Sunday, September 29, 2024

Material Handling - Transport Between Work Stations - Inspection Stations and Storage Points - Manufacturing Process Design

 



https://www.mmh.com/   -   https://mhwmagazine.co.uk/



Material Handling - Explanation by Maynard

In Operation Analysis Book  (1939)




The material must be transported to the work station, it must be handled by the operator before and after processing, and finally it must be taken away again. 

 Material handling adds nothing to the value of the part, although it does increase its cost. Therefore, a determined attempt should be made to reduce material handling to an absolute minimum.

The material-handling problem resolves itself into two natural subdivisions, the handling of material to and from the work station and handling at the work station.

Material Handling to and from Work Station. There are a number of different ways of transporting material to and from work stations, and the one which is the most effective and efficient will depend upon such individual conditions as the size of the material to be moved, the amount, the frequency of movement, and the distance transported.

The oldest, and probably even yet the most commonly employed method is movement through human agency. A move man or an operator carries or uses a hand truck to move material from place to place.


In certain instances, this is a proper and efficient method. For example, if a given material is so light and so small that a supply sufficient for 2 hours work can be carried in a container the size of an ordinary bread pan, a mechanical means of transportation would be uneconomical. The handling time during the process of manufacture between operations may be as little as 1 per cent of the total processing time, because of the large number of pieces that may be carried at one time. This could undoubtedly be reduced somewhat by relaying out the work space and arranging the operators so close together that they can pass material from one to the other without getting up. Even this is not particularly desirable, however, for little if any real saving would be made. The operations performed on such parts are usually rapid and comparatively monotonous. Getting up and going for a fresh supply of material every 2 hours or so breaks the monotony and actually acts as a rest period by providing a change of occupation. If the, handling operation did not provide this interruption and rest, fatigue would cause the operators to seek it anyway by extra trips to the washroom or drinking fountain. Material handling on small parts that provides an occasional break during a monotonous operation is desirable.

Hand Trucks. The larger the parts are, the more effort is required to handle them by hand. Added weight involves added muscular effort, and added volume means more trips to transport
a given number of pieces. As weight and volume increase, trucks of some sort become increasingly desirable. . Human labor is required to push them from place to place, but they add to the effectiveness of that labor by making it possible to move a large number of parts easily and at one time.

Hand trucks are superior to no trucks at all, but they offer a number of disadvantages. They are bulky, and since they must be pushed through the aisles that are used by anyone who desires to go from one part of the plant to another, with or without material, they cause interference to easy movement and often serious congestion. Where only one aisle is available, empty trucks commonly flow back against the stream of loaded trucks. In addition, the trucks occupy considerable valuable floor space at the various work stations. The replacing of hand trucks by conveyers will often result in worth-while economies.


Electric Trucks. Electric trucks are used for much the same purpose as hand trucks. They require the services of an operator, but usually more material may be handled per trip, and handled faster. Electric trucks are made in a number of different styles, and special trucks are made for special applications.

Tractor-trailer Systems. When miscellaneous material must be transported to a number of different places located over a large area, electric trucks may be replaced to advantage by a
tractor-trailer train. For example, a  train replaced eight electric trucks. Before its installation, the electric trucks were used to transport material, some of them being assigned to- specific departments and some operated from a central point. Wherever material had to be moved, the electric trucks were used. The departmental trucks took finished material to other departments and usually returned empty. The other trucks were sent empty to whatever part of the plant they were needed. They did the required moving and then returned to the dispatch station empty. An earnest attempt was made by the dispatcher to route the trucks so that they were loaded as much as possible, but it was a difficult task. In addition, often when a rush call for service was received, all trucks were , and delays were frequent.

The installation of the tractor-trailer system reduced labor and greatly improved service throughout the plant. A route was laid out that took the train past every important material station in the plant. A regular schedule was set up, calling for several complete trips per day. The train moved along its route, drop-ping off trailers at the proper destinations and picking up others bound for different departments. Delays were reduced to a minimum, and each department knew, within a minute or two, the time it would receive incoming material or could ship outgoing  material. A few of the old electric trucks were retained at first for emergency service, but the tractor-trailer system functioned so well and gave such rapid service that there was little call for them.

Conveyers.


Conveyers are widely used throughout industry and, where they are properly installed to meet a definite need, will give worth-while economies. Considerable care must be taken to determine if a conveyer will really be an advantage before it is put in, for not all handling problems can be solved by this means. A shop superintendent was once heard to refer contemptuously to an elaborate overhead conveyer system as a "traveling storeroom". As a matter of fact, this is just what it amounted to. Because there was no real need for a conveyer in this department, it was used principally to keep unwanted material off the floor. Material would sometimes slowly circle the department for a week at a time before it was removed from the conveyer. This was wasteful, of course, and was the direct result of an improper installation.

There is a wide variety of kinds and types of conveyers offered by conveyer manufacturers for industrial use. Since conditions in every plant differ, all installations are in a sense special, but most conveyers designed to handle standard materials such as cartons, boxes, or tote pans are made up of standard sections or units. Gravity conveyers are in general cheaper than power-driven conveyers but, of course, require that the opposite ends of the conveyer be at different levels.

A conveyer does not have to be expensive or even purchased to be effective. Often a homemade arrangement of wooden boards will be as efficient as any conveyer that can be installed. On punch-press work, for example, where a product is made in several operations of approximately equal length, if the punch presses are set side by side, wooden chutes  make excellent conveyers. At a given work station, the operator lays aside his finished part in the raised end of a chute. The part rolls or slides to the next operator and arrives in a position convenient for grasping.

Roller conveyers take advantage of the force of gravity to bring about material movement. The rollers run freely on ball bearings ; hence, a comparatively slight drop per foot of travel is necessary. If long distances must be covered, an occasional belt conveyer may be used to boost the material from the low end of one roller conveyer to the high end of the next. .

Other commonly used conveyers are the belt conveyer, , the spiral conveyer which may be either a roller conveyer or - a sheet-metal spiral with a steeper pitch, and the overbad chain conveyer. Many other types are alsQ^Ti|ilable, and special conveyers for almost any sort of specific material-handling problem can be obtained. Information and advice can be obtained from the leading conveyer manufacturers whenever an installation is contemplated. The main point to be decided upon first is the necessity for the conveyer. If a conveyer is desirable, a suitable type can be found.

Conveyers for Miscellaneous Work.


 It is commonly felt that conveyers are applicable only where a standard product is manufactured in quantities. Under certain conditions, however, they may be used successfully to handle a miscellaneous variety of work. For instance,  a conveyer was used in a a storeroom for finished material. A number of miscellaneous products are kept in this storeroom. When an order is received, material is taken from the shelves of the storeroom and is placed on the conveyer which takes it to a checker. When the order has been checked, other conveyers take it to various packing stations for packing and shipping. In spite of the variety of product handled and the number of ways in which orders are packed and shipped, a large saving was made by conveyerizing the stores and shipping department.

Another and perhaps even more striking example of the use of conveyers on miscellaneous work occurred in a machine shop doing milling and drilling operations on small quantities of metal parts. Horizontal milling machines, vertical milling machines, and sensitive, radial, and multiple spindle drill presses were used, and there was a total of 51 machines in the department. Because of the small lot sizes, each machine worked on several different jobs each day. The order in which operations were performed was by no means fixed, for some jobs required drilling before milling, others milling before drilling, and others were milled, drilled, and milled again.

In the former layout,  material was moved about by laborers. They brought unfinished material to the various work stations and removed finished material. Material was piled about the machines and, besides occupying floor space, was decidedly unsightly. In addition to the material-handling problems, the matter of proper production control presented difficulties. In every shop, there are always certain jobs that are undesirable from the worker's viewpoint. When a number of jobs are available, the operators will choose the most desirable and will put off doing the least desirable as long as possible. Therefore, the production department has to be continually on the alert to prevent jobs being neglected until they become overdue.

A conveyer installation eliminated the move men and overcame production-control difficulties.  All material is sent out from the central dispatch station, The dispatcher has a set of records which show when each job is wanted and what the operations are that must be performed. At the proper time,, he places material on the outgoing conveyer and by means of a control apparatus shunts it off on the proper lateral conveyer which takes it to the machines.  When the operation has been completed, the material is put on a return conveyer located directly below the outgoing conveyer. The job returns to the dispatcher who sends it out to the next operation. In this way, a definite control of the order in which jobs are to be done is obtained. A definite check on the production of each man is available, and certain phases of the clerical routine are simplified.

Material Handling at the Work Station. When material has been brought to the general neighborhood of the work station, the from that point until the operation Is complete is  usually done by the operator. When material is brought by truck, or tractor-trailer train, he usually has to walk a varying distance to the material and transport it to working position himself. Conveyers or overhead cranes usually bring the material close to the operator.

When the material is at the work station, it must be picked up and moved to the working position. The work is done, after which the material is set aside. When the job is finished, the complete lot of material may be removed from the immediate vicinity of the work station by the operator.

The exact procedure followed "will vary considerably with varying conditions and products; but unless the material is brought directly to the operator by conveyer and the work is done on the part while it is still on the conveyer, there will be a certain amount of material handling at the work station. This should be reduced as much as conditions permit. The initial and final moves can sometimes be shortened by rearranging the layout of the department. Material handling at the workplace can be reduced by detailed motion study.


As a matter of fact, the design  a single material handling-transport operation seldom leads to the installation of a conveyer system or other expensive handling means unless the operation is highly repetitive. Usually it results in the design and installation of simple handling devices such as the gravity chutes  or the development of special tote pans or racks, which facilitate the handling of the particular job.

At the same time, the desirability of the more elaborate handling devices should be considered. If several analyses indicate that a conveyer system, for example, offers possibilities, then a more general study and design of material handling at a more broader level may be undertaken. These greater possibilities should be kept in mind during all design projects. 




2020

2018

Get 30% More Productivity by Shifting Your Focus from Runtime to Uptime
The drive for higher levels of productivity has caused some AGV manufacturers to select larger batteries that can last longer between recharge periods.
April 23, 2018
https://www.mmh.com/article/get_30_more_productivity_by_shifting_your_focus_from_runtime_to_uptime/agvs

General Motors increases manufacturing productivity with automated vehicles
Self-driving vehicles reduce time and waste in large facility’s complex manufacturing operations.
 February 8, 2018
https://www.mmh.com/article/general_motors_increases_manufacturing_productivity_with_automated_vehicles

2014
Material Handling Developments
The One Level Shuttle AS-RS (OLS) is a highly efficient Automated Storage and Retrieval System designed for expedited handling of cartons, totes, and trays in high transaction environments.
http://www.invata.com/warehouse-automation/automated-storage-and-retrieval-systems-asrs/shuttle-asrs/

For more information on recent development in material handling visit
Material Handling Solutions and Equipment - Information Board

2012

Comprehensive Lecture Notes on Material Handling Equipment - 2012 - Michael G. Kay, North Carolina State University

http://www.ise.ncsu.edu/kay/Material_Handling_Equipment.pdf

2010
Material Handling System Design and Redesigm
http://ie473.cankaya.edu.tr/uploads/files/file/LectureNotes/LectNote03%20MHS%20Design.pdf


Apple Handling Methods and Equipment in Pacific Northwest Packing and Storage Houses.
Handling of Apples

U.S. Department of Agriculture, Production and Marketing Administration, Marketing and Facilities Research Branch, 1953 - Apples - 302 pages





Full Knol Book on Operation Analysis - Method Study: Methods Efficiency Engineering - Knol Book


Updated 25.1.2022,  7 May 2020
  3 July,  28 June 2015
First posted on 23 Nov 2015

Saturday, September 28, 2024

2025 - USA - Best Industrial Engineerng Programs - Undergraduate, Graduate and Doctoral

 Industrial Engineering specifies, evaluates and improves results. Cost, Delivery, Quality and Flexibility (#IISE).

#IndustrialEngineering   for   #SocietyProsperity  through #Productivity  #Improvement satisfying all constraints and limits. 

INTRODUCTION TO MODERN INDUSTRIAL ENGINEERING. 

635+ Downloads in the current academic year. 10000 downloads 2023-24 A.Y.

Free Download from:

https://academia.edu/103626052/INTRODUCTION_TO_MODERN_INDUSTRIAL_ENGINEERING_Version_3_0



Undergraduate

Doctoral


https://www.usnews.com/best-colleges/rankings/engineering-doctorate-industrial-manufacturing



1. Georgia Tech

2.Purdue

3. Univ. of Michigan. Ann Arbor

4. Virginia tech

5. Univ. of California, Berkeley

6. Northwestern,

7. Stanford

8. Cornell

8. Univ. of  Illinois, Urbana Champagne

10. Texas A &M

11. Penn State

11. Univ. of  Wisconsin - Madison


https://www.niche.com/colleges/search/best-colleges-with-industrial-engineering/


2024 Graduate schools

https://www.usnews.com/best-graduate-schools/top-engineering-schools/industrial-engineering-rankings











Accenture - IoT - Digital Transformation - Operations Twin - Digital Twin Practice

 


Haier Europe makes its products smart and connected with Internet of Things.

https://www.accenture.com/us-en/case-studies/industrial/haier-smart-connect-services



Visual Design in Accenture Operations Twin


Timeframe


March-October 2021


Introduction

A digital twin is an accurate representation of something from the “real world.” As part of their Industry X initiative, Accenture wanted to develop a digital twin program that integrated artificial intelligence and machine learning in order to empower users to optimize and prioritize their work based on real data and predictions.


Over the course of several months, I worked in the design team of three visual designers, and two experience designers. We worked closely with the business analysts and used user research, tests, and check-ins with subject matter experts to guide the designs.



 Industry X Plant Control Tower - an Accenture Operations Twin Application

With the Industry X Plant Control Tower, an Accenture Operations Twin Application you are unlocking many Possibilities for your Industry – here are just 5:

 
1️⃣ Predictive Maintenance: With real-time data from sensors and IoT devices, Digital Twins can forecast equipment failures before they happen, minimizing downtime and saving costs.
 
2️⃣ Efficient Operations: By creating a virtual representation of an industrial process, operators can simulate different scenarios, optimize processes, and improve overall efficiency.
 
3️⃣ Remote Monitoring and Control: Imagine having the ability to remotely control and monitor complex machinery or critical infrastructure from anywhere in the world.
 
4️⃣  Energy Efficiency: Industries can reduce energy consumption by modeling and simulating energy usage patterns.
 
5️⃣  Data-Driven Decision Making: Digital Twins provide a wealth of data that can drive informed decision-making and strategic planning.
























Friday, September 27, 2024

Overall Process Effectiveness - A Measure for the Effectiveness of an Operation/Process

 Overall Process Effectiveness to Measure the Effectiveness in an Operation Process

by Lisbeth del Carmen Ng Corrales 1,2,María Pilar Lambán 1,Paula Morella 1,Jesús Royo 1,Juan Carlos Sánchez Catalán 3 andMario Enrique Hernandez Korner 1,2

1

Design and Manufacturing Engineering Department, Universidad de Zaragoza, 50018 Zaragoza, Spain

2

Department of Industrial Engineering, Universidad Tecnológica de Panamá, Ciudad de Panama 0819-07289, Panama

3

Smart Systems, Tecnalia, Basque Research and Technology Alliance (BRTA), 20009 Donostia-San Sebastian, Spain

Author to whom correspondence should be addressed.

Machines 2022, 10(2), 133; https://doi.org/10.3390/machines10020133

https://www.mdpi.com/2075-1702/10/2/133

As established in the literature for the development of rigorous research, research questions are established, which we will answer using the AR methodology. This paper attended to answer these research questions:

RQ1. Can the new indicator measure the effectiveness of the lateral unloading truck process?

RQ2. Does the AR methodology provide solutions to the organizational issue?

RQ3. Has this study identified opportunities for improvements in the unloading process?


The process begins with the arrival of the truck at the external part of the unloading area, the driver gets off with the documentation corresponding to the transported material he is transporting. Then, the driver enters the warehouse, hands over the documents to the unloading operator who checks if the material belongs to that unloading section. If it does, he tells the driver to park the truck in the unloading track, otherwise, he is shown where to go. The operator records the following data in the document: route, time window, time of entry, time of exit, supplier, and registration.

Once the truck is on the unloading track, the driver gets off, puts on helmets and boots to start the process of preparing the truck to unload the material. The driver opens the side tarp of the truck, removes the side safety boards, and waits for the unloading operation. The operator begins the process by verifying that the material inside the truck is in good condition, if so, he proceeds to unload the containers. Otherwise, if the products contained are disordered in the truck, not loaded sideways, or in poor condition (wet, damaged, dumped, etc.), he calls the supervisor to verify the integrity of the container to proceed with the unloading process or asks the truck to leave. The operator uses a long-shovel forklift to unload the material and place it in the reception area, where it is temporarily stored and then placed in the warehouse. The material is stored in containers, the containers of the same type are placed together. It is also considered that all the material transported in the same truck must be placed in the reception area as close as possible.

Once the unloading process is finished, the operator signs the document confirming, the driver proceeds to place the lateral safety boards, close the tarp, and leave the premises, leaving the unloading track for the next truck. Before continuing with the next truck, the operator must perform a verification of the products in the containers. The list of materials detailed in the documentation provided by the driver upon arrival must coincide with the material that was unloaded from the truck. If there is a difference, the operator takes note of it and notifies the supervisor to report the discrepancy.


The aim of this new indicator OPE is to measure the effectiveness of a logistic process. This framework considers that the effectiveness of the process is affected by internal and external factors. Internal factors are those situations that occur within the company and are managed and controlled internally in the organization. In contrast, external factors originated outside the company, depending on the participation or collaboration of external agents to manage and control them. Both factors influence and affect positively or negatively the performance of the company.

The factors that were analyzed for the development of the indicator are availability, performance, quality, and punctuality. The availability measures the real total time the system is operating without time losses due to the lack of resources that prevent the process from running smoothly. The resources that affect the availability are the lack or failure of the forklift, lack of operator, among others.


This framework goes in pursuit to integrate important aspects of the process in a single measure of effectiveness (Figure 4). The perspectives to be measured with this framework are the availability of resources, the performance of resources, the quality of the process, and the added factor of punctuality. This last factor seeks to include a broader picture that affects the development of the process.


Through the framework proposed it can be possible to record and measure the process to obtain data for continuous improvement. Besides, the OPE allows the losses identification to take action and generate continuous improvement for lean performance.

The success of this collaborative research provides a practical contribution to the company that will improve the unloading process with the OPE implementation. Besides, it generates theoretical knowledge that can be applied to other departments or companies.


With the OPE results, the company identified two improvements that help resource efficiency. First, it was noticed that more than 50% of trucks do not arrive in the planned time window, affecting the unloading schedule by shifts. Improvements are being made in the planning of truck arrivals, and meetings have also been held with suppliers to take joint action. Establishing a collaborative process with the supplier will strengthen the process flow between them [48]. The second improvement is the time redistribution of the operator to the unloading process. It was identified that the operator has a lot of leisure time with the availability parameter, so it was decided that the operator would attend two unloading areas.



Overall Equipment Effectiveness: Systematic Literature Review and Overview of Different Approaches

by Lisbeth del Carmen Ng Corrales 1,2,*,María Pilar Lambán 1,Mario Enrique Hernandez Korner 1,2 andJesús Royo 1

1

Design and Manufacturing Engineering Department, Universidad de Zaragoza, 50018 Zaragoza, Spain

2

Department of Industrial Engineering, Universidad Tecnológica de Panamá, Ciudad de Panama 0819-07289, Panama

*

Author to whom correspondence should be addressed.

Appl. Sci. 2020, 10(18), 6469; https://doi.org/10.3390/app10186469


(This article belongs to the Special Issue 2021 Smart Manufacturing on Production System, Quality Assurance, Process Optimization, and Digital Modeling)

https://www.mdpi.com/2076-3417/10/18/6469









Overall Equipment Effectiveness and Efficiency (OEEE)

Equipment Effectiveness and Efficiency - EEE 

Is your equipment used effectively and efficiently.

Effectiveness - Right use. Using for the best purpose that it is suited.

Efficiency - using it rightly with proper speed and load to get the best productivity.

Effectiveness first . Efficiency Next. Both have to be present in the use.


OEE vs. TEEP: What’s the difference?


Overall equipment effectiveness (OEE) and total effective equipment performance (TEEP) are two related KPIs that are used in manufacturing and production environments to help prevent losses by measuring and improving the performance of equipment and production lines.


OEE is a metric used to measure the effectiveness and performance of manufacturing processes or any individual piece of equipment. 


TEEP is also a metric used in manufacturing and production environments to measure the overall efficiency and effectiveness of equipment or a production line. 


TEEP is calculated by multiplying four factors: availability x performance x quality x utilization.







Is it Overall Equipment Efficiency or Effectiveness?
Overall Equipment Efficiency is often used where Overall Equipment Effectiveness is intended.
Hence it is wrong usage and an error committed somebody that was repeated by many more persons.

Is it wrong to call OEE ‘Overall Equipment Efficiency’?
Calling OEE ‘Overall Equipment Efficiency’ is fundamentally wrong because efficiency relates to the input side of the process where effectiveness (which OEE measures) relates to its output side.



















Creative Industrial Engineering Using Generative AI - GenAi

 

Usage of GenAI is increasing in creative activities.

Can industrial engineers use GenAI to develop improvement solutions in processes and systems.

They have to train AI basic modules first to generate creative appropriate solutions first.

Is any research going on in any university or company in that direction.


Navigating  the Future of Creative Work

Managers and professionals in creative industries, as well as their coworkers have to  take a proactive stance to prepare for additional generative AI support. 

Invest in learning, reskilling, and upskilling. Creative professionals need to acquire AI literacy and learn how to use generative AI tools effectively. . Organizations must encourage creative leaders to prioritize transferable and sustainable skills like problem formulation, experimentation, and critical judgment.

Begin rethinking creative workflows. Generative AI can impact creativity at various stages, from ideation to execution and evaluation.  The key question is how to harmonize artificial and human insights for optimal creative outcomes.

Develop bespoke AI solutions that can augment creative staff members’ potential, where there are opportunities to do so. For example, Publicis Groupe, , has built CoreAI, an intelligent system that leverages its proprietary data on 2.3 billion consumers and trillions of content and media data points to offer AI capabilities across the company’s services.

There are many accessible and affordable platforms that support the development of custom chatbots for various creative functions. OpenAI’s GPT Store, for example, features hundreds of chatbots, from image generators and logo designers to ideators and concept developers, that can support the creative process.

Examine how to best use generative AI to automate the repetitive and tedious tasks in creative workflows. The aim is to enable professionals to have more time and energy to concentrate on the new and unique aspects of their work. For example, Autodesk uses GenAI in its design software  handles many routine tasks.


Creators need to rethink their workflows, enhance their AI skills, and explore new possibilities with generative AI tools. The future of creativity could be a cooperative effort that continues to expand the frontiers of innovation.


https://www.linkedin.com/pulse/how-genai-changes-creative-work-mit-sloan-management-review-c0kte/











University of Oklahoma Norman Campus - Industrial Engineering Programs

30. University of Oklahoma Norman Campus
 Norman, Oklahoma

Fall 2024
CLASSES BEGIN Aug. 19
https://www.ou.edu/registrar/academic-records/academic-calendars/fall-2024




INTRODUCTION TO ENGINEERING - INTRODUCTION TO MODERN INDUSTRIAL ENGINEERING.  
#IndustrialEngineering for #SocietyProsperity.
For the Academic Year 2024-25 -  Bachelor in Industrial Engineering  #BSIE. 10,600+ Downloads for 2023-24. 
Free Download  from: 



2024

Make Processes and Systems Better

Since 1965, we in the School of ISE have been making processes and systems better in EVERY industry. You’ll find our graduates in aerospace, healthcare, manufacturing, oil and gas, finance, transportation, consulting, and everywhere in between. We graduate leaders who integrate analytics and systems thinking to find solutions to engineering problems.


$28M in collaborative research funding in force in 2023-2024
100 journal articles by ISE faculty in 2022-2024
18 faculty members, our largest faculty strength
98% job placement at the time of graduation


17 faculty members are working on 17 Federally supported research grants and contracts from DoD, DoT- FAA, NSF, NIST, and USDA with a total value that exceeds $25M.

Kash Barker 
John A. Myers Professor, David L. Boren Professor, Industrial and Systems Engineering, University of Oklahoma
26.9.2024
13 tenured/tenure track, 1 practice, and 3 research faculty = 17 strong in the OU School of ISE! Things are happening at the hashtag#flagship!





MS Degree - https://sis.ou.edu/StudentRegistrationSsb/ssb/courseSearch/courseSearch

Productivity Management Course Offered  -NO

Industrial engineers, to improve, integrate, inform, and innovate.

Improve
Industrial engineers are improvement engineers. ISEs help organizations add value by eliminating waste, maximizing quality and productivity, and using resources effectively.

Integrate
Industrial engineers are integration engineers. ISEs bring people, processes, and technologies together to solve complex problems in all types of organizations.

Inform
Industrial engineers are information engineers. ISEs use computer-based tools to collect data, organize and analyze information, and present solutions for decision-making.

Innovate
Industrial engineers are innovation engineers. ISEs use a holistic approach, combining engineering expertise with a business perspective, to solve modern, often large-scale, problems.

http://www.ou.edu/coe/ise/academics




Contact  - Janet Allen
Office: CEC 116-G
Phone: (405) 550-3969
Email: janet.allen  @ou.edu




Randa Shehab
Associate Dean, Nettie Vincent Boggs Professor
Office: CEC 107
Phone: (405) 325-4277
Email: rlshehab  @ou.edu

Research Interests
Engineering education, cognitive ergonomics, human-system integration

2020
Shivakumar Raman
Director of ISE; David Ross Boyd Professor; Morris Pittman Professor; Samual Roberts Noble Foundation Presidential Professor
http://www.ou.edu/coe/ise/people/shivakumar_raman

https://www.linkedin.com/in/shivakumarraman/ (Connected)
https://scholar.google.com/citations?user=Bg4JTooAAAAJ&hl=en






Updated on 7 July 2020, 2 Sep 2019




Thursday, September 26, 2024

New Machine Tools - Productivity Engineering Applications


Lesson 102 of Industrial Engineering ONLINE Course.

Refer to Industrial Engineering Case Studies Collection for case studies and productivity engineering applications




New.

Popular E-Book on IE,

Introduction to Modern Industrial Engineering.  #FREE #Download.

In 0.1% on Academia.edu. 10,380+ Downloads so far.

https://academia.edu/103626052/INTRODUCTION_TO_MODERN_INDUSTRIAL_ENGINEERING_Version_3_0


Productivity Engineering Principle of Industrial Engineering.

Industrial engineering is concerned with redesign of engineering systems with a view to improve their productivity.

https://nraoiekc.blogspot.com/2017/06/productivity-engineering-principle-of.html



New Cutting-edge Turning-Milling center, MC-100

Efficient Truck Axle Machining with Advanced Turning-Milling Technology


_________________________________



_________________________________


SEMA Maschinenbau

25 Sept 2024

In this video, we showcase our cutting-edge turning-milling center, MC-100, tailored for the complete production of heavy-duty truck axles. Utilizing a turning-milling machine concept, the axle itself is rotated, allowing various machining operations— turning inside and outside, turning the steady rest seat, gear milling, milling, drilling, threading, chamfering, and more—to be performed without the need for multiple setups.


This approach ensures exceptional precision in cylindrical and symmetrical components, like truck axles, where maintaining concentricity and surface finish is critical. By rotating the workpiece, the machine achieves consistent machining across the entire surface, reducing complexity and setup time.


For truck axle manufacturers, this system offers:

 - complete flexibility in handling different axle designs and dimensions

 - enhanced efficiency through continuous operations on a single machine

 - optimized setup and cycle times, resulting in increased productivity

 - high repeatability and precision in turning and milling, critical for heavy-duty applications


Key Features:

 - turning process for comprehensive machining of truck axles

 - single-machine operation for all necessary processes: milling, drilling, threading, facing, turning inside and outside, turning the steady rest seat, gear milling

 - on both sides of the main spindles, there is a combined lathe chuck for external clamping (3-jaw-chuck) and internal clamping (mandrel)

 - seamless transition between operations, minimizing downtime

 - flexible setup for varying axle specifications






The New GENOS M560V-5AX


The new GENOS M560V-5AX is an impressive next-generation product evolved from two of the company’s best-selling vertical machining centers – the GENOS M560V which has become a standard-bearer in the industry, and the GENOS M460V-5AX which launched in 2017 as an answer to a market need for an affordable, compact 5-axis vertical machine,


Machine Design


The GENOS M560V-5AX is built with a double-column machine design, affording it maximum structural integrity. The machine offers an impressive working envelope with a 500mm table and wide axis travels (X: 1,050 mm, Y: 560 mm, Z: 460 mm), while still maintaining a compact footprint of 2,515 mm x 3,750 mm. Further optimizing the machine’s design, the GENOS M560V-5AX includes a trunnion table positioned parallel to the front of the machine which allows for easier access to the table and good visibility during machining. This, and other user-friendly features on the machine, reduce physical burden on the operator. Additionally, the machine comes standard with a 60 ATC (automatic tool changer) magazine and can also accommodate tools measuring up to 400mm in length.


Built-In Energy Savings Features


The GENOS M560V-5AX comes standard with Okuma’s Thermo-Friendly Concept, an on-board thermal and energy management technology to support both stable, high-accuracy machining and reduce energy consumption.


Key Specs of the GENOS M560V-5AX Vertical Machining Center:


Table Size: 500 mm

Max Workpiece Dimensions: 700 x 500 mm

Spindle Maximum Speed: 15,000 min⁻¹

Spindle Motor Power: 22/18.5 kW

Axes Travel: 1,050 mm (X-axis), 560 mm (Y-axis), 460 mm (Z-axis)

Floor Space: 2,515 x 3,750 mm (w x d)

Weight: 10,000 kg

With its versatility and 5-axis cutting capabilities, the GENOS M560V-5AX provides shops with the ability to expand their operational possibilities.


https://www.okuma.com/press/okuma-america-corporation-debuts-the-genos-m560v-5ax-machining-center-at-imts-2022


https://www.okuma.com/products/genos-m560v-5ax


High machining capacity and high-rigidity machine construction

that makes highly efficient production possible


Capable of heavy machining of a wide variety of materials and has a powerful standard spindle that reduces machining time.


Maximum spindle speed 15,000 min-1, maximum output 22 kW

Maximum cutting capacity 672 cm3/min

(Material to be cut: S45C steel, end mill machining)

https://www.okuma.co.jp/english/product/5avmc/genos_m560v-5ax.html



Machining a Latch Bracket with Okuma Genos M560v 5AX and PowerMill (Full Video)

Autodesk Advanced Manufacturing

4 Feb 2019

Here's the complete 5-axis machining cycle of a latch bracket. This video shows Okuma's latest CNC machine, the GENOS M460V-5AX, designed to deliver 5-axis milling at a lower price point. Machining cycles created and simulated using Autodesk PowerMill and the live cutting was showcased at IMTS2018.


A Linkedin Post

https://www.linkedin.com/feed/update/urn:li:activity:7044654017292980225 


Unfolding Swiss Style Machines Advances

July 12, 2023

Bill Koenig

By Bill Koenig

Senior Editor,

SME Media

https://www.sme.org/technologies/articles/2023/july/unfolding-swiss-style-machines-advances/


New Machine Tools - Productivity Engineering Applications

Increasing productivity of each and every input is to be attempted by industrial engineers.

Process Improvement - Productivity Analysis and Productivity Engineering.

Industrial engineer analyzes each process into its ultimate, simple elements, and compares each of these simplest steps or processes with an ideal or perfect condition and modifies the element appropriately. - F.W. Taylor - Hugo Diemer.

Prof. Hugo Diemer  - Taylor's Industrial Engineering

https://nraoiekc.blogspot.com/2020/05/prof-hugo-diemer-taylors-industrial.html

Industrial Engineering

Industrial engineering redesigns and installs engineering systems primarily. It also examines and redesigns managerial processes that impact productivity in engineering systems. Machine tools and other machines are important components of engineering systems. Industrial engineers have to analyze the currently available machine tools in the market and the existing machine tools being used in the factory, plant and processes to identify more productive and profitable replacement of new machine acquisition opportunities.

This collection offers you information on new machine tools and application of new machine tools to increase productivity to help you in giving ideas and directions in developing alternatives for your current machine tools in operations productivity improvement exercises/studies.

Reasons for buying a  new machine tool: Increase productivity, increase capacity, reduce costs, new machines for new products,  tighter quality standards, process flexibility,  and make more parts instead of buy. 

Analysis of of the appropriateness of existing machine tools and the scope to utilize new machine tools that are being offered by various companies is also part of facilities industrial engineering. Industrial engineers need to evaluate the existing facilities every year to find opportunities for replacing them for productivity.

The machine tools and other production equipment are also examined during process improvement studies using process charts. Each time an operation is being examined, the opportunity of using equipment that is available with outside vendor is to be compared with using the equipment available within the company. This is the comparison of the element of work being currently done with the best alternative available.


Top Machine tool companies: DMG Mori, Germany/Japan - Yamazaki Mazak - TRUMPF, Germany

SMTCL, China - Amada, Japan - Dalian, China - Komatsu NTC Ltd. - Schuler, Germany

Toyoda, Jtekt, Japan - Okuma, Japan


A DECISION SUPPORT SYSTEM FOR MACHINE TOOL SELECTION

Continuous introduction of new technologies force companies to use new machine tools. 

Appropriate selection of a machine tool for a production system is an important task.

https://pdfs.semanticscholar.org/bf55/aa817da37d73faacd6db6a3fc6d1f75f43ef.pdf



New Machine Tools and Their Applications to Improve Productivity


2024


Productive Machines makes autonomous machine tool optimization available to all

SHEFFIELD, 10 April 2024 News

Productive Machines , a provider of autonomous machine tool optimization technology, today made its core technology available in a fully automated Software-as-a-Service (SaaS) offering. Productive Machines’ pioneering SenseNC Finesse software is the world’s first to provide automated optimization of all milling operations,, enabling manufacturers to set up each machine tool and run the production preventing chatter vibrations at every cutter location across the toolpath.

The software uses an Artificial Intelligence (AI) model to optimize machine processes and is deployed at more than ten major manufacturers already, including Renault and MASA Aerospace. By making it available as an automated SaaS product, Productive Machines aims to help many more manufacturers globally eliminate trial and error iterations on machine tools, reduce waste and deliver better products faster.


Machines configured with Productive Machines' have demonstrated the ability to produce parts in half the original time, significantly improve surface quality, and reduce waste by up to 25 percent. Users have reported a substantial decrease in tooling costs, up to 20 percent, on optimized machines.

https://productivemachines.co.uk/productive-Machines-makes-autonomous-machine-tool-optimization-available-to-all.html



2020

North American debut of the all-new VARIAXIS C-600, a full simultaneous 5-axis Multi-Tasking machining center featuring a flexible, automation-ready design and the new MAZATROL SmoothAi CNC.

25/2/2020

https://www.mazakusa.com/news-events/news-releases/new-machines-and-technology-to-debut-at-mazak-midwest-discover-event/

The Best of both Worlds - Schütte  ECX series,   single-spindle automatic 

With the new ECX series, Schütte presents a single-spindle automatic for the first time. The ECX represents the optimal solution for decreasing lot sizes in mass production. It combines the flexibility and simple handling of single-spindle automatics with the productivity of multi-spindle automatics and thus closes the gap between the two worlds.

http://my.page2flip.de/15433595/17758102/17758154/html5.html#/8


Double Column type Machining Centers - shibaura-machine.co.jp

https://www.shibaura-machine.co.jp/en/product/machinetool/lineup/m/


Compact with huge potential - compact 105 linear grinding machine

The innovative, compact 105 linear grinding machine impresses with its high productivity, short cycle times and lasting precision. This is made possible by special kinematics, which ensure maximum accuracy with an innovative axis arrangement. With scalable automation solutions and intelligent expansion options, the machine adapts exactly to the production requirements.

http://my.page2flip.de/15433595/18693150/18693151/html5.html#/1

New Entry Level 5-Axis Universal Machine Technology Increases Job Shops looking for machining solutions that increase productivity.

https://www.automation.com/en-us/articles/august-2020/universal-machine-increases-job-shop-productivity


Machine Tool Components That Help Improve Process Efficiency, Productivity

July 29, 2020, Article From: July 2020 Manufacturing Engineering, Kip Hanson, Contributing Editor

Stuff a shop needs to utilize machine tools effectively and efficiently to make parts efficiently, accurately, and cost-effectively.

https://www.practicalmachinist.com/manufacturing-engineering/machine-components-help-improve-process-efficiency-productivity/

2019

Trends In CNC Automation: Efficient, Connective, Simple

by Industrial Automation Asia | May 23, 2019 | Issues & Insights

https://www.iaasiaonline.com/trends-in-cnc-automation-efficient-connective-simple/

New DUO Machine for Series Production: The VL 5 DUO from EMAG delivers a boost to the Production of Powertrain Components up to 250 mm

08/07/2019

https://www.emag.com/press/news/single-view/article/new-duo-machine-for-series-production-the-vl-5-duo-from-emag-delivers-a-boost-to-the-production-of.html


A new CNC sliding-head lathe: the 12 mm bar capacity Cincom L12 Type X. 

It is intended primarily for production of dental abutments and implants, but is also well suited to manufacturing parts for the medical industry in general.

https://www.citizenmachinery.co.uk/new-sliding-head-lathe-tailored-to-medical-component-production/

Toward Intelligent Machine Tool, Engineering

Volume 5, Issue 4, August 2019, Pages 679-690

https://www.sciencedirect.com/science/article/pii/S2095809919307635


EMO 2019 Fair - Machine Tools on Display from Leading Manufacturers

3 SEPTEMBER 2019

https://www.aero-mag.com/emo-hannover-2019-machining-technology/

MHI Machine Tool Launches the New MAF-E II Series of Table-type Horizontal Boring Mills.

Thermal Deformation Control Provides Stability in  High Processing Accuracy and Productivity --

2019-07-24

https://www.mhi.com/news/190724.html

Retrofitting an aging CNC machine with a new CNC can improve its productivity, cut soaring maintenance costs - Siemens retrofit services

https://assets.new.siemens.com/siemens/assets/api/uuid:0223e6fc-c93e-4d8d-846c-97626e9c824f/siemens-machine-tool-retrofit-article.pdf



A Low-Cost Vision-Based Monitoring of Computer Numerical Control (CNC) Machine Tools for Small and Medium-Sized Enterprises (SMEs) 

Sensors (Basel). 2019 Oct; 19(20): 4506.

https://www.ncbi.nlm.nih.gov/pmc/articles/PMC6832709/

2016

New Machines for  Productivity, Flexibility, & Connectivity


New-generation automatic lathe
INDEX Corporation  ABC machine 

for turning out simple to moderately complex parts in cycle times up to 15% faster than the series’ previous standard, with rapid spindle acceleration (8 g), shorter spindle ramp-up times, higher rapid traverse rates, and quick chip-to-chip times. 

Suitable for runs of 5,000 to 50,000 parts in the 42-60 mm range. Provides low cost per piece targets, even for complex parts.

Up to 19 tools  with live tools for both turrets. Very short cycle times are achievable due to simultaneous machining with up to three tools. The ABC is equipped with up to five driven back-working tools and offers driven tools in all turret positions.

The machine is available in two-, three-, or four-axis versions. The motorized 27-kW, 6000-rpm spindle, can generate up to 95 Nm of torque.

Within the easy-to-access work area, mounted above the main spindle is the upper turret used mainly for I.D. work. The lower turret is typically for O.D. work. A synchronized spindle operates in the upper turret. Both turrets feature a rapid traverse of 36m/min. The ABC can handle heavy-duty polygon turning and thread milling with a counterspindle or drive attachment.

Also, the ABC can can be fitted with a quiet-running Index bar loader, which may save 4-30 seconds per cycle, and automatic part unloader automation.

www.indextraub.com

"Ultra narrow" machines for high speed, high volume
MAZAK recently introduced the new UN Series of high-speed horizontal (left) and vertical (right) machining centers, the UN-600/30H and UN-600/30V, respectively, to address requirements for high productivity, reliability, maintenance and automation in automotive manufacturing.

Designed for the mass production of automotive components, these #30 taper machines feature an extremely small footprint (as indicated by their UN designation, for "ultra-narrow") and are up to three times more productive per unit of floor space than normal-sized machines, according to the developer.

UN Series machines are automation-friendly, allowing multiple machines to be placed together and tended by one robot.

The width of the UN-600/30V vertical machining center is 27.4 in.; it can accommodate a maximum workpiece diameter of approximately 23.6 in. This is possible because of the interpolated machine C- and Y- axes for the X-axis, which is programmed in the same way as a conventional machine X-axis.

The UN-600/30V offers 20-tool storage capability.

The UN-600/30H horizontal machining center has the same, 23.6 in. maximum workpiece diameter and is substantially smaller than other horizontal machining centers in its class. This is due to a compound X-axis, whereby half of the axis stroke is on the machine table and the other half is on the machine column.

The UN-600/30H features 30-tool storage capability.

New integral spindle/motors are used for faster acceleration/deceleration to provide unsurpassed high productivity. The UN Series machines feature high-speed 20,000 rpm machine spindles that accelerate to top speeds in just 0.55 seconds, and perform synchronized tapping at 8,000 rpm.

www.MazakUSA.com

Five-axis vertical machining for faster production

MAKINO’s latest full five-axis machine solution is the DA300 vertical machining center, combining speed, precision and flexibility for complex part applications. The DA300 “delivers the highest productive capabilities for multi-axis workpieces in the smallest of machine footprints.” 

It is developed as a single setup, multi-side accessible, or full-contouring operation for processing complex parts comming in industrial hydraulic and pneumatics elements, optical, electrical and semiconductor components, medical and dental products, diecastings, automotive components, and aerospace parts.

“The DA300 integrates numerous features that increase productivity and efficiency by providing significant reductions in non-cut time.  “The machine provides a 50% reduction in spindle acceleration time, 15% reduction in positioning time, 40% reduction in tool-change chip-to-chip time, and (it) includes a standard vision-type broken-tool sensor [Vision B.T.S.] that optically checks tools outside the work zone to ensure tool consistency and part quality while simultaneously reducing non-cut time during tool changes by 80%.

When all of these time savings are combined,  dramatic advantage in reduced part-production times and increased profitability can be obtained.

The DA300 worktable is an integral, 340X300-mm table, accommodating workpiece sizes up to 450 mm in diameter, 400 mm tall and weighing 250 kg. The machine provides X-, Y- and Z-axis travels of 450, 620, and 500 mm, respectively, at feed rates of up to 60,000 mm per minute.

The direct-drive, motor-driven A-axis table offers 150 degrees (+30 to -120) of tilt capability at 100 rpm. The rotary C-axis has full 360-degree rotational positioning at 150 rpm. Combined, these rotational axes have the range and speed necessary for high productivity in complex five-face or full five-axis machining.

www.makino.com

New high-productivity HMC
MATSUURA MACHINERY USA INC.’s new H.Plus-504 horizontal machining center achieves high productivity thanks to high speed, rigidity, precision, reliability, and low cost of ownership. The series delivers long periods of reliable, unmanned operation, high accuracy, and exceptionally efficient production. Since the H.Plus series’ debut in 2000, over 1,700 of the machining centers have been installed worldwide in various industries, including: aerospace, aircraft, automobile, medical and precision subcontractors.

The H.Plus-504 is equipped with 500x500-mm pallet and #40-taper spindle. In response to customer and market demand for accommodating larger workpieces, the H.Plus-504 possesses the largest working envelope in its class and will handle a maximum workpiece size of 800x1,000 mm (DxH), weighing 750 kg on each pallet.

In addition to the standard 12,000 min-1 spindle, a 20,000 min-1 (108.4 Nm) for high-speed machining and 15,000 min-1 (350.0 Nm) for high-torque, heavy-duty machining are available.

A rotary indexing table (B axis) is provided as a standard feature, which is driven with a direct drive motor with a maximum feed rate of 100 min-1. In addition, Matsuura's DCS (Dynamic Clamp System) and ADC (Automatic Acceleration and Deceleration Control) contribute to shorter cycle and indexing times.

www.matsuurausa.com


1999

Case Study 64 of Industrial Engineering ONLINE Course  


High Speed Machining of  Bulkhead at Raytheon Aircraft Makino (Mason, Ohio) MC1516 high-speed horizontal machining center


Raytheon Aircraft Company (Wichita, Kansas) does industrial engineering, that is continuous improvement in engineering. Attention is given to  maximize throughput and efficiency. 

Raytheon engineers came to know about high speed machining and  decided to use a Makino (Mason, Ohio) MC1516 high-speed horizontal machining center with a seven-pallet modular machining center (MMC) to machine  bulkhead.   MC1516's Jet 50 spindle provides up to  15,000 rpm. The 50 taper spindle provides horsepower at various ranges and brings a high level of rigidity.  

To machine the bulk heads,  end mills reach 12,500 rpm and achieve metal removal rates as high as 320 cubic inches per minute.  In two setups, the MC1516 machines thin wall tolerances under 0.00010 inch to near net shape. Roughing and finishing are conducted simultaneously using carbide end mills.

The seven-pallet MMC allows the spindle engagement for more than 90 percent of the time. The MMC allows setups offline and keeps the MC1516 constantly fed.

The new technology adoption had challenge of learning quickly. The team consisting  of people in every discipline involved in the process, from manufacturing engineers, programmers to the operator  worked with Makino to learn and optimize the new process. The planned learning paid off with production parts being machined immediately after installation. Raytheon quickly realized the efficiencies, such as reduction in machine and labor hours per part. The machine uses  universal vacuum fixturing also. While the larger bulkhead is machined on a dedicated fixture, vacuum fixtures allowed operators to set up smaller parts in one operation.

The successful process improvement using high speed machining  will be extended to more parts.

https://www.mmsonline.com/articles/high-speed-machining-helps-modernize-bulkhead-manufacturing

Machine tools - Production machining case studies

5 axis machine
https://www.productionmachining.com/search?q=case+study+five+axis&page=2

7/2/2020 
Meet Production Machining’s 2020 Emerging Leaders
https://www.productionmachining.com/blog/post/meet-production-machinings-2020-emerging-leaders



ud. 26.9., 7.9.2024, 7.9.2023,  9.10.2022
pub. 7.9.2021

Tuesday, September 24, 2024

De - Clutter to Flow Better - A Business Novel on TOC - Visweswaran Sundararam - Book Information

 De - Clutter to Flow Better

(application of Theory Of Constraints (TOC) in business transformation)

Author Name: Visweswaran Sundararam


About the book by the publisher.


This is a business novel.  The setting is realistic, the characters represent their various functions, and yet are not reduced to mere cardboard personas who merely mouth the lines expected of them given their role/ function with their organizations.


 The consultant and his assistant who come to the rescue of these hapless managers weave their magic. No, not by waving a wand or uttering incantations, but using the demonstrated techniques of asking the right questions, remaining silent while the group collectively puts its brains together to solve their never-ending challenges, gently nudging them when they threaten to go astray from their paths, etc. 


The solution is not dished out to them in a spoon, but they are made to earn it for themselves. And, herein, lies the author’s own expertise and experience as a successful management consultant, having seen this all and having dealt with it on innumerable occasions. 


https://notionpress.com/read/de-clutter-to-flow-better


https://www.amazon.com.au/CLUTTER-application-Constraints-business-transformation-ebook/dp/B0D676WWTL


https://www.linkedin.com/posts/visweswaran-sundararaman-93b6296_visuism-activity-7212090012518035457-l41M/










Automated Inspection - Introduction and Bibliography


Industrial Engineering - Role of Engineering, Mechanization and Automation


In process improvement study or projects, to do a task in the most productive manner, the most efficient manual method (best manual method), best mechanized method and best automation method are to be compared and the most productive method has to be employed. This comparison has to be done at element or suboperation level.

Source: Book: Motion and Time Study: Design and Measurement of Work, Ralph M. Barnes, 7th Edition, Chapter 18. Motion Study, Mechanization, and Automation.

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.




Automated Inspection - Bibliography




 What Is Automated Visual Inspection And How Is It Used?
Averroes
May 21, 2024

Automated visual inspection leverages technology to scrutinize products or equipment without human intervention, marking a significant evolution in quality control methodologies. 

Automated visual inspection is a technology-driven method that uses cameras, sensors, and algorithms to detect defects and ensure compliance with standards, highlighting its ability to operate faster and more accurately than human inspectors.

Applications in Industries

Semiconductor Manufacturing

Main Tools & Systems Used For Semiconductor Metrology (2024)
Averroes
May 20, 2024

Food Processing

Biopharma Manufacturing

Syntegon’s AIM Automated Inspection Machines offer the best quality inspection services powered by artificial intelligence. They  developed the  first Automatic Inspection Machine, the AIM275, in Japan in 1975. It  marked the first use of SD technology in particle detection, which has since become a staple of many pharmaceutical production facilities. Today, both camera-based inspection and SD technology can be integrated.

AIM 2|5 Series – Automated Inspection with Artificial Intelligence.

AIM 3000 ‒ Combining Visual Inspection, HVLD and Operational Excellence
Syntegon’s AIM 3000 guarantees high detection rates of moving particles by checking twice on two identical stations.

AIM 8000 Series ‒ AI-Ready, Versatile Platform for a Wide Variety of Products
The AIM 8000 is a flexible modular machine designed for customised solutions, with a vision system built to handle highly complex inspection requirements for particulate and cosmetic defects.


AIM 5022S: Automated inspection machine for syringes

Automated inspection machine for cartridges
Proven and reliable technology based on long-term experiences with dental and insulin cartridges



Automotive Manufacturing

A large, multinational automobile manufacturer responsible for producing millions of vehicles annually, engaged with IBM® to streamline their manufacturing processes with seamless, automated inspections driven by real-time data and artificial intelligence (AI).

As an automobile manufacturer, our client has an inherent duty to provide high-quality products. Ideally, they need to discover and fix any defects well before the automobile reaches the consumer. These defects are often expensive, difficult to identify and present a myriad of significant risks to customer satisfaction.

IBM worked with the client’s technical experts to deploy IBM Inspection Suite solutions to help them reduce defects and downtime while enabling quick action and issue resolution. The solutions deployed include fixed-mounted inspections (IBM Maximo® Visual Inspection Mobile) and handheld inspections (IBM Inspector Portable). Hands-free wearable inspections (IBM Inspector Wearable) were also made available for situations that required a head-mounted display.

Automated Inspection Solutions for Railroads


Mining

Medical Device Manufacturing
Construction
Solar Farms
Oil and Gas





April 10, 2024

TEST AND INSPECTION ASSEMBLY
Beyond the Human Eye: AI Improves Inspection in Manufacturing
By Ramūnas Berkmanas

Since implementing AI, a car seat manufacturer has seen a 30 percent reduction in defect rates.
Manual quality control methods limit the efficiency and effectiveness of modern manufacturing processes.
For one, manual inspection is too inconsistent. Due to factors like fatigue, human inspectors are prone to variability in their defect detection rates, which can range between 60 and 90 percent. Additionally, manual inspection is also slow. Manual processes often cannot keep up with fast-moving assembly lines, resulting in bottlenecks.

Common Use Cases are given in the article.



2021

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


2020

AI Adds Continuous Improvement to Vision Systems
Cogniac helps manufacturers take vision system investments to the next level with AI-based models.
Peter Fretty
DEC 17, 2020


NEXIV VMZ-S3020 CNC video measuring system
December 11, 2020
Nikon Metrology

Automated Gauging for Process Control of Machining Operations

November 10, 2020


Gauging system provides 30% increase in manufacturing capacity
15 SEPTEMBER 2020
Manual gauging processes have created a bottleneck and preventing the achievement of  throughput necessary to achieve a part-manufacturing target at Olympus NDT. By automating inspection processes using a programmable shopfloor gauging system, the company eliminated the bottleneck and increased the output per hour with improved part quality and reduced scrap.


A New Programming Approach for Robot-based Flexible Inspection systems
William Brice Tekouo Moutchiho
utzverlag GmbH, 27-Mar-2019 - 226 pages
Preview

CNC Lathe In-Process Gauge

Supplier: Autonetics

The guage is a single part: the gauging head. The head was adapted for the FANUC robot tending the machine/cell. The robot grips the gauge as needed in a quick, automated tool change.  

Inspection Process
After the first roughing pass, the robot brings the measurement head into the machining envelop and positions it at the end of the part. A scan is then started and the robot move across the length of the part. Based on the scan, a 2D point cloud of the part is constructed. The point cloud is quickly processed and various diametrical and axial features are analyzed. The results are displayed on the Autonetics HMI. The measurements are automatically sent to the machine tool allowing the final cutting pass to remove the exact amount of material. After the last cutting pass is made the part is scanned by the robot with the gauge once more for a final assessment of the part.

Advancements in Automated Inspection - EWI - 2017
https://www.slideshare.net/EWI_engineering/advancements-in-automated-inspection

Flexible Measurement Systems - Robotic Inspection
https://www.dynalog-us.com/automated-in-line-gauging.htm

https://www.dynalog-us.com/case-study-world-first-calibrated-fms.htm
https://www.dynalog-us.com/case-study-katayama-automates-in-line-measurement.htm

https://www.amtcpl.com/software-based-automatic-multi-gauging-systems.html

https://blog.eaglegroupmanufacturers.com/precision-machined-parts-measuring-tools-every-cnc-shop-should-have

Gauging System Intelligent Process Control Software Automatically Updates CNC Tool Offsets
15 Feb 2018


Automatic Measurement in CNC Machines

Sipotek Machine Vision Systems

In Process Part Measurement - HaaS Tips - Video
https://www.haascnc.com/video/tipoftheday/ffzi6rwicuu.html

6 Factors to Consider Before Moving to Automated Inspection
A properly programmed automatic-visual-inspection system can significantly reduce the risk of bad inspections, and lead to reduced costs over time.
Dr. Helmut Hamfeld
JUL 05, 2016
https://www.machinedesign.com/markets/manufacturing-equipment/article/21832077/6-factors-to-consider-before-moving-to-automated-inspection

https://www.automation.com/en-us/articles/2009-2/automated-inspection-gaging-systems-improve-qualit

4 ways - Machine vision cameras or laser sensors integrated into equipment
2. Separate inspection station with Machine vision cameras or laser sensors
3. Turnkey systems with Machine vision cameras or laser sensors designed for specific component or family of components.
4. Robots to handle parts or cameras
https://blog.jrecorp.com/blog/four-types-of-automated-inspection-systems




Springer Handbook of Automation

Shimon Y. Nof
Springer Science & Business Media, 16-Jul-2009 - Technology & Engineering - 1812 pages

Automation is undergoing a major transformation in scope and dimension and plays an increasingly important role in the global economy and in our daily lives. Engineers combine automated devices with mathematical and organizational tools to create complex systems for a rapidly expanding range of applications and human activities. The Springer Handbook of Automation incorporates these new developments and presents a widespread and well-structured conglomeration of new emerging application areas of automation. Besides manufacturing as a primary application of automation, the handbook contains new application areas such as medical systems and health, transportation, security and maintenance, service, construction and retail as well as production or logistics. This Springer Handbook is not only an ideal resource for automation experts but also for people new to this expanding field such as engineers, computer scientists, designers. It is edited by an internationally renowned and experienced expert.

Automating Quality Systems
J.E. Tannock


1988 - Report FMS - Automated Inspection

Four key conclusions can be made based on the information available about automated inspection in flexible machining systems.
1. There are very few FMS installations that have automated inspection fully integrated into the system. 
2. A major factor is the reluctance of management to invest large amounts of capital because of concerns about the length of the payback period.
3. Many vendors, user groups, and research institutions are actively involved in research and development in all aspects of automated inspection.
4. The trend in FMS automated inspection is toward controlling the process through in-process gaging and deterministic metrology.


Updated  24.9.2024, 29.9.2022,  23 Sep 2021, 17 December 2020
First published 16 July 2020