Wednesday, June 30, 2021

Lessons 16 to 30 - Industrial Engineering Online Course by Industrial Engineering Knowledge Center

 

Industrial Engineering Knowledge Center - Industrial Engineering Online Course - Lessons 1 to 15


Dr. K.V.S.S. Narayana Rao, Professor,  National Institute of Industrial Engineering, Mumbai, India.

Author of Principles of Industrial EngineeringFunctions of Industrial Engineering and Focus Areas of Industrial Engineering.







16

Industrial Engineering Described in Shop Management by F.W. Taylor

Process Industrial Engineering - Illustration - Process Improvement via Toolholder Change

17

Productivity Improvement in Machine Shop - F.W. Taylor

Tool Wear and Temperature Analysis for Process Improvement

18

Development of Science in Mechanic Arts - F.W. Taylor

Dynamic Control of Circulatory Pumps for Heating Systems Saves 20% of Energy Cost

19

Time Study for Process Time Reduction - F.W. Taylor

Process Industrial Engineering - Illustration - Additive Manufacturing of Fixtures - Productivity Benefits

20

Taylor on Quality, Human Relations and Management

Process Industrial Engineering - Illustration -Alternative Lubricants and Productivity - Case Study

21

Gilbreth's Human Effort Industrial Engineering Motion Study - Part 1

Illustration of Human Effort Productivity Improvement - Bricklaying Improvement by Gilbreth

22

Gilbreth's Human Effort Industrial Engineering - Motion Study - Part 2

Illustration of Human Effort Productivity Improvement - Pig Iron Handling by Taylor

23

Gilbreth's Human Effort Industrial Engineering - Motion Study - Part 3

Illustration of Human Effort Productivity Improvement - Bicycle Balls Inspection Example - Taylor

24

Gilbreth's Human Effort Industrial Engineering - Motion Study - Part 4

Case Study - Method Study - Cast Iron Housing Loading and Unloading 2014

25

Gilbreth's Human Effort Industrial Engineering - Productivity Science of Motion Study - Variables Affecting of Motion Time.
ACCELERATION - AUTOMATICITY - COMBINATION WITH OTHER MOTIONS, AND SEQUENCE - COST - DIRECTION AND USE OF GRAVITY - EFFECTIVENESS - FOOT-POUNDS OF WORK ACCOMPLISHED - INERTIA AND MOMENTUM OVERCOME - LENGTH

Case Study - Method Study - Welding Fixture Redesign - Productivity Improvement 2002

26

Gilbreth's Human Effort Industrial Engineering - Productivity Science of Motion Study - Future Scope

Case Study: Method and Motion Study in a Printing Company - 2019

27

Process Charts - Gilbreths - 1921

Case Study - Examining All Operations in a Process

28

It is important that industrial engineers have to recognize that scientific management was evaluated by Lilian Gilbreth, a psychologist from a human behavior  perspective and a positive opinion was given. Industrial engineering, appeared as a part of the system of management and engineering developed to reduce cost of products made using engineering processes and methods.


Psychology Evaluation of Scientific Management by Lilian Gilbreth - 1914

Implementing Standard Work - Issues

29

After discussing the contribution of Taylor and Gilbreth in more detail, the contribution of many other industrial engineering researchers, professionals, consultants and authors are provided in a series of notes to introduce more industrial engineering concepts. These concepts and their applications will be discussed in more detail in various focus area modules of the course.

Harrington Emerson - A Pioneer Industrial Engineer - His Principles and Practices

Case Study: New Scheduling Algorithm Substantially Improves Foundry Productivity - 2017

30

Prof. Hugo Diemer - Taylor's Industrial Engineering

Industrial Engineering Exercise: Productivity Analysis of a Newly Introduced Machine

Faucet Design and Manufacturing Process - Industrial Engineering

My suggestion to industrial engineers: 
Find 5 new engineering developments every day in elements related to facilities, products and processes in your organization and assess their use.  Best Practices in #IndustrialEngineering 

https://nraoiekc.blogspot.com/2022/06/good-and-best-practices-in-industrial.html 


The article is just started.


Manufacturing Process


https://www.vigafaucet.com/faucet-manufacturing-process/

http://www.madehow.com/Volume-6/Faucet.html

https://tresco.in/production-process/



Design

https://www.hgtv.com/design/rooms/kitchens/faucets-that-function


Portable Danish Robot Expands Production with California Manufacturer

Universal Robots now performs machine tending at RSS Manufacturing & Phylrich in California. Deploying the robot arms from Denmark has vastly improved the company’s ability to stay competitive.

Productivity


August 1, 2016  |  Lean, Continuous Improvement


The Benefits of Adopting a Continuous Improvement Approach.

For Waterstone Faucets, adopting a Lean and continuous improvement approach has made a positive impact on their business. Waterstone Faucets is a full line manufacturer and distributor of high quality kitchen faucets located in Murrieta, CA. 


July 08, 2013 09:57 AM Eastern Daylight Time

STONY BROOK, N.Y.--(BUSINESS WIRE)--Before the faucet maker RSS Manufacturing & Phylrich put the UR5 robot to work, bending 1500 units on a tube bender using manual labor would take 3 days. With the Universal Robot, the same job took four hours.

https://www.businesswire.com/news/home/20130708005724/en/Portable-Danish-Robot-Expands-Production-California-Manufacturer











Industrial Engineering Knowledge Center - Industrial Engineering Online Course - Lessons 1 to 15

 

Dr. K.V.S.S. Narayana Rao, Professor,  National Institute of Industrial Engineering, Mumbai, India.

Author of Principles of Industrial EngineeringFunctions of Industrial Engineering and Focus Areas of Industrial Engineering.






Industrial Engineering Course Lessons


Introduction to Industrial Engineering - Module 1


Day 1 
Industrial Engineering - History

Industrial engineers (IE) are employed and productivity improvement and cost reduction are practiced in many companies using IE  philosophy, principles, methods, techniques and tools.
Apple Inc. - Industrial Engineering Activities and Jobs

Day 2

Industrial Engineering - Definition and Explanation

IE Continuous Improvement - 3 Years - 50% Cost Reduction - Diplexer Line Case Study


Day 3

Industrial Engineering Introduction

BMW - Industrial Engineering Activities and Jobs


Day 4

Pioneering Efforts of Taylor, Gilbreth and Emerson

Coca-Cola - Cisco Systems - Industrial Engineering Activities and Jobs


Day 5

Industrial engineering Principles, Methods Tools and Techniques

DuPont - Industrial Engineering Activities and Jobs

Day 6

Functions and Focus Areas of Industrial Engineering

Value Engineering - Paddy Transplanter - Case Study

Day 7

Industrial Engineering of Belting - 1893

Ford - Industrial Engineering Activities and Jobs

Day 8

Productivity Science

GE going strong on Lean & Kaizen
GlaxoSmithKline - GE - Industrial Engineering Activities and Jobs

Day 9

Product Industrial Engineering

Value Analysis and Engineering - Examples by L.D. Miles - Part 1

Day 10

Process Industrial Engineering

Process Industrial Engineering - Illustration: Process Industrial Engineering Using Robo Cylinder

Day 11

Industrial Engineering Economic Analysis

Honda - Industrial Engineering Activities and Jobs

Day 12

IE Measurements

Milling - Estimation of Machining Time

Day 13

Value Creation for the Organization by Industrial Engineers - Productivity Engineering

Process Industrial Engineering - Illustration:  Gear Machining Productivity


Module  2

Contribution of Taylor, Gilbreth, Emerson, Maynard, Barnes, Lehrer, Shigeo Shingo

Day 14

Taylor - Productivity Science and Art of Metal Cutting - Important Points

Process Industrial Engineering - Illustration:    Cryogenic Machining Adoption - Productivity Improvement at Lockheed Martin


15

Taylor's Industrial Engineering - First Proposal 1895

Process Industrial Engineering - Illustration - Investment in Sliding-Head Lathe with Chipbreaking Feature




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Tuesday, June 29, 2021

Is There a Cost Reduction Benefit in Using Hybrid Computers?

 

Industrial engineers have to monitor technology developments and identify technologies that have application in the processes they are managing for productivity. They have to check technical feasibility and assure that the required quality of the output is achieved in their process. Then they have to check the economic benefit to the organization. It is termed IE economic analysis.

In 1977, I am given the assignment of writing a short essay on hybrid computer. The productivity aspect may not have been highlighted at that time. It was difficult to access journals and magazines also. Now access to the publications is more easy.

The reference given below provides the description of studies made to check whether there is feasibility of using hybrid computers for engineering problems and whether there is cost reduction benefit.


EVALUATION OF HYBRID COMPUTER PERFORMANCE ON A CROSS SECTION OF SCIENTIFIC PROBLEMS 

R. D. Benham 


ABSTRACT 

Hybrid and small digital computers were evaluated on several types of technical problems. Comparisons with processing on a large digital computer were made for 12 scientific studies. Accuracy, time and cost (man and machine), convenience and flexibility, and computer requirements were evaluated by a cross section of scientists and engineers.

https://www.osti.gov/servlets/purl/4185202/



The Design of a Hybrid Computer.

Masters Thesis - 1968 - James Joseph Becker

https://scholarsmine.mst.edu/masters_theses/6702/


Med Prog Technol. 1977 Apr 25;4(4):185-91.

A hybrid computer system for use in cardiology

L D Nadel, M R Kramer, D C Shultheis, T A McCulloh

https://pubmed.ncbi.nlm.nih.gov/865418/



Home/Magazines/Computer/1976.07

Computer

Hybrid Digital/Analog Computer Systems

July 1976, pp. 15-24, vol. 9

DOI Bookmark: 10.1109/C-M.1976.218640

https://www.computer.org/csdl/magazine/co/1976/07/01647415/13rRUwInv74


Low Cost Automation

Ubiquity of Industrial Engineering Principle of  Industrial Engineering

Illustration: Google's  Engineering Productivity Department - Evolution of the Department through Automation of Testing. Emergence of Software Engineering Productivity Engineer & Specialist. 




Mechanization refers to the replacement of human power with mechanical power of some form. 

Automation and mechanization are often confused with each other; Mechanization saves the use of human muscles whereas automation saves the use of human judgement.

Atomation can be defined as the technology by which a process or procedure is performed without human assistance. Automation is done by using mechanical, hydraulic, pneumatic, electrical or electronic devices and computers. The obvious advantage of  automation is requirement of human effort, hence high man's productivity. Automation also provides  improvement in material handling, improvement in quality , accuracy and precision. 

Low cost automation is a technology that automates some activities of  the existing equipments, tools, 
methods and people, using mostly standard automation components available in the market.


Jidoka - Automation and Mechanization - Process Engineering and Industrial Engineering in Toyota Production System

Jidoka, a pillar of Toyota Production Systems advocates automation with human touch in all operations of a process to increase productivity of operators as well as that of total systems.


2002

Low-cost automation (LCA) involves the introduction of standard equipment, mechanisms, and devices to convert manual operations to automatic ones. Investment cost is low, as the term itself implies, and the ROI in terms of improved productivity and better work efficiency is high. In the workshop, participants see LCA as automation that assures quality, provides flexibility, increases productivity, and reduces cost. At the same time, it is easy to implement and affordable for small and medium enterprises (SMEs), the main users of LCA. Common areas in the manufacturing process for LCA application are machining, cold extrusion, grinding, material handling, quality inspection, dimensional accuracy, surface finishing, and assembly and packaging.

A workshop topics: 
The different means of automation; 
The concept and practice of LCA; 
Problems relating to introducing LCA; 
Planning and designing for LCA; Cost-benefit analysis of LCA: and 
Process for implementing LCA.

The benefits of using LCA:

It contributes to process improvement, cutting machine downtime, cost reduction, better product quality, more precision manufacturing, on-time delivery, greater job safety, reduction in manpower requirements and human error, and environmental protection. 

The key success factors for the implementation of LCA are:  trained and skilled manpower, appropriate product types, availability of the requisite hardware and software, 

Low Cost Automation, APO news item


CII National Competition on Low Cost Automation (LCA)

CII Institute of Quality, in 2018 eastablished National Competition on Low Cost Automation (LCA) to support the "Make-in-India" campaign by enhancing the competitiveness of Indian Industry in the global market. This competition catalyzes the wide spread adoption of LCA practices across Indian Industry through sharing best case studies. This competition focuses on core techninial concepts / inovative ideas resulted in improvement in PQCDSM (Productivity, Quality, Cost, Delivery, Safety & Morale). LCA Awards will be presented in six categories (Productivity Improvement, Karakuri Kaizen, Quality Improvement, Pokayoke, Set-up Change (SMED) and Safety & Energy).

My personal enquiry got the answer that for LCA, the ROI (payback period) has to be less than two years.

There is a very good site offering tutorials on low cost automation
331 tutorials are there starting from 001 given below.

http://www.misumi-techcentral.com/tt/en/lca/



001. Tutorial 1. Principal Components for Low Cost Automation
https://www.misumi-techcentral.com/tt/en/lca/2009/07/0001-pictorial-and-explanations-on-lca-standard-components---1-how-to-select-standard-components.html

The LCA is comprised of the following configuration, and this establishes the reference for the components' functionality.

LCA = Mechanism + Actuator + Controller

Some important topics - First tutorial starting numbers
002 - Precision shafts.
008 - Hollow shafts
009 - Linear guide mechanisms
011 - Bearing mounting
015 - Hinge pins
017 - Sensor mounting
021 - Motion mechanism design
022- Principles of positioning
023 - Locating pins
026 - Mechanical LCA
029 - LCA Construction Elements
031 - Ball screw
036 - Timing belt
037 - Sensor usage 
041 - System configuration




Fundamental technologies required for automating screw fastening process

173 Production Technology Level-up Course for Machine Designers - 9: Automating Screw Fastening - 1
http://www.misumi-techcentral.com/tt/en/lca/2013/12/173-production-technology-level-up-course-for-machine-designers---9-automating-screw-fastening---1.html
174 Production Technology Level-up Course for Machine Designers -10: Automating Screw Fastening - 2
http://www.misumi-techcentral.com/tt/en/lca/2014/01/vol-174-production-technology-level-up-course-for-machine-designers--10-automating-screw-fastening--.html

175 Production Technology Level-up Course for Machine Designers - 11: Automating Screw Fastening - 3
http://www.misumi-techcentral.com/tt/en/lca/2014/02/175-production-technology-level-up-course-for-machine-designers---38-automating-screw-fastening---3.html


Related articles

Automation - Current Status and Issues
https://nraoiekc.blogspot.com/2014/11/automation-current-status-and-issues.html

Productivity Automation Engineering
https://nraoiekc.blogspot.com/2017/09/productivity-automation-engineering.html


Bibliography: Low Cost Automation

Slideshare Presentations

Low cost automation - SlideShare
Jan 31, 2015 

Automation slides,plc,scada,HMI
BOSCH
https://www.slideshare.net/vcbxvdf/pathania-plc

https://www.slideshare.net/saianjaneya/industrial-automation-history

https://www.slideshare.net/indira_kundu/basics-of-automation-plc-and-scada



Google: "low cost automation" examples

A study of automation of business operations in large scale manufacturing industries with reference to production lines in maharashtra state
Researcher: Yambal,Sucheta S.
Guide(s): Bajpai,S.A.
University: Dr. Babasaheb Ambedkar Marathwada University
Completed Date: 3/12/2016




LOW COST INTELLIGENT AUTOMATION IN MANUFACTURING
Heinz-H. Erbe
Published 2002, IFAC Proceedings Volumes

Videos

1:14
Low Cost Automation - Institute for Manufacturing (IfM), University of Cambridge
Jun 25, 2018

10:34
Low Cost Automation ~ In Hindi ~ with examples - Learn Mech Tech
Dec 16, 2018

Automatic Needle Filling Machine


Padmatech Industries Pvt Ltd formally my known as Padmatech Engineering system provide Low cost industrial Automation, Since last decade. in process industry. PIPL optimize processes of client and results of this clients reduces there manufacturer cost, safety operation, less risk in operation, less manpower dependency.   Padmatech Industries Pvt Ltd achieve pay back period from 28 days to 1 year/18 months depends upon automation cost and volume of work.
___________________

https://www.youtube.com/watch?v=66QDOmzyRts
____________________

2:14
Low Cost Intelligent Automation - increase productivity and flexibility and achieve Zero Defects -· AviasLCIA
Aug 27, 2010


Low Cost Automation — A case study - INDUSTR.com
Toyota Kirloskar Auto Parts Pvt. Ltd.BENGALURU, INDIA 
May 23, 2017
Adopting conventional automation is still impractical in terms of return on investment (ROI usually requires 10 ~ 15 years).  An automation, which consumes zero or very little power (eco-friendly), with zero or minimum actuators (safety), highly flexible & reliable in nature, which occupies less space (lean concept), that needs zero or minimum maintenance (high efficiency), with minimum investment and running cost, is termed as LCA.

Karakuri Automation
‘Karakuri’ is  a Japanese word, which means achieving motion with no power or low power. It’s an ancient Japanese technique to move dolls without actuators or power. In Karakuri technique,  different mechanisms like rope & pulley mechanism, counter weight mechanisms, cam & follower mechanisms, etc, are used to achieve unique motion or to convert one form of motion into another like vertical to horizontal and linear to rotary. Combining these motions together to form an automation solution requires an engineering approach. 

Unlike conventional automation, Karakuri LCA provides safer, cost-effective, lean & maintenance-free flexible solutions with a target ROI of less than 2 years.

Video: “Jishuken” & “Low Cost Automation(Karakuri)” – Toyota Kirloskar Auto Parts
_____________________

https://www.youtube.com/watch?v=jK1bobq6K3s
______________________



Low Cost Automation Tutorial | Technical Tutorial - MISUMI
www.misumi-techcentral.com › lca
#230 Safety Design - 2: Case Examples of Intrinsic Safety ... #140 Low Cost Automation and Quality - 3: Automating Molded Platic Product Extraction and Quality ...

310 Know-how on automation - Low Cost Automation Tutorial ...
www.misumi-techcentral.com › lca › 2017/10 › 310-kn...
Oct 13, 2017 — Low Cost Automation Tutorial ... For example, to develop a device that is large and meets the high-speed and high-precision requirements, ...


PDF Low Cost Automation(LCA): A Case Study - ResearchGate
www.researchgate.net › publication › 268807051_Low...
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Low-cost automation: How robotics are shaping medium-sized ...
www.metec-tradefair.com › News › Topics › Low-cost...
Low-cost automation brings a breath of fresh air to medium-sized companies and ... Thus, for example, the linking between linear bearings, a corresponding ...



Design and implementation of low cost automation system in ...
home.iitm.ac.in › samuelgl › pdf9
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May 26, 2016 — Keywords: low cost automation; productivity need analysis; PNA; heavy vehicle brake assembly; operator fatigue; productivity improvement.

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iosrjeniosrjen.org › Papers
PDF
Abstract: - Low Cost Automation (popularly known as LCA) is the introduction of simple pneumatic, hydraulic, mechanical and electrical devices into the existing ...

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www.hindawi.com › journals › jie
by AC Valdiero · Cited by 1 — ... a pneumatically driven manufacturing cell for low cost automation applications. ... such as pneumatic servo position applications [1–5]; for example, Festo has ...
Pneumatic cylinder A: O1
Pneumatic cylinder C: O3
Pneumatic cylinder B: O2
Manual actuation button: I1

A review on low cost automation using pneumatic system
data.conferenceworld.in › BVCOE18
PDF
This paper emphasizes on Low cost automation (LCA) using fluid power i.e. pneumatics. This paper also involves case studies of various industries which got ...

Low Cost Automation & Robotics - Igus
drylin® delta robots and robolink® DP robotic arms offer the same technical advantages as our gantries. Delta is available in two sizes and starts as low as $6,200. Countless component combinations are available for robolink® so you can design an individual solution that meets the needs of your business.

low cost automation using electro pneumatic system - IAARC
www.iaarc.org › fulltext › isarc2007-5.2_5_028.pdf
PDF
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robolink® Low Cost Automation - Igus
www.igus.in › info › robotics-low-cost-robotics
Low Cost Automation - test, invest, profit. The phrase Low Cost Automation stands for a significant increase in productivity with the help of a simple and affordable ...

low cost intelligent automation in manufacturing - Semantic ...
pdfs.semanticscholar.org › ...
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by HH Erbe · 2002 · Cited by 18 — This represents a way of low cost automation. To run the manufacturing process ... specialist have to be consulted (for example the machine builder).This is ...

Articles | Low Cost Automation: Retrofitting Old Machines
www.industrialautomationindia.in › articleitm › articles
Low-Cost Automation: Retrofitting Old Machines ... For example, if the spare parts you were searching for are no longer manufactured, you are likely to find the ...

LOW-COST AUTOMATION FOR THE FURNITURE AND ...
PDF
EXAMPLES OF LOW-COST AUTOMATION APPLICATIONS 58 ... A small or medium-sized furniture manufacturer, for example, starting with hand tools, could ...

Simple & Low Cost Automation Services Industry | Tetrahedron
www.tetrahedron.in › corporate-training-companies › si...
The tetrahedron is the Best Simple & Low-Cost Automation Industry. It provides a solution for small & medium level companies. Automation in an assembly line.
Missing: examples ‎| Must include: examples

Low Cost Automation - SAE International
Aug 11, 1998 —  Tilt tables, turn tables, and lift tables are all examples of simple LCA.

Karakuri - Home
karakuri.item24.de › ...
... one hand and the creativity of the on-site workforce on the other (low-cost automation). ... A number of practical examples are provided here in video format.


Low cost automation | INCIBE-CERT
www.incibe-cert.es › blog › low-cost-automation
Mar 22, 2018 — Low cost automation ... For example, AES hardware encryption is 10 times faster than on the software, ... Example: CoDeSys for Raspberry Pi.

o-Controller Based Low Cost Automation - Industrial Research ...
www.ircc.iitb.ac.in › archives › sept_2002 › focus-sharm
Low Cost Automation ... For example, if the system indicates "fault in pneumatic system", or "defect in clamping system", the maintenance people will find it much ...

Kitchen Jidoka: Low Cost Automation Example - An interestng example of cover of dust bin getting open when the door of the sink is opened. Good explanation of "nagara" also.
May 24, 2017 — This photo from the kitchen of an apartment-hotel is an example of the first type of jidoka – low cost automation eliminating a step of human work. 

Case Study of Automation for Duplex Grinding ... - IJLTEMAS
www.ijltemas.in › DigitalLibrary
PDF
Low cost automation is a technology that creates some ... In low cost automation using Robotic arm is generally ... Some examples of techniques for such.

www.rejinpaul.com downloaded from 
www.rejinpaul.commsajce-edu.in › images › Mech › Mech-Open-elective
PDF
OAN751 Low Cost Automation. OE. 3. 3 0 0 3. 14. OMT751 ... To study the communication mechanics in a biomedical system with few examples. • To study ...

Karakuri - Low-Cost Automaiton | Haberkorn
www.haberkorn.cz › karakuri-low-cost-automaiton
... parts and components on the one hand and the creativity of the on-site workforce on the other (low-cost automation). ... Field-proven application examples.

Low-cost automation 'on a shoestring' demos in action ...
www.digitalshoestring.net › low-cost-automation-on-a-s...
Low-cost automation 'on a shoestring' demos in action. Leave a Comment / News / By admin. The Digital Manufacturing on a Shoestring project continued to ...



Cutting Costs with Pneumatics: Low-cost Automation from the ...
books.google.com › books › about › Cutting_Costs_with...
... Costs with Pneumatics: Low-cost Automation from the Econom. and Techn. Perspectives Problem-solutions for Pract. Application Demonstrated by Examples.

Low-cost automation – the mechanical solution - item ...
be-product.item24.com › directlink › cat
Low-cost automation (LCA) relieves strain on workers and boosts productivity without requiring complex control systems or drives. For example, by connecting ...



Karakuri | FlowStore Systems | Lean Manufacturing principles
www.flowstore.co.uk › karakuri
... rotating joints, pulleys, hinges, latches etc to help achieve low-cost automation. ... However, many examples are visible on digital media to provide inspiration.

low cost automation ppt
eventiinlive.it › Crusher
Low Cost Automation for the MAP and IMAGE Spacecraft T2-081 - Low Cost ... Low Cost Automation Tutorial #004 Installing Shafts - 2 : Practical Examples.

Low Cost Automation | Pneumatics | Automation - Scribd
www.scribd.com › document › Low-Cost-Automation
Jan 29, 2014 — Low Cost Automation - Free download as Word Doc (.doc), PDF File (.pdf), Text File (.txt) or read online for free. capstan.

Introduction of Industrial Automation - bbsbec
bbsbec.edu.in › wp-content › uploads › 2020/01 › Intr...
PDF
Example : Bottling Plant for beverages ... Low Cost Automation: A technology that creates some degree ... Examples of automated manufacturing system.

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www.instructables.com › Circuits › Microcontrollers
25 steps
1.
ESP32 Pinout
2.
In this image you can notice that I only used two pins to connect 16 relays, which is made possible by MCP23017. You can see about this in the video, “IO ...
3.
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www.bebetterdomore.com › blog › five-low-cost-mark...
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www.mckinsey.com › operations › our-insights › huma...
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www.thefreelibrary.com › ... › January 1, 2016
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lean automation - DiVA
www.diva-portal.org › diva2:588910 › FULLTEXT01
PDF
by A Delkhosh · 2012 · Cited by 8 — At last some industrial and educational examples are reviewed to check the circumstances of ... Toyota have developed so-called low-cost automation. Lean.

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item24us.news › karakuri-kaizen-automation-with-smarts
Of course, the main purpose of the above example is to entertain, but it does highlight ... It all starts to take shape when you look at low-cost automation (LCA).

Global study and implementation of Karakuri
odr.chalmers.se › bitstream
PDF
by P Bellur Shashi Kumar · 2018 — studies, examples of low cost automation that can be used in further studies. The studies will also help understand the differences in continuous improvement ...

Laboratory automation - Wikipedia
en.wikipedia.org › wiki › Laboratory_automation
Laboratory automation is a multi-disciplinary strategy to research, develop, optimize and ... For example, Indiana University-Purdue University at Indianapolis offers a graduate program ... It can be anticipated that more laboratories will take advantage of this new reality as low-cost automation is very attractive for laboratories.



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www.mdpi.com › pdf
PDF
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brainly.com › Engineering › College
May 9, 2020 — Justify with proper description why low cost automation is required to improve productivity in small scale industries. List out some examples. 1.
1 answer

IFAC Professional Brief - International Federation of Automatic ...
www.ifac-control.org › publications › pb_erbe_final
PDF
by HH Erbe — At a first glance low cost automation could be regarded as cheap hardware ... As an example one may consider Computer Integrated Manufacturing (CIM). The.

Shivaguru - Somandurai : Low cost automation project ideas ...www.superprof.co.uk › low-cost-automation-project-id...
Low cost automation project ideas and Fourth generation of industrial revolution ideas and implementation. Methodology. My teaching is simple and practical ...



PLC Controlled Low Cost Automatic Packing Machinewww.ripublication.com › ijame-spl
PDF
Low Cost Automation (popularly known as LCA), is the introduction of simple pneumatic, hydraulic, mechanical and electrical devices into the existing production ...

Low cost plc with hmi
theportlandballet.org › seafood-importing › low-cost-pl...
Our Automations are low cost automation amp user friendly. lowest cost high ... Examples of PLCs are Allen Bradley PLC 5 Allen Bradley SLC500 SIMATIC PLC ...

Low Cost Automation For Grinding Machine Ppt
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Updated on 31.5.2021,  28.11.2020, 24 June 2019, 22 February 2014

Sunday, June 27, 2021

API Based Services for Performance Improvement and Productivity Improvement

 


Provide real-time customer sentiment analytics to agents using Contact Lens API for Amazon Connect

Zero Flow Processes - Eliminate Operations and Reduce Resource Input

 

In Japanese industrial engineering, Shigeo Shingo talks of flow of machines and flow of operators. The flow here describes the activities of machines and men. Can we reduce them to zero?


Like zero defect movement, can we launch zero flow processes movement and study the work of machines and men in the operations of processes to reduce them?

Saturday, June 26, 2021

Machine vision Based Inspection Productivity Improvement on Bottling Line - IE Case Study - 2013

  



Machine vision increases hourly output of bottling line

March 2013

Machine vision in  automated systems improves productivity, increases throughput, and eliminates human error. 

Beer Bottles Inspection Case Study 


Malted beverages are extremely popular in China, and 95% of all beer bottles are returned for recycling. They are inspected for damage, sterilized, and refilled. Bottle inspection is performed manually in most plants. There are roughly 3,000 bottling lines in China. They run at 18,000 to 24,000 bottles/hr and use human operators. Each line employs three shifts of 18 to 20 well-trained workers who inspect bottles on a fast-moving conveyor belt. The manual inspection is labor intensive and can cause eyestrain and fatigue. 


Machine vision can be used to perform inspection tasks.  Shangdong-based Mingjia Packaging Inspection Technology Co. Ltd. and Waterloo, Ontario-based Teledyne DALSA, a manufacturer of multicamera and digital-imaging products, are developing automated inspection systems for the Chinese-beer industry. “Checking that bottles are fit for reuse is a task that can be accomplished quickly and efficiently by machine vision according to Teledyne DALSA.

Some companies are already using machine- vision inspection systems purchased from abroad Mingjia was founded to design and develop affordable equipment to help beer producers adopt machine-vision inspection in place of manual bottles manually.

Mingjia started its relationship with Teledyne DALSA in 2008. Zhang had approached the Canadian firm  for initial equipment development: The design called for a multicamera system capable of scanning bottles from multiple angles. Teledyne DALSA’s VA41 Vision Appliance is so used for its ability to survey many views simultaneously. This compact machine-vision controller supports up to six cameras — three analog and another three based on the IEEE 1394 serial-bus interface. Serial communications include RS-232, USB, and Ethernet for connecting the controller to the factory network. Mingjia’s configuration of the VA41 uses four analog cameras from a Japanese OEM, runs Teledyne DALSA’s Sherlock machine-vision software, and has enabled inspection rates of up to 42,000 bottles/hr.


Bottle-inspection System 

The inspection equipment is placed immediately before the filling machines on a bottling line. Glass bottles,  on a moving conveyor belt,  pass through the equipment’s inspection chamber at high speed and each of the four cameras connected to the VA41 performs a specific task.

A camera positioned in the chamber at Stage 2 scans and checks the entire surface of the sidewall of an empty bottle, looking for defects, abrasions, and foreign matter. A similar process is repeated at Stage 5, once the bottle has been rotated through a 90° angle. Full-body scanning also makes use of mirrors to reduce the number of cameras required. A group of three mirrors, one behind the bottle and two oriented at 45° to the camera, enable 160% of the bottle’s body to be viewed and accurately checked. The camera at Stage 3, positioned above the bottle, scans the mouth for scratches, cracks, chips, and other irregularities, while the Stage 4 camera checks the base. “Inspecting the base is challenging because, when scanned, the nonslip surface texture molded into the glass bottom of each bottle generates unwanted signals and produces an image that is confusing to inspection algorithms.”  Noise present in the image makes it difficult for the global-analysis software to distinguish between the ribbed background pattern and particles of dirt or other contamination adhering to the glass. To address the issue, optics and special lighting illuminate bottles from above and below, avoiding false alarms and preventing good bottles from being rejected.

The machine vision is also useful for detecting a bottle’s fill level and checking that labels have been applied correctly.

Upgrade to further increase productivity

Mingjia  is developing an upgrade to the machine-vision hardware of its bottle inspection system by replacing the VA41 with a controller named GEVA. The Sherlock application software will be used. GEVA, Teledyne DALSA’s latest industrial controller, offers excellent cost savings for multicamera vision applications. Encased within an aluminum chassis, it provides the basis for a powerful industrial vision system. Unlike the VA41, which uses analog and IEEE 1394 serial-bus architectures, GEVA provides expandable Gigabit Ethernet (GigE) camera interfaces that significantly reduce cost. At the heart of the platform is a dualcore processor equipped with highspeed memory resources.

The controller has two camera ports that both support eight 640 × 480 mono cameras performing simultaneous inspection procedures. As part of the upgrade, Mingjia is also planning to replace third-party cameras with Teledyne DALSA’s Genie systems, which employ GigE technology and transmit data over standard CAT-5e and CAT-6 cables.

“GEVA is about two and a half times faster than VA41. This upgrade will enable Mingjia to substantially speed up inspections — to 64,000 bottles/hr, or possibly even 72,000

https://www.machinedesign.com/automation-iiot/sensors/article/21832428/machine-vision-boosts-productivity-on-bottling-line


https://www.teledynedalsa.com/en/home/

https://www.automate.org/companies/teledyne-dalsa