional terms, such as “bottleneck”, “leanness”, “continuous improvement”, etc., but infuse them with rigorous engineering knowledge and, thereby, offer a possibility of designing and operating production systems with the highest efficiency and guaranteed performance. 

These methods are based on fundamental laws that have been discovered in the emerging field of Production Systems Engineering (PSE) and summarized, along with numerous industrial case studies, in our university-level textbook: J. Li and S.M. Meerkov, Production Systems Engineering, Springer, 2009 (below, we refer to this book as PSE, Springer, 2009). The goal of the current volume is to present these laws and methods in a format suitable for an industrial audience – without lengthy mathematical derivations but with logical justifications and emphasis on applications. That is why we use the title Production Systems Engineering for Factory Floor Management (PSE FFM) and view this volume as an industrial textbook. It can be used for either self-study or as a text for an industrial short course (2-3 days) on production systems management. 

The target audience includes plant, shop, and department managers; production supervisors; industrial, manufacturing, production, and quality engineers; production system designers; and supply chain specialists.  As far as prerequisites are concerned, we believe that high school algebra and elementary statistics are sufficient to learn the techniques described here; an engineering degree would be helpful but not mandatory.

You will learn from this volume answers to  the questions listed below. 


Question 1: In a serial production line with identical machines and identical buffers, which machine is the bottleneck? If the machines are not identical, is the worst machine necessarily the bottleneck?

Question 2: To maximize production system’s throughput, would you prefer machines with long or short up- and downtime, provided that their stand-alone throughput remains the same?

Question 3: To maximize the throughput, would you allocate work so that buffers are full, or empty, or neither? In the latter case, which buffer occupancy indicates that work is allocated optimally? Similarly, which buffer occupancy indicates the best buffer capacity allocation?

Question 4: How would you select lean buffering for a production system? For example, are buffers of capacity 1000 parts lean? How about a buffer of capacity 10?

Question 5: In a production system with parts transported on carriers, how would you select the number of carriers so that throughput is maximized?

Some of these questions can be answered without any measurements or calculations – just based on fundamental laws that govern production systems, such as laws of reversibility, monotonicity, and improvability. Others require measurements, typically, machines’ up- and downtime, or blockages and starvations, or buffers’ occupancy. Still others are based on both measurements and calculations.
http://www.productionsystemsengineering.com/Booksamples_pseia.html


Manufacturing Systems Engineering: A Unified Approach to Manufacturing Technology, Production Management and Industrial Economics

Katsundo Hitomi
Routledge, 19-Oct-2017 - Technology & Engineering - 560 pages

This second edition of the classic textbook has been written to provide a completely up-to-date text for students of mechanical, industrial, manufacturing and production engineering, and is an indispensable reference for professional industrial engineers and managers.
In his outstanding book, Professor Katsundo Hitomi integrates three key themes into the text:
* manufacturing technology
* production management
* industrial economics

Manufacturing technology is concerned with the flow of materials from the acquisition of raw materials, through conversion in the workshop to the shipping of finished goods to the customer. Production management deals with the flow of information, by which the flow of materials is managed efficiently, through planning and control techniques. Industrial economics focuses on the flow of production costs, aiming to minimise these to facilitate competitive pricing.

Professor Hitomi argues that the fundamental purpose of manufacturing is to create tangible goods, and it has a tradition dating back to the prehistoric toolmakers. The fundamental importance of manufacturing is that it facilitates basic existence, it creates wealth, and it contributes to human happiness - manufacturing matters. Nowadays we regard manufacturing as operating in these other contexts, beyond the technological. It is in this unique synthesis that Professor Hitomi's study constitutes a new discipline: manufacturing systems engineering - a system that will promote manufacturing excellence.

Key Features:
* The classic textbook in manufacturing engineering
* Fully revised edition providing a modern introduction to manufacturing technology, production management and industrial economics
* Includes review questions and problems for the student reader




Course Materials for Manufacturing System Design
Peter L. Jackson, John A. Muckstadt, John M. Jenner

School of Operations Research and Industrial Engineering

Cornell University
https://people.orie.cornell.edu/jackson/aseehtml.html

The Manufacturing System Development Game
PERMANENT LINK(S) https://hdl.handle.net/1813/8749
AUTHOR Muckstadt, J. A.; Jackson, P. L.; Jenner, J. M.
ABSTRACT
This paper published in the "Journal of Algorithms" 13 (SODA '90 special issue) 79-98
https://ecommons.cornell.edu/handle/1813/8749



Topic 4: Manufacturing Systems Design
Topic 5: Robotics
Teachers
Dr. G. Bengu, IE Dept.
Objective
To introduce large scale manufacturing systems design and concepts. Students will learn and experiment with different designs of manufacturing systems. The manufacturing systems concepts such as Flow Line Systems, Flexible Manufacturing Systems, Automated Storage and Retrieval Systems, Just In Time Production Systems will be introduced. Interactive Simulation/Animation tools are used for this purpose as well as for the economical analysis of manufacturing systems design. Students will access the simulation/animation tools through a hypertext/multimedia environment, for example view a simulated factory floor, change relevant key parameters and observe the effects on the system performance. Students will analyze the trade offs with different design alternatives using economical analysis functions as well as direct performance measures. Students will also be introduced to the use of spreadsheet tools for such analysis. The spin off benefit of this lecture will be the use of other tools and techniques from topics such as in Quality Control and Concurrent Engineering and the resulting synergy accross manufacturing curriculum. The chosen application areas will focus on personal computer production.
Lecture Material
The layout of production facilities, in a factory floor as well as the choice of the characteristics of individual production facilities such as type of machine are largely based on the nature of the product and can be categorized in terms of type of production.

Flow Line Assembly: System design for large volume standard productions such as cars, televisions, radios, etc. The product is a standard one which can be mass produced.
Just in time and flexible manufacturing systems(JIT & FMS): Design for moderate volume but high variety products such as consumer electronics. There are similar products produced but they are in moderate numbers but not in large quantities and there are many batches like these.
Job Shop: Every product is unique and hence each has to be produced in different ways. The storage of raw material, work-in-process inventory as well as finished product requires a storage area and a retrieval process. Next subject will touch these issues with the following example.
Automated Storage and Retrieval Systems(AS/RS): Design of a automated warehouse system facilitated by conveyor, elevators and barcode readers. The delivery of materials between work centers usually occurs thorough a material handling system. The last example will touch issues in this area.
Material Handling systems: Design of automated quickest vehicle track.
https://www.ewh.ieee.org/soc/es/Aug1996/030/cd/en495w16/begin.htm










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Friday, February 12, 2021

MachineDesk - MachinePark - Machine Shop Productivity Software

 


https://www.machine-desk.com/en/company

In February 2021, MachineDesk, the SaaS system in the Cloud for managing production facilities is launching on the market.


_________________


https://www.youtube.com/watch?v=K9ugIxm3WeY

_________________


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Wednesday, February 10, 2021

Nestle Purina’s Advanced Robotic Packaging Operation - 2015 - 2020

 


The cartoning and case packing operations are done on four impressive systems from CAMA.

In the plant at Wroclaw, the system has to handle 660 cans/min in 4-, 8, 12-, and 24-count cartons. The system dedicates one cartoner to the 4- and 8-count cartons and a second cartoner to the 12- and 24-count cartons. 

The 4-count cartons run at about 165/min, the 8-count at 85/min, the 12-count at 55/min, and the 24-count at 28/min.


Nestle Purina’s ‘Most Modern’ Packaging Operation

Sophisticated use of robotics is the key to this impressive cartoning and case-packing line for 85-g tins of cat food in 4, 8-, 12-, and 24-count cartons.

Pat Reynolds

Nov 25th, 2020

https://www.packworld.com/machinery/robotics/article/21204564/nestle-purinas-most-modern-packaging-operation



Robot Revolution, a one-hour program featuring latest 2020 market outlook for food, beverage, and packaging applications, including L'Oreal and Nestle Purina, as well as risk assessment and cobot safety. Access PACK EXPO Connects—60 education sessions for FREE through March 31, 2021.




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Monday, February 8, 2021

Product Lifecycle Management - Introduction

Digital Paradigm

PLM is a digital paradigm. Under the PLM paradigm, products are managed across the lifecycle with digital computers, digital information and digital communication. - John Stark

Definition of PLM

Product Lifecycle Management (PLM) is the activity of managing a company’s products all the way across their lifecycles; from the  idea for a product to its retirement by the company and disposal of units used by the consumers. PLM is the management system for all company’s products. 

The business objectives of PLM is to increase product revenues, reduce product-related costs, maximise the value of the product portfolio, and maximise the value of current and future products for both customers and shareholders.

Lower prices provide value to customers and lower costs provide value to shareholders.

Management of products includes activities such as planning,  organisation and acquiring of resources, allocation and co-ordination of product-related resources, decision-taking,  and control of results. A product must be managed in all phases of the lifecycle to make sure that everything works well, and that the product makes good money for the company.

Scope of PLM

Objectives and Metrics
Organisation and Management
Activities
People
Products
Product Data
Product Data Management System
PLM Applications
Facilities and Equipment
Methods and Techniques

With the PLM Paradigm, the activities of managing a company’s products are organised, defined and documented in cross-functional business processes across the product lifecycle. The processes fit into the company’s Business Process Architecture. Wherever possible, tasks are run in parallel to reduce cycle times.

With PLM, top managers understand and can formulate the need for effective product lifecycle management. They define the key metrics and also participate in developing and approving  how the activity will be managed.

Strategic Benefits

Cost Reduction

PLM enables a company to reduce product-related costs. It’s important to reduce product costs. Otherwise the customer will choose a competitor’s product that costs less than the company’s product. Product-related material and energy costs are fixed early in the product development process. PLM provides the tools and knowledge to minimise them. And PLM helps cut recall, warranty and recycling costs that come later in the product’s life.

Cost Reduction Over Life Cycle (Product Industrial Engineering)
PLM enables the value of a product to be maximised over its lifecycle. With accurate, consolidated information about mature products available, low-cost ways can be found to extend their revenue-generating lifetimes.

Issues in the Traditional Product Development and Engineering Environment

Among the main issues in the traditional environment were serial workflow, departmental organisational structures and piecemeal improvements.

Waste to be eliminated (Recognized in PLM environment also)


transportation
inventory
motion
waiting
overproduction
non-value-adding processing
defects

Business Processes in the PLM Environment

A business process describes how the company wants to work on a particular activity.

Business processes related to products contain all the company’s knowledge about how to design, manufacture, support, use and recycle a product. Errors and/or waste in these processes can cost millions of dollars and waste months of time.

Process
The ISO 9000 Introduction and Support Package: Guidance on the Concept and Use of the Process Approach for management systems document defines a process as a “set of interrelated or interacting activities, which transforms inputs into outputs”.

Process Mapping is  the activity of documenting an existing process. The other terms,  Business Process
Mapping, or Process Charting, or Process Flow Charting also describe the same activity.

Process Modelling

The term Process Modelling, or Business Process Modelling, is usually used to
describe the activity of creating models of future processes.

Business Process Management (BPM) is an overall approach to the improvement of
a company’s business processes. It includes process mapping, process modelling, process measurement and process improvement.

Use Case
A Use Case describes, from the user viewpoint, the interaction between a user of a system and the system. The interaction is made up of many individual actions. A Use Case can be used, during system design, to show expected behaviour and to clarify requirements.

A process approach (different from department approach) is one of the eight principles for a company’s quality management system (QMS) recommended in the ISO 9001:2008 Quality management systems—Requirements document.

Business Process Architecture has a hierarchy of business processes, processes, sub-processes, sub-sub-processes and activities. At the highest level of the hierarchy are the business processes. A correctly-organised, coherent process architecture will enable effective working across the product lifecycle. 

Processes may be divided into three groups. These are operational processes, support processes and management processes. Operational processes create value for external customers. Support processes create value for internal customers.

The three main operational processes are Supply Chain Management, Customer Relationship Management, and Product Lifecycle Management.

There are six product-related processes that are found in most companies. Five of them correspond to the five phases of the product lifecycle. These are the Product Idea process, the Product Definition process, the Product Realisation process, the Product Support process, and the Product Phase Out process. The sixth one is Product Portfolio Management process.

Revenues Result from Processes (Effectiveness is given by the processes)
The product, the source of company revenues designed and manufactured by the activities of the business processes. This means that the quality and cost of the product are functions of the processes. 

Waste is possible Results from Processes (Inefficiency gets designed in)

Disjunctures, superfluous steps, and inefficient activities in business processes all contribute to unnecessarily extending lead times, increasing costs and rework. And, the elapsed time between the first idea for a product, and the moment that the first customer receives the product, depends on the efficiency and effectiveness (first time right satisfying the requirements) of the processes.

Understanding and Improvement
Unless processes are understood, there’s no way of improving them, no way of
improving “how the company works”.

Methods are used across the product lifecycle. Examples include Activity Based Costing (ABC), Concurrent Engineering, Design for Assembly (DFA), Design for Environment (DFE), Design for Recycling (DFR), Design for Six Sigma (DFSS), Design for Sustainability (DFS), Design to Cost (DTC), Early Manufacturing Involvement (EMI), Early Supplier Involvement, Failure Modes and Effects Analysis (FMEA), Fault Tree Analysis (FTA), Group Technology (GT), Life Cycle
Assessment (LCA), Life Cycle Design (LCD), Open Innovation, Plan-Do-Check Act - Study (PDCAS), Poka Yoke (Mistake Proofing), Quality Function Deployment (QFD), Reliability Engineering, Roadmapping, Robust Engineering, Simultaneous Engineering, Stage/Gate methodologies, Taguchi techniques, TRIZ, Value Analysis (VA) and Value Engineering (VE).

The methods mentioned above have all met with success in one or more companies,
and should be understood by companies embarking on PLM initiatives.

Phases of the Product Lifecycle (Stark)

Our product lifecycle is defined as having five phases: imagination; definition; realisation; support; retirement. It’s recognised that, for users of the product, there are also five phases in the product’s lifecycle: imagination; definition; realisation; use (or operation); disposal (or recycling).

Eight step approach to process improvement (Stark)

1 Prepare Write down the scope and objectives. Plan the expected activities, taking care to include activities such as planning, communicating, reporting, interviewing, documenting, presenting and sustaining.

Search for related knowledge and develop a file with useful information.

2 As-is Understand and document the as-is situation. Document the specifics of the As-is product lifecycle processes, activities and steps. Document input and output information. Document users and use of the information. Document objectives, performance measures, problems, requirements. 

Study the documentation: Identify problems and weaknesses holding back performance. Identify 
waste. Identify the causes

3 To-be: Define 3 or 4 options for the to-be state (Based on the knowledge developed about possibilitie s to improve). SWOT to get the best to-be state 

4 Strategy: Identify several potential alternatives to improve. Decide on the implementation strategies. SWOT to get the best implementation strategy

5 Plan: Develop a detailed implementation plan for an initial project and for further rollout phases

6 Communicate:  Communicate a compelling case of success

7 Implement Start small, get some success. Check results against targets. Communicate success 

8 Sustain When the initial project ends, start the planned follow-on activities


Product Data

Product data is the definition of a product. It’s all the knowledge and know-how about the product. In addition, it’s all the knowledge and know-how about the way the product is designed, manufactured, supported, used and recycled. The quality of product data is a key element of product success. One small error can cost millions of dollars.

 Product Data
The term “product data” includes all data related both to a product and to the processes that are used to imagine it, to design it, to produce it, to use it, to support it, and to dispose of it.

Conceptual Product Data Model
A conceptual data model is a high-level data model that people throughout a company can understand.

Logical Data Model
A logical data model is a much more detailed model than a conceptual data model. It shows all the details about the entities that are required for the business to function normally.

Configuration, Configuration Management
The configuration of a product is a definition of all its configuration items (e.g., component, specification document, etc.) and of the way they are organised. Configuration Management (CM) is the activity of documenting initial product specifications, and controlling and documenting changes to these specifications.

Metadata
Metadata is “data about data”, “data describing other data”. It’s the key information about a larger volume of data, such as its name, its status, its location, and its owner. Metadata is similar to the catalogue information of a book in a library. That might contain the book title, author name, book number and book location.

Tools to Represent Product Data

Excel
Powerpoint
UML
One of the languages used is the Unified Modelling Language (UML).
Data Model Diagrams

A Generic Vision for Product Data in PLM


Clean, Standard, Process-Driven Data
Digital Data
Data Management
Legacy Data
The different types of legacy data will be identified. Policies will be defined for
managing them and, where possible, for eliminating them.
Data Exchange

Product Data Activities in the PLM Initiative


Product Data-Related Projects
Product Data Modelling
Product Data Improvement
Product Data Cleansing
Product Data Migration



Information Systems in the PLM




PLM applications

Idea Management applications. These enable gathering and evaluation of ideas in a structured fashion, and the selection and management of the best ideas

CAE/CAD/CAM applications. The focus in this group is on defining, analysing and simulating product, service and process definition data. Functionality of this type may be found in applications such as CAD, MCAD, 

ECAD, Electronic Design Automation (EDA), geometric modelling, CAM, C APP, Rapid Prototyping, CAE, 

DFM, DFA, Software Engineering, NC programming, BOM, routing definition, plastic behaviour analysis, 

Factory Simulation, technical publishing, and parts library applications. These applications are used in 
discrete manufacturing to create the right product and process definition data. In process manufacturing, 
menu management and recipe management applications have an equivalent role

PDM technologies. The focus here is on managing product, service and process definition data th roughout the product lifecycle. Functionality of this type may be found in applications such as Engineering Document Management, Engineering Data Management, Product Data Management, Technical Document Management, Knowledge Management, Configuration Management, Enterprise Content Management, Regulatory Management and Quality Management applications

Visualisation/Viewing. Visualising, viewing and printing product and process definition data. This group includes technologies such as Digital Mock Up and viewers

Collaboration software. The focus here is on applications that allow people at different locations, or in 
different organisations, to work together over the Web with the same product and process definition data. Collaboration software technologies include e-mail, electronic whiteboards, discussion groups, chat rooms, intranets, extranets, shared project spaces, portals, vortals and project directories

Data exchange and interoperability applications. The focus here is on applications that allow product and process definition data to be transferred from one format, that’s usable in one application, to another format that’s usable in another application

Customer-oriented applications. The focus here is on capturing product and process definition data from customers, and presenting product and process definition data to customers. Customer-oriented 
technologies include applications for presenting product catalogues to customers, and applications for 
capturing customers’ needs, requirements, feedback, orders and complaints

Supplier-oriented applications. Capturing product and process definition data from 
suppliers and presenting product and process definition data to suppliers. Supplier-oriented technologies include RFQ applications, CSM applications, strategic sourcing and auctions

Process definition and management. Definition and management of processes and 
workflows across the product lifecycle. These include the product development process, release 
management, and the Engineering Change Management process

Project and program management. Definition and management of projects addressing 
activities in the various parts of the product lifecycle

Portfolio Management. Management of the portfolio of products, and the portfolio of projects to develop new products and modify existing products

Regulatory/Standards/Compliance Management applications. 

Integration. The Integration group includes both integration between PLM applications, and integration 
between a PLM application and another application such as a CRM, ERP or SCM application


PDM Systems
A PDM system is one of the most important components of PLM. It can manage all the product data created and used throughout the product lifecycle. It can provide exactly the right information at exactly the right time.

A PDM system has eight main components. They are:

Information Warehouse 
Information Warehouse Manager 
Infrastructure 
System Administration Manager 
Interface Module
Product And Workflow Structure Definition Module
Workflow Control Module
Information Management Module

A PDM system will help improve product development productivity. Product development managers will know the exact status of a new development. They’ll be able to assign resources better, and release designs faster and with more confidence. Design engineers will know which parts are available and which procedures should be followed when designing new parts. Manufacturing engineers will be able to see how similar parts have been made previously.

A Generic Vision for PLM  IT Applications

Digital Company
PLM Application Architecture and Strategy
Product Data Management for PLM
PLM Applications Throughout the Product Lifecycle
PLM Application Standardisation
Interfaces

Application Activities in the PLM Initiative

Application-Related Projects
PLM Application Status Review
Software Development Approaches
PDM System Selection and Implementation


Best Practice PDM System Selection

Prepare the PDM System Project
Hold a Kick-Off Meeting

Know Thyself
Document the Business Objectives
Document the Current Situation
Activities in Scope
Product Data
Users of Product Data
 PLM Applications
Product Data Management Systems
Identify PDM System Requirements

Know Your Partners

Return on Investment



Important  Activities in PLM Implementation 

define Use Cases       
mentor executives   
create workflows   
prepare new roles  
coach Team Members  
define process KPIs 
plan OCM activities  
select a PDM system  


cleanse product data
migrate product data
plan roll-out strategy 
define Initiative KPIs 
implement a PDM system  
harmonise applications 
develop an OCM glossary 

map the current process 
define product data KPIs
manage the closure phase
model the future process
plan roll-out activities
plan training activities
restructure product data
communicate about changes

manage the Planning phase
define new business processes
align change expectations
maintain PLM applications
develop a process glossary
develop new reward systems
manage Initiative start-up
create new job descriptions




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