Saturday, January 28, 2023

Machine Tool Productivity Improvement

 

New Videos

How To Maximize Machine Productivity
MSC Industrial Supply Co.
26 Jan 2023
In this episode of MSC's How To, Jacob Sanchez is joined by Nate Schaub at Wagner Machine Company in Champaign, Illinois, where Nate shows him Wagner’s tried and true methods of maximizing their machines' productivity.
Join Jacob as he gets down to the root of Wagner Machine Company’s efficient machining operations. What does machine productivity mean to the everyday operator, and how can you as a machinist level up your own efficiency? Find out on this episode of How To.


MSC MillMax® Maximizing Productivity Through Milling Optimization
MSC Industrial Supply Co.

Productivity Calculator: Milling
MSC Industrial Supply Co.

How to Maximize Machine Productivity
MSC Industrial Supply Co.
If you are stuck wondering why your machine’s not as productive as you need it to be, it may be time to evaluate your tool holders. Tools alone are not the answer. Find out more here: http://bit.ly/2GaEQ09

MSC MillMax® Maximizing Productivity Through Milling Optimization - April Webinar
In this webinar, learn how MillMax® will help you realize substantial improvements. After 18 months of testing across industries including Aerospace, Automotive, Transportation, and General Machining customers like you have taken the guesswork out of machining optimization to deliver productivity improvements quickly without significant machine downtime. 

Hosted by: 
Jamie Goettler leads MSC’s metalworking sales and innovation efforts. With over 20 years of experience in metalworking and industrial distribution.
Over $1 Million in Profit Improvements and we are just getting started.

MSC MillMax® Maximizing Productivity Through Milling Optimization
MSC Industrial Supply Co.


Machine Work Study - Productivity Improvement Based on Machine and Machine Work Redesign 
#IndustrialEngineering  #Productivity #machineworkstudy #workstudy



TOOLING MATTERS: BOOST PRODUCTIVITY BY SAVING ONE SECOND OF CYCLE TIME
Don Sears

5 Simple Steps for Boosting Productivity in Your Machine Shops

 VIDEO: HOW TO INCREASE PRODUCTIVITY WITH CONSISTENT TOOL SETUPS
Brought To You by Haimer | Posted Dec 27, 2022





























Productivity Foreman and Quality Foreman - Do You Have in IE Department - Quality Department - Production Department?

 

Productivity foreman must have the skill to complete the task in standard time and then must be able to guide and train operators to do in standard time.


Quality foreman must have the skill to complete the task with required quality in specified standard time and then train operators to produce quality output.

Do you have  productivity  foreman and quality foreman recommended by F.W. Taylor?

Functional Foremanship - F.W. Taylor. 

Lesson 342  of  Industrial Engineering ONLINE Course/Productivity Management Module. 

#IndustrialEngineering   #CostReduction #ProductivityManagement  

http://nraoiekc.blogspot.com/2013/08/functional-foremanship-fw-taylor.html


Machine Work Study - Productivity Improvement Based on Machine and Machine Work Redesign


Lesson 81: Process and Operation Analysis for Finding Productivity Improvement Opportunities - Module.  Process Analysis - Eliminate, Combine, Divide,  Rearrange, Simplify (ECDRS).

Three Major Channels of Process Improvement.


1. Process Redesign by Process Planning Team.
2. Process Improvement Study by Industrial Engineering Team.
3. Continuous #Improvement by Involving Shop Floor Employees and All Employees. Continuous Improvement - Employee Participation Principle of Industrial Engineering


Machine Work Study - Innovation in Industrial Engineering by Narayana Rao K.V.S.S.



Productivity promotes competitiveness.
IE promotes productivity.
Innovations in Industrial Engineering are needed to increase productivity and competitiveness.

Taylor's Industrial Engineering


Taylor's industrial engineering consists of reduction of cost of production or productivity improvement based on redesign of machines, cutting tools, machining parameters and operator work practices in using machines,  hand tools or only hands. This point was only indicated in a paragraph on additional contributions of Taylor by  Ralph Barnes in his book on Motion and Times Study (3r ed. and 5th ed.). Barnes main focus was motion study (work methods design). Barnes described the work of Taylor in improving loading of material with shovels in detail. More chapters were devoted to  Gilbreth's motion study and only in case of time study Taylor is given the credit.  It so happened in industrial engineering curricula that "Motion and Time Study" became the core subject of IE. There is no other subject that directly addressed continuous improvement of processes.

In the industrial engineering literature the contribution of Taylor and the implications of those contributions were not captured adequately in Motion and Time Study and there is no other subject that focuses on work related to machines.  Industrial engineering discipline lost the insight of Taylor. Peter Drucker said, after Taylor, there is no further great insight in industrial engineering. As industrial engineering discipline ignored Taylor's ideas, Drucker thought may be even Taylor's insight is half insight. It is the failure of subsequent industrial engineering academicians and professionals not to recognize the shortcoming of the theory and practice that evolved in industrial engineering discipline. 

The situation can be corrected by developing machine based industrial engineering following Taylor's lead. As work study became a popular subject (even Barnes acknowledge the subject), "machine work study" can be the name given to machine based productivity improvement. It is actually machine based industrial engineering. It is redesign of machine, its tools and accessories and machining processes based on the data generated in the industrial practice.  Cost data is an important industrial data and industrial engineering specially emerged as a discipline through its focus on engineering redesign based on cost data to reduce cost of production.



Machine Work Study – Industrial Engineering Analysis of Machine in Production System - A Presentation 



Machine Work Study – Man Work Study – Taylor’s Conceptualization of Scientific Study of Man-Machine Systems is a presentation done by Dr. K.V.S.S. Narayana Rao, Professor,  (NITIE), in December 2015

Taylor (1911) “The Principles of Scientific Management”  - Scientific management in a machine shop. 

Taylor described the implementation of scientific management in a machine shop.

First Stage – Machine Related Improvements

The slide-rules developed for determining optimal speeds and feeds were used to determine the optimal speed and feed for every element of work done on this machine.

The Pulling power of the machine at its various speeds and feeds was determined.

The belt drive and pulleys of the machine were adjusted so that the machine can be run at the proper speed for each element.

The shape of tools was specified and the tools made of high-speed steel (already in use in the company) were properly dressed, treated, and ground.

After preparing the machine, tools and instruction cards in this way, the machinist was asked to work according to the new instruction card and all varieties of work were finished on the lathe and the times were recorded.
The gain in time was found to range from two and one-half times to nine times.


Handwork of Operators – Time and Motion Study

The change from rule-of-thumb management to scientific management involves, however, not only a study of machine effort, that is the proper speed for doing the work and a remodelling of the tools and the implements in the shop, but also study of human effort.

Hence elaborate analysis of the hand work was done.

Hand work depends upon the manual dexterity and speed of a workman, independent of the work done by the machine. On some machines, the time saved by scientific hand work was greater than that saved in machine-work.


Industrial Engineering Discipline - Neglected Machine Productivity Improvement

Industrial Engineering discipline has not developed a subject for analysis of machine related elements and over time the area got neglected. Facilities planning and Material Handling were included in IE programmes but they were also not integrated adequately with process improvement (productivity engineering) function adequately.

Early Authors on Scientific Management.

They recognized the machine work improvement.

Bertrand Thompson  (wrote between 1914 to 1920)

Scientific management was implemented -  first, by determining with the aid of experienced investigators the best materials, equipment, machine methods and man methods to use. In many machine shops, it was the practice to issue to the workman an instruction card containing directions as to feeds, speeds, tools, and times of machine elements and also the manual elements with their standard times in their proper sequence. The combination of machine work improvement and man work improvement resulted in substantial improvements in machine shop work

Malcolm Keir (1918)

Scientific management advocates development of science and a thorough investigation of the work involving analysis of materials, equipment, environment; motion study, fatigue study, time study; research into the laws of health, psychological experiment and community improvement.

Farquhar (1919)

Difference between improving impersonal means of production and human effort in production.


In his paper, he took up for description first, the mechanical phase - the more purely impersonal aspects - divorced so far as possible from the human factor.  He stated that the two were to a certain extent interactive, yet sufficiently distinct to warrant separate treatment.

H.B. Maynard (1927 & 1937)

H.B. Maynard, a popular industrial engineer of the next generation, was a coauthor of "Time and Motion Study and Formulas for Wage Incentives" Stewart McKinley Lowry, Harold Bright Maynard, Gustave James Stegemerten, McGraw-Hill Book Company, Incorporated, 1927. In that book "operation analysis" was described. It evaluated various aspects of the production system including the machine. Maynard and Stegemerten later   authored "Operation Analysis" in which they discussed each and every step of operation analysis in a separate chapter. This book should have been included in IE curriculums.

One Conclusion

There is a need for developing a subject of machine element analysis in IE curriculum based on the definition. "Industrial engineering is system efficiency engineering and human effort engineering" by Narayana Rao.


Machine Work Study Case Study - SMT Machine - Production Line -  Productivity Improvement 


What should we pay attention to when using a dispensing machine?

Published on August 19, 2022


Ralph Barnes - Machine Work Study Indication

What are the question that can be asked and evaluated in machine work study? - Barnes


Based on the questions suggested Barnes:

1. What is the operation?
2. What is the purpose of the operation?
3. What is the transformation of the material required?
4. What is the equipment now used?
5. What are the alternative equipments?


For example see the U20 Die Casting Machine
Product of 25 ton class can cast at parting injection
U Series Features
Less air trapped in the metal flow during die fill, it makes the casting parts excellent.
With parting injection system, it makes less re-melting material and can reduce a lot of re-melting cost.
Sprueless system it makes die opening stroke shorter.
You can consider U20 die casting machine instead of the one  now being used in 25 ton class die casting.


6. What are the cutting tools now used?
7. What are alternative cutting tools?
See the case studies of benefits of alternative cutting realized by many machining organizations.
Cutting Tool Alternatives for Machine Process IE - Cost and Productivity Benefits

8. What are the cutting parameters now used?
9. What are the alternative cutting parameters?
10. What should be the best specifications for machine and machine parameters for the minimum cost that does the required material transformation reliably and accurately?

Six sigma studies in machining process provide number of examples of determining the best specification for cutting parameters.

In doing six sigma studies, "Boundary Limit Strategy" has to be used.

Technical constraints which act as boundary limits are to be first ascertained, and then, bearing in mind economic considerations, working point within these limits are to be determined using optimization studies. direct analytical, evolutionary optimization or six sigma optimization.
See for examples Six Sigma in Machining Processes


Maynard provided a list of questions for machine work study in his book "Operation Analysis." These questions are at more elementary levels.



Questions on Machine, Equipment and  Tools - Maynard and Stegemerten (1939)

Barnes has focused on the motions and activities of the operators and he mentioned machines in a brief manner. It is Maynard and Stegemerten who documented the practice of Westinghouse in the book "Operational Analysis." In this description of productivity improvement many aspects related to machine are covered first and then only at the end of standardizing the machine related aspects, motion study, the work of the operator is investigated.

The following questions are suggested by Maynard and Stegemerten for logical analysis of machine, equipment and tools.

About Machine


1. Is the machine tool best suited to the performance of the operation of all machine tools available?

2. Would the purchase of a better machine be justified?

About Fixture - Workholding


3. Can the work be held in the machine by other means to better advantage?

4. Should a vise be used?

5. Should a jig be used?

6. Should clamps be used?

7. Is the jig design good from a motion-economy standpoint?

8. Can the part be inserted and removed quickly from the jig?

9. Would quick-acting cam-actuated tightening mechanisms be desirable on vise, jig, or clamps?

10. Can ejectors for automatically removing part when vise or jig is opened be installed?

11. Is chuck of best type for the purpose?

12. Would special jaws be better?

13. Should a multiple fixture be provided?

14. Should duplicate holding means be provided so that one may be loaded while machine is making a cut on a part held in the other?

About Cutting Tools


15. Are the cutters proper?

16. Should high-speed steel or cemented carbide cutting tool be used?

17. Are tools properly ground?

18. Is the necessary accuracy readily obtainable with tool and fixture equipment available?

19. Are all operators and machines provided with the same tools?

20. Can a special tool be made to improve the operation?

About Inspection or Dimension Checking


21. If accurate work is necessary, are proper gages or other measuring instruments provided?

22. Are gages or other measuring instruments checked for accuracy from time to time?

Because of the wide variety of tools available for different kinds of work, this list could be extended almost indefinitely with specific questions. Foundries, forge shops, processing industries, assembly plants, and so on all have different kinds of tools, and different questions might be asked in each case. The list given above, drawn up principally and by no means completely for machine work, will indicate the kind of searching, suggestive questions that should be asked. 

A special list might well be drawn up by each individual plant to cover the questions on the kind of machines, machine tools that are used in its own work.

Machine Work Study - Introduction - YouTube Video Presentation

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__________________

Machine Work Study:  Methods, Techniques and Tools - YouTube Video Presentation

_________________

_________________

Toyota Machine Work Study - Machine Improvement in Toyota Production System (TPS)

Machine Work Study - Lessons

Study of machine work has to begin with production engineering lessons related to the machine in use. In this series of lessons of machine tool work is covered.

Metal Cutting Theory - Productivity Focus Lessons


50

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

News - Information for Maintenance Operation Analysis
https://nraoiekc.blogspot.com/2020/07/news-information-for-maintenance.html

51

Machine Tools - Industrial Engineering and Productivity Aspects

52

Machining Cutting Tools - Industrial Engineering and Productivity Aspects

53

Machine Tool Toolholders - Industrial Engineering and Productivity Aspects

54

Metal Cutting Temperatures - Industrial Engineering and Productivity Aspects

55

Machining Process Simulation - Industrial Engineering and Productivity Analysis

56

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

57

Surface Finish - Industrial Engineering and Productivity Aspects

58

Work Material - Machinability - Industrial Engineering and Productivity Aspects

59

Machine Rigidity - Industrial Engineering and Productivity Aspects

60

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

61

Machine Tool Cutting Fluids - Industrial Engineering and Productivity Aspects


62

High Speed Machining - Industrial Engineering and Productivity Aspects

63

Design for Machining - Industrial Engineering and Productivity Aspects



Process Planning of Machining




Process Analysis for Productivity Improvement Opportunities




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Productivity Engineering


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Machine Work Study - Machine Time Estimation - Machine Time Reduction - Machining Cycle Time Optimization


Now the machine shop process industrial engineering that includes all focus areas of industrial engineering is developed.

Machine Shop Process Industrial Engineering 


Productivity Science
Productivity Science of Machining - Stephenson - Agapiou
IE Measurements
Process Industrial Engineering - Process Alternatives and Economic Analysis of IE Proposed Alternatives
IEOR - Optimization in Machining Processes
IE Statistics Optimization - Six Sigma Method
Human Effort Engineering in Machine Shop
Applied Industrial Engineering in Machine Shop
https://nraoiekc.blogspot.com/2020/04/machine-shop-process-industrial.html


Lesson 80 of  Industrial Engineering ONLINE Course


Handbook of Standard Time Data for Machine Shops
https://babel.hathitrust.org/cgi/pt?id=mdp.35128001400272&view=1up&seq=15

Machining Data Handbook
https://archive.org/details/DTIC_ADA092695/page/n25/mode/2up

More Related Posts

Machine Work Study - Productivity Improvement Based on Machine and Machine Work Redesign
#MachineWorkStudy
https://nraoiekc.blogspot.com/2019/06/machine-work-study-productivity.html

Productivity Science of Machining I - Industrial Engineering Research by Taylor Part 1
#MachineWorkStudy
https://nraoiekc.blogspot.com/2020/06/ie-research-by-taylor-part-1.html

Principles of Machine Utilization Economy and Practices
#MachineWorkStudy
https://nraoiekc.blogspot.com/2016/11/principles-of-machine-utilization.html

Equipment Productivity Improvement - Bibliography
#MachineWorkStudy
https://nraoiekc.blogspot.com/2012/09/equipment-productivity-improvement.html

Machine Work Study in Garment Manufacturing Factories
#MachineWorkStudy
https://nraoiekc.blogspot.com/2021/05/machine-work-study-in-garment.html



Process Machine Effort Industrial Engineering - Lessons - IEKC Online IE Course Module
#MachineWorkStudy
https://nraoiekc.blogspot.com/2021/10/process-machine-effort-industrial.html

Machining Time Reduction - Machining Cost Reduction - Industrial Engineering of Machining Operations
#MachineWorkStudy
https://nraoiekc.blogspot.com/2020/03/machining-time-reduction.html

Machine Cost and Work Measurement - Time and Cost Estimates for Metal Forming Processes
#MachineWorkStudy
https://nraoiekc.blogspot.com/2019/11/machine-cost-and-work-measurement-time.html

Machine Work Study in Toyota Production System - Machine Improvement in Toyota Production System (TPS)
#MachineWorkStudy
https://nraoiekc.blogspot.com/2019/11/machine-work-study-machine-improvement.html

Total Productive Maintenance - Nakajima - JIPM - Japan Management Association
#MachineWorkStudy
https://nraoiekc.blogspot.com/2013/12/total-productive-maintenance-japan.html

New Videos

How To Maximize Machine Productivity
MSC Industrial Supply Co.
26 Jan 2023
In this episode of MSC's How To, Jacob Sanchez is joined by Nate Schaub at Wagner Machine Company in Champaign, Illinois, where Nate shows him Wagner’s tried and true methods of maximizing their machines' productivity.
Join Jacob as he gets down to the root of Wagner Machine Company’s efficient machining operations. What does machine productivity mean to the everyday operator, and how can you as a machinist level up your own efficiency? Find out on this episode of How To.


MSC MillMax® Maximizing Productivity Through Milling Optimization
MSC Industrial Supply Co.

Productivity Calculator: Milling
MSC Industrial Supply Co.

How to Maximize Machine Productivity
MSC Industrial Supply Co.
If you are stuck wondering why your machine’s not as productive as you need it to be, it may be time to evaluate your tool holders. Tools alone are not the answer. Find out more here: http://bit.ly/2GaEQ09

MSC MillMax® Maximizing Productivity Through Milling Optimization - April Webinar
In this webinar, learn how MillMax® will help you realize substantial improvements. After 18 months of testing across industries including Aerospace, Automotive, Transportation, and General Machining customers like you have taken the guesswork out of machining optimization to deliver productivity improvements quickly without significant machine downtime. 

Hosted by: 
Jamie Goettler leads MSC’s metalworking sales and innovation efforts. With over 20 years of experience in metalworking and industrial distribution.
Over $1 Million in Profit Improvements and we are just getting started.

MSC MillMax® Maximizing Productivity Through Milling Optimization
MSC Industrial Supply Co.




Updated on 28.1.2022,  19.8.2022,  30.5.2022,  16 Oct 2021,   18 August 2021,  16 May 2021,  1 March 2021,  5 August 2020,  23 May 2020, 11 May 2020,
16 November 2019,  4 July 2019,
27 June 2019, 




Friday, January 27, 2023

Quality Principle of Industrial Engineering

 

Industrial engineering is concerned with redesign of engineering systems with a view to improve their productivity. Industrial engineers analyze productivity of each  resource used in engineering systems and redesign as necessary to improve productivity.

Defects reduce productivity. Hence reducing defects is part of industrial engineering work. Reducing defects in production and reducing defects in incoming materials is part of industrial engineering.

It has to be ensured that the increase in productivity due to the use of low-cost materials, processes and increasing speed of machines and men, should not lead to any decrease in quality of the output. Hence in each step of productivity improvement, IEs have to make sure that the quality of the system does not go down.

Productivity Engineering - Principle of Industrial Engineering



TAYLOR - NARAYANA RAO PRINCIPLES OF INDUSTRIAL ENGINEERING


Download full paper - Principles of Industrial Engineering
IISE Annual Conference Proceedings - 2017.  Industrial and Systems Engineering Conference, Proquest
INSTITUTE OF INDUSTRIAL AND SYSTEMS ENGINEERS
https://www.proquest.com/docview/1951119980

Productivity Science - Productivity Engineering - Productivity Management - Important Steps of Industrial Engineering



2-Productivity Engineering


______________________

Productivity Engineering - Principle of Industrial Engineering


Industrial engineering is primarily engineering redesign to improve productivity. Productivity engineering can be an alternative name to industrial engineering. Efficiency engineering is also an alternative name and it was used for the discipline by some authors.

Industrial engineering is concerned with redesign of engineering systems with a view to improve their productivity. Industrial engineers analyze productivity of each  resource used in engineering systems and redesign as necessary to improve productivity.

It has to be ensured that the increase in productivity due to the use of low-cost materials, processes and increasing speed of machines and men, should not lead to any decrease in quality of the output.

Similarly, operators should not feel any discomfort, not have any health problems or safety issues in the redesigned more productive processes.

Developments in Productivity science provide more and more directions for productivity engineering over the period.

______________________


______________________


Productivity Engineering


Productivity engineering is applied to engineering elements in products or services and processes. Engineering elements, activities, operations and processes are present in design, manufacturing, construction maintenance, operation, transportation, materials handling, and information processing etc. in industrial organizations. Engineering processes are present in agriculture and related activities and service businesses also.


Productivity Engineering - Focus Areas of Industrial Engineering 


Product Industrial Engineering

Process Industrial Engineering
https://nraoiekc.blogspot.com/2017/02/process-industrial-engineering.html

Human Effort Industrial Engineering

Principles of Productivity Engineering  -  Mundel - Nadler


Methods Redesign for Efficiency/Productivity - Material, Product Design, Material Transformation Steps, Machine Effort, Human Effort - Marvin Mundel, Gerald Nadler


Nadler credits Mundel for the following steps to be followed in methods redesign.

Product Industrial Engineering


1. Change the material being used or contemplated to help meet the goal for the operation being studied.
2. Change the present or contemplated design of product to help meet the goal for the operation being studied.

Process Industrial Engineering


3. Change the present or contemplated sequence of modification work on the material or product to help meet the goal of for operation being studied.
4. Change the equipment used or contemplated  for the operation to help meet the goal for the operation being studied.

Human Effort Industrial Engineering


5. Change the method or hand pattern used or contemplated for the operation to help the goal for operation being studied.


(Source: Gerald Nadler, Motion and Time Study, McGraw-Hill Book Company, New York, 1955,   p.193. Nadler in turn gives credit to Marvin E. Mundel, Motion and Time Study Principles and Practice, Prentice-Hall, New York, 1950, pp. 23-26.)

Industrial Engineering FREE Online Course Modules

Process Industrial Engineering Module Lessons - Notes


Productivity Engineering - Productivity Improvement Techniques (PITs)


Indicated by David Sumanth

Technology Based PITs

1. CAD, CAM, CIM
2. Robotics
3. Laser technology
4. Renewable energy
5. Energy conservation
6. Rebuilding old machines
7. Group Technology
8. Advanced and Recent Maintenance Technology
9. Material Handling Technology 
10. Material Reuse and Recycling

Product Based PITs

1. Value Engineering
2. Product Diversification
3. Product Simplification
4. Product Standardization
5. Product Related Research and New Product Development
6. Product Productivity Improvement through Reliability Improvement


Process (Task) Based PITs

1. Methods Engineering




New Productivity Improvement Techniques (PITs)


Technology Based PITs

1. Industry 4.0 Technology Set and Applications
2. Artificial Intelligence
3. Data and Business Analytics
4. Autonomation
5. PokaYoke

Product Based PITs

1. Design to Cost
2. Design for Value
3. Frugal Innovation
4. Smart Products
5. Digital Twin


Process (Task) Based PITs

1. Process Reengineering
3. Cloud Computing
4. Six Sigma
5. Lean Manufacturing (Toyota Production System)



Principles of Industrial Engineering - Narayana Rao - Detailed List

Clicking on the link will take you to more detailed content on the principle


The full paper on the principles by Prof. K.V.S.S. Narayana Rao is now available for downloading from IISE 2017 Annual Conference Proceedings in Proquest Journal Base.



Updated  2023 - 27.1.2023 
2021 - 8.9.2021, 25.8.2021
2019 - 10 November 2019,  1 June 2019
2018 - 25 May
First Published  29 June 2017

Thursday, January 26, 2023

Operational Excellence - The Concept - The Practice

 Excellence is Exceeding Customer Expectations.


Operational Excellence,  is a broader methodology that aims to improve the overall performance of an organization by aligning all aspects of the business with the company's vision and strategy. 

It emphasizes the importance of leadership, culture, and employee engagement to create and drive a culture of excellence and continuous improvement . Operational Excellence function can use all tools or techniques. Its  aim is to bring the entire organization together to strive for excellence.

https://www.reliableplant.com/operational-excellence-31886

https://instituteopex.org/what-is-operational-excellence/

https://www.ibm.com/cloud/blog/delivering-value-through-operational-excellence

https://www.forbes.com/sites/forbestechcouncil/2022/12/20/understanding-operational-excellence-and-the-continuous-optimization-of-it-operational-efficiency/

Excellence is Exceeding Customer Expectations.




Consultants




Operational excellence looks beyond cost reduction and process improvements towards the achievement of long-term sustainable growth. It is a mindset that embraces certain principles and tools to create a culture of excellence within an organization. Operational excellence means every employee can see, deliver and improve the flow of value to a customer.




Operational Excellence
Business Improvement
The focus of Operational Excellence is a hybrid of cost containment, operational throughput and a stable work force. The objective is a management team who are equipped to operationalise business strategy, implement change in their organisation’s processes and systems, and maximise value over the life of the asset.

Deloitte’s Operational Excellence offerings assist Operational Executives to operationalise business strategy, implement improvement and change in their organisation’s processes, systems and people, as well as to maximise the value over the life of an asset or organisation.  Operational Excellence includes:

- Environmental scanning & Strategic Context
- People, Performance and Culture
- Process Optimisation
- Supply Chain and Sourcing
- Asset Care
- Asset and Resource Optimisation
- Continuous Improvement
- Management Control Systems
- Organisational Redesign and Simplification
- System Capacity and Capability
- Social Labour Plan Commitments




Companies

https://www.jpmorganchase.com/about/our-business/operational-excellence














Industrial Engineering - Lean Six Sigma and Operational Excellence - Difference

 

Industrial engineering is engineering activity to support managers to increase productivity and reduce costs in engineering systems and processes and thereby products and services at lower units costs.


Interesting explanation by Joseph Paris

The differences between Lean Six Sigma and Operational Excellence

Lean Six Sigma and Operational Excellence are both methodologies that aim to improve the performance and efficiency of an organization, but they have some key differences.

Lean Six Sigma is a methodology that combines the principles of Lean manufacturing and Six Sigma to eliminate waste and defects in an organization's processes. It is focused on finding and removing the causes of problems using data and statistical analysis. The goal of Lean Six Sigma is to improve the quality and efficiency of processes, resulting in cost savings and increased customer satisfaction.


Operational Excellence, on the other hand, is a broader methodology that aims to improve the overall performance of an organization by aligning all aspects of the business with the company's vision and strategy. It emphasizes the importance of leadership, culture, and employee engagement to drive continuous improvement and create a culture of excellence. Operational Excellence is not limited to specific tools or techniques but aims to bring the entire organization together to strive for excellence.

In summary, Lean Six Sigma is a methodology that specifically focuses on improving the efficiency and quality of processes using data and statistical analysis, while Operational Excellence is a broader methodology that focuses on aligning all aspects of the business with the company's vision and strategy and creating a culture of excellence throughout the organization.

https://www.linkedin.com/pulse/artificial-intelligence-continuous-improvement-joseph-paris/


CNC Sewing Machines - Productivity & Quality Benefits

 



https://www.demasewingautomation.com/products/industrial-sewing-machine/industrial-sewing-machine/programmable-sewing-machine


HOW TO CHOOSE A CNC MACHINE-FROM USAGE APPLICATION TO PATTERN MAKING OF THE AUTOMATIC SEWING MACHINE

Published on August 11, 2021

https://www.linkedin.com/pulse/how-choose-cnc-machine-from-usage-application-pattern-light-ma/


CNC Sewing Machine with Laser Cut
RPAS-LM-C-1-1200X800-A-IS1(2)-VR1(2)-LC100-1P220

SpeedMax 2500RPM
Power3.98kW
Voltagesingle phase 220V
https://www.richpeace.com/cnc_sewing_for_hometextile-show-987.html



News Related to CNC Sewing Machines

The brand-new DA 911-906 takes automated sewing processes for medium-heavy applications to a new level of productivity.

As an innovative sewing system, the DA 911-906 combines high-quality CNC sewing with fully automatic material feeding and stacking in a single sewing unit. 

By linking and automating the upstream and downstream processes directly before and after the actual sewing process, an overlapping mode of operation is made possible. 

A single operator can prepare the next work step, so there is no downtime and the process is operated at maximum productivity.


DA 911-906 can be used for a wide range of medium-heavy sewing applications. For example, one of the applications where the DA 911-906 is used is for sewing foam onto automotive seat cover parts. As the clamp securely fixes the two fabric layers and guides them to the machine, slipping of the fabric layers is prevented. As a result, in addition to working efficiently, the usually necessary laminating process can be completely eliminated, which not only shortens the operation itself, but also the entire production process.



Pub 16.1.23


















Monday, January 23, 2023

The Evolution of Productivity Management

The Evolution of Productivity Management

Chapter of Productivity Management in Engineering Organizations - Online Book




The Evolution of Productivity Management - Important Contributors and Their Contributions and Systems



Importance of productivity improvement was highlighted by the first President of ASME in 1880. Henry Towne in 1886, presented a paper in ASME Conference strongly highlighting the need for engineering efforts to reduce cost of production on a continuous basis. He also presented a paper in 1889 explaining the method followed in his company to involve all production/shop employees in cost reduction effort. 

F.W. Taylor responded to these cost reduction calls by explaining the initiatives he had taken. in 1893, he presented his paper on the improvements done in the area of belt design to reduce overall cost belt systems that included installation cost, maintenance cost and operation time lost due to maintenance time. In 1895, he presented a full explanation of the productivity improvement system utilizing study and reduction of time taken by machines and men to do elementary activities that are present in multiple different engineering jobs. Then he advocated fixing of piece rates and daily rates that provided additional income or higher wages to operator to learn and use new methods and produce higher output. In this paper, he suggested organizing a rate fixing department, that later on became industrial engineering department that takes the responsibility of improving productivity in engineering organizations. This paper became popular as piece rate system. F.W Taylor is regarded as the father of industrial engineering for this engineering innovation in the area of organizing engineering knowledge or practice.

F.W. Taylor


Piece Rate System

Shop Management

Scientific Management

Frank Gilbreth


Motion Study

Applied Scientific Management


Paul Mali


Improving Total Productivity - Paul Mali 1978 - Chapter Summaries


1981

Total Involvement as a Productivity Strategy

Ian Rolland
Chairman and Chief Executive Officer of Lincoln National Life Insurance Company
and President and chief executive officer of Lincoln National Corporation Company in Fort
Wayne, Indiana.

Robert Janson
Executive vice-president of Roy W. Walters & Associates, Inc., consultants to management, in Mahwah, New Jersey.
California Management Review, WINTER / 1981 / VOL. XXIV / NO. 2, pp. 40-48

• Productivity is a long-term survival issue. Unless a company focuses on productivity as a key
ingredient of their corporate philosophy, it won't survive.
• Companies must plan for productivity. Productivity does not just happen. It requires a strategy that is comprehensive, long-range, and monitored. It requires rational, purposeful behavior on the part of everyone.
• Employee security must be assured. Productivity should not be looked at as cost cutting or it
will make people insecure. This does not mean that they won't be doing different things, however.
• Employee involvement is the key ingredient to productivity. Management must create a
structure that focuses people's energy inward to their own jobs and organization rather than
how unhappy they are or how bad the organization is.
• Ownership and commitment are essential. Unless everyone feels part of the effort and looks on it as something that will help them, it won't work.
• Productivity and individual responsibility work together. An organization should be designed
for accountability to the lowest possible level. This requires in many cases a broad redesign
of tasks and jobs.
• Productivity is a very complex issue. The important thing is to have a strategy that is long term,
with measurable goals. Individual units will have different applications.
• A good strategy will have multiple phases. The effort should not be looked at as a "quick
fix." It takes time to move the organization in a new direction.
• Productivity strategies must support and strengthen the business mission. The mission
of the company, with its goals and objectives, comes before individual productivity efforts.


David J. Sumanth (1984)


Productivity management is a formal process involving all levels of management and employees with the ultimate objective of reducing the cost of the manufacturing, distributing, and selling of a product or service through an integration of the four phases of the productivity cycle, namely, productivity measurement, evaluation, planning, and improvement.



D. Scott Sink (1985)


Basic Productivity Management Process includes the following: (1) measuring and evaluating productivity; (2) Planning for control and improvement of productivity based on information provided by measurement  and evaluation process; (3) making control and improvement interventions; and (4) measuring and evaluating the impact of these interventions.


The essence of productivity management process is to direct and motivate productivity planning and action through the productivity measurement system.

A Synopsis of Productivity Management


Productivity management involves planning, organizing, leading, controlling, and adapting processes, technologies, output and inputs based on the relationship between quantities of outputs (including in revenue/price terms) from a system and quantities of input (including in cost/price terms) to the system.  Productivity management is an important planning and control function like other management functions. But, there is a growing concern that it has been overlooked and that it needs to be better developed.

In the 1985 book, Scott Sink expressed the opinion that there are no significant breakthroughs.  Much of the success in Japan and elsewhere appears to result from more effective implementation.

Productivity managers have to understand the various functions that contribute to the creation of goods and/or services. They have to take a large strategic view of the system and examine the individual machines and operators to make productivity improvements that are alignment with the productivity strategy and show measurable results.




Prem Vrat, G.D. Sardana, B.S. Sahay (2009)


Productivity Management


All activities of overall management which determine productivity policy, productivity planning, productivity audit, productivity monitoring and control, productivity measurement, productivity evaluation, organisational structure, procedures, processes and resources to implement productivity improvement programmes and policy.

Narayana Rao Kambhampati (2017)


Productivity management is included as a principle in principles of industrial engineering.
(Kambhampati, Venkata Satya Surya Narayana Rao, "Principles of Industrial Engineering", IIE Annual Conference. Proceedings; Norcross (2017): 890-895).
https://nraoiekc.blogspot.com/2017/06/productivity-management-principle-of.html

Productivity management

Productivity management is the responsibility of industrial engineers. Productivity management practice has two areas of focus in industrial engineering. One is an evaluation of management processes and plans for their impact on the productivity of engineering activities and processes. If the evaluation shows that productivity can change due to change in management process or plan, industrial engineers have to come up with redesigns and recommend them to management at various levels. Due to this component, industrial engineers have to learn management principles and
methods in various industrial and business functions.

The second component is the application of management theory and practice to the task of productivity improvement. Every industrial engineer is a productivity manager. He has to learn complete management theory and its application in IE practice.


Principles of Industrial Engineering - 2017


Principles of Industrial Engineering - YouTube Video Presentation

Functions of Industrial Engineering - 2018

Functions of Industrial Engineering - YouTube Video


(C) Narayana Rao K.V.S.S. 2019

Next Chapter
4. Total Productivity Management

2022
2022
Title Reimagining Work in the New Norm: The Exponential Workplace
Author(s) Azim Pawanchik
https://www.apo-tokyo.org/publications/reimagining-work-in-the-new-norm-the-exponential-workplace/


2023

Productivity Tips in Social Media





Your productivity is a work done in certain period.
More work done in the same period with the same resources increase productivity.
You need to get organized to be more productive.
You need to be more focused on your work if you want to be more productive.
Good execution plans can increase your productivity.
You need improve  your process and systems if you want to accelerate performing the same job. 
Your personal life have influence on your business life and productivity.

Everything varies wildly from day-to-day, from month to month, from year to year…

Working with passion can bring more work done.
Enjoying what you work will help you to do more work.
Inspiration is the productivity creator.
Negative individual emotions have a negative effect on your work done.

Preparation will increase possibilities of quality of the work you done.
Focus on the desired results will increase a possibility of quality accomplishment.
There will be always the possibility of improvement.
Tracking the progress will improve your work done over the time.
Lists are a very useful stuff.
Finding constraints and cut them permanently will increase personal and business efficiency.

Outsourcing of unimportant stuff will help you.
First do the most important things.
Help from other people is welcomed and accepted.

If you finish easier tasks as first, you will increase your overall productivity.


What you can to do today, do it today, not tomorrow.
Your productivity in many cases will depend on the productivity of your environment.
Physical environment can influence your productivity.

Taking a short break will improve your personal productivity.
Refreshing the mind give us additional energy.
Accepted criticism make better work done in the shorter period.
Distraction has a negative effect on you.



Learning from other people and businesses will give you possibilities to escape their mistakes.
Stress has a negative effect on work you done.
Celebrating success with your team will give you and your team additional potential energy.
Self-confidence is important.
Proactive, not reactive is the basis for success.

Notebooks are useful when something important comes to our mind.
It is normally that nothing goes right all the time. Technology is here to help you. Don’t escape from the new technology. Do not be afraid if you don’t know how to use something new.
Everything can be learned.
Everything can be systematized. Everything can be improved and simplified.

Posted by Dragan Sutevski
Dragan Sutevski is a founder and CEO of Sutevski Consulting, creating business excellence through innovative thinking. 
https://www.entrepreneurshipinabox.com/11324/60-productivity-rules-updated-expanded/

Ud. 23.1.2022
Pub. 12.10.2019

Saturday, January 21, 2023

Productivity Management Course Lessons

2023 - For CEOs at Davos, Efficient, Profitable Operations Take Center Stage.
Companies say they are giving priority to profitability and efficiency amid concerns about macroeconomic conditions. 
In many cases, executives say they are looking to deploy new technology to help cut costs. 
“We have to be much tougher on costs and achieve the same growth plans with a lot less investment,” Uber Technologies Inc. Chief Executive Dara Khosrowshahi. 
“We in the tech industry will have to get more efficient." -  Satya Nadella, chief executive of Microsoft Corp.
Creating long-term value and efficiency is key to any organizational transformation, said Ernst & Young CEO Carmine Di Sibio.  
https://www.wsj.com/articles/for-ceos-at-davos-efficient-profitable-operations-take-center-stage-11674151208?st=8gffac5pq3i9x4f&reflink=desktopwebshare_permalink


Module of Industrial Engineering FREE ONLINE Course


1000 persons accessed in the first year (2020-2021). Second time daily sharing (2021-2022) Started on 1 June 2021. 



Why Focus on Productivity and  Productivity Management?

Chapter of Productivity Management in Engineering Organizations - Online Book



For a Society or  a nation to raise the standard of living of its population, it must strive to maximize the return from its resources or improve productivity so that the economy can grow and sustain a better quality of life.  (ILO, Introduction to Work Study).

The management of an enterprise is responsible for seeing that the enterprise resources ... are combined in the best possible way to achieve the highest productivity. (ILO, Introduction to Work Study).

The Japanese economy successfully weathered the oil crises of the seventies without suffering serious damage ... This success has been attributed primarily to Japan's high productivity. (Shigeo Shingo)

Productivity is a long-term survival issue. Unless a company focuses on productivity as a key
ingredient of their corporate philosophy, it won't survive. (Ian Rolland and Robert Johnson)

Companies must plan for productivity. Productivity does not just happen. It requires a strategy that is comprehensive, long-range, and monitored. It requires rational, purposeful behavior on the part of everyone.  (Ian Rolland and Robert Johnson)

We can easily state that productivity is the only source of real economic growth and progress. A nation must maintain competitive levels of productivity in key industries to even maintain its standard of living in what is becoming an increasingly competitive world market. (D. Scott Sink)

The manufacturing sector of the Japanese economy has led the world in productivity growth rates for almost 30 years. In a number of key industries, Japan has far surpassed the United States in absolute levels of productivity. One factor contributing to Japan's success is its focus on improving competitive capability, efficiency, and "striking power" in strategically selected target industries.  (D. Scott Sink)

Japan's government and industry cooperate to manage industrial policy strategically. As part of the strategy, growth, productivity, quality, and innovation are managed systematically in target industries. (D. Scott Sink)


(C) Narayana Rao K.V.S.S. 2019

Review of the Concept and Importance of Productivity 

____________________________



https://www.youtube.com/watch?v=7dqVIVjVSoA

Competitiveness, Strategy, and Productivity

Eddy Witzel

https://www.youtube.com/watch?v=b0YfKoK2uF0

____________________________


337. Functions of Productivity Management

338. The Evolution of Productivity Management

339. Productivity Management - F.W. Taylor

340. Productivity Management in Operations Management Since 1886

341. Productivity Management - Improving Productivity - Stevenson in Operations Management Book

342. Functional Foremanship - F.W. Taylor

        Productivity - Basic Concepts

Harrington Emerson - 12 Principles of Efficiency - Productivity Management

343. Harrington Emerson - The Twelve Principles of Efficiency - Part 1 - Principles of Productivity Management

344. Harrington Emerson - The First Efficiency Principle: Clearly Defined Ideals (Objectives and Goals)

345. Industrial Engineering #Data. Harrington Emerson - The Sixth  Efficiency Principle: Reliable, Immediate, Adequate, and permanent Records. 

346. Harrington Emerson's The Seventh Efficiency (Productivity Management) Principle: Despatching.

347. Harrington Emerson's Eighth Efficiency (Productivity Management) Principle: Standards and Schedules 

https://nraoiekc.blogspot.com/2013/10/chapter-10x-eighth-principle-standards.html

348. Harrington Emerson's Ninth Efficiency (Productivity Management) Principle: Standardized Conditions. 

https://nraoiekc.blogspot.com/2013/10/chapter-11-ninth-principle-standardized.html


349. Harrington Emerson's Tenth Efficiency (Productivity Management) Principle: Standardized Operations. 

https://nraoiekc.blogspot.com/2013/10/chapter-12-tenth-principle-standardized.html


350. Harrington Emerson's Eleventh Efficiency (Productivity Management) Principle: Written  Standard-Practice Instructions. 

https://nraoiekc.blogspot.com/2013/10/chapter-xiii-eleventh-principle-written.html

351. Harrington Emerson's Twelfth  Efficiency (Productivity Management) Principle: Efficiency Reward. 

https://nraoiekc.blogspot.com/2013/10/chapter-14-twelfth-principle-efficiency.html

352. Harrington Emerson:  12 Efficiency Principles  Applied to Measurement and Cure of Wastes. 

https://nraoiekc.blogspot.com/2013/10/chapter-15-efficiency-principles.html


354.  Industrial Engineering - Its Role in Productivity Improvement

355.  Productivity Planning

356.  Manufacturing Cost Reduction Policy Deployment - Introduction.

357. Organizing for Industrial Engineering Department and Function

358. Resourcing for IE Department and Productivity Improvement Projects

359. Productivity - Communication
https://nraoiekc.blogspot.com/2022/03/productivity-communication.html

360. Productivity Training by Industrial Engineers
https://nraoiekc.blogspot.com/2022/03/productivity-training-by-industrial.html

361. Productivity Control - Productivity Management - Koontz & O'Donnell

https://nraoiekc.blogspot.com/2022/03/productivity-control.html

362. Principles and Practices of Productivity Management

https://nraoiekc.blogspot.com/2021/06/principles-of-productivity-management.html



366. Industrial Engineering Strategy

367. Success Stories - Industrial Engineering, Productivity Improvement and Productivity Management






Productivity Month in India - 30 Lessons starting from 12 February 2022

Ud. 21.1.2023, 6.3.2022, 12.2.2022,  31.1.2022,  9.9.2021, 29.8.2021

Pub 1.8.2021