Wednesday, May 21, 2025

Industrial Engineering 4.0 - Intelligent Die Casting - Quaker Houghton

Industrial Engineering 4.0 - Computer Aided Industrial Engineering: Work Systems Analysis in Industry 4.0

Rao, Kambhampati Venkata Satya Surya Narayana; Rathod, Aniket.  IIE Annual Conference. Proceedings; Norcross (2021): 49-54.

https://www.proquest.com/openview/d32ef32bbaa911d170e046479790c035/1  


10,600+ Downloads/Reads so far. 
INTRODUCTION TO MODERN INDUSTRIAL ENGINEERING. 
Free Download EBook (122 pages).  Download from:

https://academia.edu/103626052/INTRODUCTION_TO_MODERN_INDUSTRIAL_ENGINEERING_Version_3_0 


Industrial Engineering -  Make it Effective.

As Industrial Engineer are you recommending and using new technologies to improve productivity?

https://www.linkedin.com/pulse/current-issues-interest-industrial-engineering-may-2025-kvss-1hekc


Industrial Engineering 4.0 - Intelligent Die Casting

 

2025

World of DieCast iQ™

Intelligent die casting solutions from Quaker Houghton

https://diecastiq.quakerhoughton.com/


Dr Mark Cross, Global Business Development Director - Die Casting at Quaker Houghton


“More intelligent die casting is necessary to improve productivity, efficiency, and quality, reduce costs and enhance sustainability.


“Operations can be further optimized with modern monitoring technology to maintain parameters, helping to improve process stability, reduce cycle times and manufacture consistent high-quality products.


“Our comprehensive product range and unrivalled process expertise and experience at Quaker Houghton provides the complete solution to improving die casting performance throughout the die casting manufacturing value chain." 

https://www.foundry-planet.com/d/quaker-houghton-to-showcase-intelligent-die-casting-solutions-at-euroguss-mexico-2023/


07/27/2022Interview

Transformation of the drives

EUROGUSS 2022 interview – Dr Mark Cross

https://www.euroguss.de/en/euroguss-365/2022/interview/euroguss-2022-interview-dr-mark-cross

https://en.wikipedia.org/wiki/Quaker_Houghton



Intelligent Die Casting Cell


YIZUMI Intelligent Die Casting Island focuses on providing a complete set of turnkey solutions for industrial production processes like robotic automated intelligent manufacturing systems, peripheral equipment, and related technical support and services. It meets the fully automated production needs of the die-casting industry and completes the full set of automated production processes such as robot take-out, inlaying, spraying, product cooling, de-slagging, trimming, engraving, conveying, etc. in the die-casting and post-processing related industries, and is suitable for different die-casting production lines.


Easy central integrated control

Adopting well-known brand PLC and high-definition touch screen, with the human-machine dialogue interface which is constantly optimized according to the needs of customers' front-line operators, it can conveniently carry out quick view of information and set and read alarms detection for various parameters, etc.


Removal and insertion robot system

Experienced in designing claw hands for various types of inlay pieces, the precise material handle arms and product robot arms ensure stable and reliable gripping.


Robotic grinding and deburring can guarantee the accuracy and reliability of product cleaning while lowering the rate of human scrap. Meanwhile, it could prevent the spread of dust and reduces the dangers of environmental pollution and occupational diseases.


LEAP Series Die Casting Machine

YIZUMI fully benchmarks against the performance and functions of world-class die-casting machines . Through the joint efforts of the international and domestic R&D teams with years of experience in the die-casting industry, we developed this series from concept to product, and have independent intellectual property rights in its technology. Yi-Cast real-time closed-loop injection system makes every injection with quality assurance. ORCA control system adopts the world's most advanced control technology and algorithm. The easy-to-use HMI enables the full digitalization of the die-casting machine. Supported by highly innovative servo + feedimng energy-efficient pump units, the machine has achieved higher Overall Equipment Effectiveness (OEE).


https://www.yizumi.com/en/ras/intelligent-die-casting-cell



https://www.foundry-planet.com/d/lk-technology-and-guangdong-hongtu-launched-the-worlds-first-12000t-intelligent-die-casting-unit/


https://diecastiq.quakerhoughton.com/


https://www.mdpi.com/2227-9717/11/10/2947


https://www.youtube.com/watch?v=B1lQi1laoB4


https://medium.com/@taohaiying6688/application-and-advantages-of-artificial-intelligence-and-robotics-in-the-die-casting-industry-5aef872cfd12


https://www.researchgate.net/publication/285385686_Modeling_of_Pressure_Die_Casting_Process_An_Artificial_Intelligence_Approach


https://www.visi-trak.com/smart-die-casting-and-foundry-4-0/


https://www.linkedin.com/pulse/larger-intelligent-solutions-transforming-die-casting-sajal-sen



https://www.youtube.com/watch?v=qHCQS3W7S5E


https://www.facebook.com/lkmachineryint/photos/a.725205084279174/2302088436590823/?type=3


https://www.toyota-industries.com/news/2021/04/12/005049/index.html


https://www.sciencedirect.com/science/article/abs/pii/S0924013620303939


https://castingssa.com/lk-group-introduces-the-worlds-first-9-000t-giant-die-casting-machine/


https://themachinemaker.com/news/godrej-boyces-smart-die-casting-die-enters-the-market


https://www.magmasoft.de/en/magmaacademy/training-sessions/training/Economical-and-High-Quality-Die-Casting-Through-Intelligent-Efficient-Temperature-Control


https://tvarit.com/principles-for-ai-based-die-casting-process-optimization/


https://easyengineering.eu/the-road-to-leap-a-story-of-yizumi-leap-series-die-casting-machine/


https://www.empcasting.com/development-trend-of-aluminum-alloy-die-casting-pr.html


https://www.advantech.com/en/resources/case-study/low-cost-automation-and-monitoring-in-the-die-cast-manufacturing-process


https://www.zetwerk.com/resources/knowledge-base/die-casting/future-of-gravity-die-casting-advancements-and-opportunities/


https://journals.sagepub.com/doi/10.1177/1550147719879378


https://hitachi.co.in/adstefan/featured-casting-processes.html


https://www.toolsforsmartminds.com/en/case-studies/46-foundires-similar/309-how-the-first-predictive-maintenance-platform-for-the-die-casting-industry-was-developed


https://www.computer.org/csdl/proceedings-article/icitbs/2021/485400a300/1wB6T2pPK3m


https://link.springer.com/article/10.1007/s12541-017-0161-x


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


Bibliography

Die Casting Productivity - Science and Engineering - Bibliography

http://nraoiekc.blogspot.com/2019/01/die-casting-productivity-bibliography.html


DFMA - Design for Die Casting - Important Points

https://nraoiekc.blogspot.com/2021/12/dfma-design-for-die-casting-important.html


Die Casting Machines - Industrial Engineering

https://nraoiekc.blogspot.com/2022/03/die-casting-machines-industrial.html


Ud. 21.5.2025

Pub. 21.4.2025

















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Procter & Gamble - Takasaki Plant - Industrial Engineering 4.0 - WEF - McKinsey Light House Plant

 


Procter & Gamble - Takasaki, Japan

The site implemented Fourth Industrial Revolution use cases such as data flow integration, digital twin, machine learning across end-to-end value chain (from R&D to customers). 

As a a result, the innovation lead time accelerated by 72%, shutdown days for trial were reduced by 21%, and order horizon from customers improved 14-fold.

JAPAN | CHEMICALS


Procter & Gamble Asia Pacific, Middle East and AfricaProcter & Gamble Asia Pacific, Middle East and Africa

2023 April


We are honoured to share that the P&G Takasaki plant is the first in Japan's consumer goods industry to be recognized as a Lighthouse factory by the World Economic Forum. The plant which manufactures P&G’s Fabric and Home Care products, has been recognized as an Advanced 4th Industrial Revolution (4IR) Lighthouse in the world.


The plant leverages 4IR capabilities such as data science, AI and machine learning across end-to-end value chain from R&D to retail customers. Altogether, it has been improving productivity and enabling faster reaction to market needs while growing production capability. At P&G, we will continue to leverage our unique strengths of superiority to improve everyday life!


https://www.linkedin.com/posts/procter-gamble-ama_pg-ama-japan-activity-7059406365122867201-1G6O/   




Combination  one of the world’s largest consumer goods manufacturers with the  leading technology provider Microsoft creates the smarter manufacturing processes in  Procter & Gamble. 


P&G is a nearly 185-year-old global manufacturing powerhouse that creates everything from well known laundry soap brands through to razers, toothbrushes and even cough drops.The company has partnered up with Microsoft to take its implementation of Industry 4.0 technology – which includes IIOT, machine learning, artificial intelligence, and more. 


P&G is making  manufacturing smarter by enabling  predictive quality, predictive maintenance, controlled release, touchless operations and manufacturing sustainability optimization — which has not been done at this scale in the manufacturing space to date.  P&G CIO Vittorio Cretella in a  statement in Microsoft site. 

https://news.microsoft.com/2022/06/08/pg-and-microsoft-co-innovate-to-build-the-future-of-digital-manufacturing/ 

https://www.industrialdecarbonizationnetwork.com/digital-transformation-1/news/taking-industry-40-to-the-next-level-at-pg


Procter & Gamble | Innovation Expo Live Podcast - Vittorio Cretella | Episode 3

https://www.youtube.com/watch?v=ZwC7k8dsgyI


For instance, P&G has embedded IIOT and advanced machine analytics into its diaper production line, one of several global pilot projects that the company has been running at facilities in Egypt, India, Japan, and the United States.


Sensors continuously monitor the production line for potential problems to identify risks early and reduce production downtime.


This helps to improve cycle time, reduce material waste, and lower maintenance costs,

https://www.industrialdecarbonizationnetwork.com/digital-transformation-1/news/taking-industry-40-to-the-next-level-at-pg


P&G turns to AI to create digital manufacturing of the future

Sep 30, 2022

https://www.cio.com/article/408351/pg-turns-to-ai-to-create-digital-manufacturing-of-the-future.html


https://www.linkedin.com/posts/vittorio-cretella_pginnovation-activity-7171188391714209793-gdUF/


Tarek HabibTarek Habib

Takasaki Plant ManagerTakasaki Plant Manager

1yr • (April 2023)


Last week we announced P&G Takasaki plant achieving the highest level of manufacturing and supply chain excellence (the Largest IWS 5.0 Establish site so far) simply proud of this team with more achievements to come.


https://www.linkedin.com/posts/tarek-habib-232506137_last-week-we-announced-pg-takasaki-plant-activity-6948137683542032385-Fowg/   



Procter & Gamble - Guangzhou

In order to meet 45% increased eCommerce demands, P&G Guangzhou leveraged AI, flexible automation, and digital twins to integrate  multi-systems across value chain to serve omni channels consumers. This increased the responsiveness of their supply chain with 30%  reduction of inventory, 15% reduction of logistics cost and 99.9% on time delivery within 3 years.

PEOPLE'S REPUBLIC OF CHINA | CHEMICALS




Ud. 21.5.2025

Pub. 19.4.2024




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Productivity Management by Industrial Engineers - A Review


Productivity Management by  Industrial Engineers

Productivity Plan - Industrial engineering department has to give an annual productivity plan that specifies the sales growth and reduction in cost giving rise to a planned increase in profit due to productivity improvement.



2025 - A to Z Industrial Engineering - Blogging Theme - Industrial Engineering Benefits the Society and Organizations




Industrial Engineering - Systems/Processes/Methods Improvement Using Engineering solutions creatively.

Industrial Engineering - Prime focus - Productivity Improvement.

Productivity improvement gives National Prosperity and Organization Prosperity.



Source: https://www.linkedin.com/posts/national-productivity-council-gandhinagar_cartoonseriesabr10-productivity-economicgrowth-activity-7301162658278379520-eyyl




A to Z of Industrial Engineering - Blogging Challenge April 2025 - Proposed Posts

https://nraoiekc.blogspot.com/2025/02/a-to-z-of-industrial-engineering.html


Existing Collection of Articles

A to Z of Industrial Engineering - Principles, Methods, Techniques, Tools and Applications

https://nraoiekc.blogspot.com/2018/06/a-to-z-of-industrial-engineering.html


Modern Industrial Engineering - Summary Explanation.

https://www.linkedin.com/pulse/modern-industrial-engineering-summary-explanation-april-kvss-8hiyc

------------------------------------------


Productivity Management- Principle of Industrial Engineering

Every industrial engineer is a productivity manager. 

He has to plan for productivity and achieve productivity improvement year after year.

As a part of productivity management, he has to assess management actions of the organization for effect on productivity and has to recommend changes if they have an adverse effect on productivity or if there is scope for increasing productivity by modifying them.

Principles of Industrial Engineering, Proceedings of the 2017 Industrial and Systems Engineering Conference, K. Coperich, E. Cudney, H. Nembhard, eds., pp. 890-895.



1

Every industrial engineer is a productivity manager. 

He has to plan for productivity and achieve productivity improvement year after year.

Productivity Management Related Principles from Literature


Harrington Emerson - Twelve Principles of Efficiency - Productivity Management


1. Clearly defined ideals.
2. Common sense
3. Competent counsel
4. Discipline
5. The fair deal
6. Reliable, immediate and adequate records
7. Despatching
8. Standards and schedules
9. Standardized conditions
10. Standardized operations
11. Written standard-practice instructions
12. Efficiency-reward

1. Clearly defined ideals.

Every organization must have defined ideals that align its employees and guide their behavior. We are today using the terms, objectives, goal, mission, purpose, value etc. for the term ideals used by Emerson.

2. Common sense

Emerson talks of higher level understanding of persons in higher levels of management to promote efficiency.

3. Competent counsel

Efficiency improvement is a specialized knowledge area, and companies have to appoint specialists to develop the efficiency develop function in the organization and take their help in announcing programs and practices.

4. Discipline

The organization has to make plans and run its operations according to the plan.

5. The fair deal

In the organization, every body must perceive fairness in dealings.


Reliable records are required for good plans including good efficiency plans.


What is to be done at each machine needs to be determined by planning department and is to be communicate to the workman.


There needs to be a schedule planned for each machine and operator in the organization based on customer deliveries promised and the associated criteria. Standard times for doing various operations are to be developed to help in developing schedules.


In the organization all facilities and environmental conditions have to be planned to meet specified objectives. A planned facility is termed standard facility. 


The movements of machine components, the motions of operators, the transport and handling of materials are to be planned to meet specified objectives.


Standardized conditions and standardized operations are communicated to concerned persons in the organization through standard practice instructions. The efficiency expected will come about only when all activities are performed as per standard practice instructions.


Efficiency improvement has to result in benefit to all involved to sustain it. Employees have to receive efficiency reward as the efficiency in organization goes and the financial benefits are realized.


Productivity Plan - Industrial engineering department has to give an annual productivity plan that specifies the sales growth and reduction in cost giving rise to a planned increase in profit due to productivity improvement.



2

As a part of productivity management, he has to assess management actions of the organization for effect on productivity and has to recommend changes if they have an adverse effect on productivity or if there is scope for increasing productivity by modifying them.

Electives to be Offered in IE Curriculum on Improvement of Various Management Systems

1. Financial Accounting System and Improvement

2. Cost Accounting System and Improvement

3. Management Accounting System and Improvement

4. Financial Management System and Improvement

5. Operations Management System and Improvement

6. Supply Chain Management System and Improvement

7. Marketing Management System and Improvement

8. Human Resource Management System and Improvement

9. Project Management System and Improvement

10. Product and Engineering Design System and Improvement

11. Maintenance System and Improvement

12. Construction Management System and Improvement

13. Transportation System and Improvement

I4. Information Systems and Improvement

15. PPC System and Improvement


Role of Benchmarking in Productivity Management

Benchmarking gives the idea of productivity improvement achieved by other companies and thereby forces thinking of IEs to find ways of implementing certain new technologies and management methods in their organizations.


Have  you benchmarked productivity improvements of the best Industry 4.0 implementing factories?


478

Bosch Automotive - Bursa - Industrial Engineering 4.0 - WEF - McKinsey Light House Plant

Deployed  AI use cases such as close loop process control for hydro-erosion, and upskilling 100% of the workforce.  

They reduced unit manufacturing cost by 9% and improved OEE by 9%.

479
CEAT - Halol, India Plant - Industrial Engineering 4.0 - WEF - McKinsey Light House Plant.

CEAT deployed Fourth Industrial Revolution use cases like advanced analytics to optimize cycle times and digitalization of operator’s touchpoints. 

The site reduced cycle times by 20%, process scrap by 46%, and energy consumption by 15% . 
Overall, this resulted in approximately a 2.5 times increase in export and OEM sales in two years.

480
Dr Reddy's - Hyderabad Plant - Industrial Engineering 4.0 - WEF - McKinsey Light House Plant

The site deployed 40+ 4IR use cases by operating in garage mode and leveraging IIoT & democratized platform for advanced analytics. 

It improved manufacturing cost by 43% while proactively enhancing quality and reducing energy by 41%.

481
Ericsson - Lewisville Plant - Industrial Engineering 4.0 - WEF - McKinsey Light House Plant

The use of digital twins led to substantial enhancements: a 25% increase in throughput and a 50% reduction in unplanned downtimes.

482
Foxconn - Shenzen Plant - Industrial Engineering 4.0 - WEF - McKinsey Light House Plant


Shenzhen factory uses computer-controlled autonomous manufacturing in the dark, basically without assembly line workers in the production of electrical equipment components used in smartphones. It is  equipped with an automated optimization system for Machine Learning and AI devices, an intelligent self-maintenance system, and an intelligent real-time monitoring system. 

The factory’s production efficiency has been increased by 30%  and the inventory cycle reduced by 15%.


483
GlaxoSmithKline (GSK) Hertfordshire Plant - Industrial Engineering 4.0

The GSK plant has applied advanced technologies throughout its manufacturing operation, using advanced analytics and neural networks.  This has improved line speeds at the site by 21%, cut downtime, increased yields, and delivered an OEE (overall Equipment effectiveness) improvement of 10%.

GSK has applied deep-learning image recognition to detect quality defects, and is using artificial intelligence to optimise machine throughput. 

By implementing digital twin technologies, it has boosted capacity by 13%, while cycle time monitoring and the use of digital visualisation tools have cut cycle times by 9%.

484
Haier - Hefei Plant - Industrial Engineering 4.0 - Industry 4.0 WEF-McKinsey Lighthouse


Haier’s Hefei air conditioner factory applied advanced algorithms, digital twins, knowledge graphs and other cutting-edge technologies in the research and development (R&D), production and testing of household central AC systems, resulting in a 33% increase in energy efficiency, a 58% drop in the defect rate, a 49% increase in labour productivity and a 22% drop in unit manufacturing costs.

485
Ingrasys - Taoyuan, Taiwan Plant - Industrial Engineering 4.0 - WEF - McKinsey Light House Plant

By deploying AI use cases across order forecasting, warehouse and production scheduling, product design, quality and assembly-testing domains, Foxconn Industrial Internet’s Taiwan factory has achieved a 73% increase in production efficiency, a 97% reduction in product defects, a 21% reduction in lead time and a 39% decrease in unit manufacturing costs.


486
Johnson & Johnson - Industrial Engineering - Productivity Improvement Activities - Industry 4.0 Lighthouse Plant

Johnson Xi’an replaced its manual facility with a Fourth Industrial Revolution-enabled new factory in 2019. This facility includes digital twins for technology transfer and material handling, intelligent automation of continued process verification (CPV) and batch execution processes. 

This has shortened the product transfer time by 64% during site relocation and has enabled a 60% decrease in non-conformance, while improving productivity by 40%, operating costs by 24% and GHG emissions by 26%.


487
K-Water - Hwaseong - REPUBLIC OF KOREA - Industrial Engineering 4.0 - WEF - McKinsey Light House Plant

K-water launched a next-generation AI water treatment plant to reduce production costs, improve responsiveness and reduce human error. It is being scaled across 40+ other sites.

It has helped K-water to reduce its chemical usage by 19%, improve labour efficiency by 42% and reduce power consumption by 10%.

488
LONGi Solar - Jiaxing Plant - Industrial Engineering 4.0 - WEF - McKinsey Light House Plant

Jiaxing site implemented more than 30 Fourth Industrial Revolution use cases, using AI and advanced analytics to boost manufacturing operations. 

The site achieved a 28% reduction in unit manufacturing costs, a 43% cut in yield loss and an 84% decrease in production lead time within one year, while also lowering energy consumption by 20%.

489
Mondelēz - Beijing Plant - Industrial Engineering 4.0 - WEF - McKinsey Light House Plant
Mondelez - Sricity

Mondelēz Beijing implemented 38 Fourth Industrial Revolution use cases, such as an AI-powered dough-making lights-off workshop and gas consumption optimization by machine learning. As a result, Mondelēz Beijing has achieved a 28% net revenue growth and 53% increase in labour productivity while reducing GHG emissions by 24% and food waste by 29%.


490
Novo Nordisk - Hillerød Plant - Industrial Engineering 4.0 - WEF - McKinsey Light House Plant

Novo Nordisk has invested in digitalization, automation and advanced analytics, building a robust Industrial Internet of Things operating system to be scaled across their manufacturing footprint, increasing equipment efficiency and productivity by 30%.

491
Procter & Gamble - Takasaki Plant - Industrial Engineering 4.0 - WEF - McKinsey Light House Plant

The site implemented Fourth Industrial Revolution use cases such as data flow integration, digital twin, machine learning across end-to-end value chain (from R&D to customers). 

As a a result, the innovation lead time accelerated by 72%, shutdown days for trial were reduced by 21%, and order horizon from customers improved 14-fold.

The plant leverages 4IR capabilities such as data science, AI and machine learning across end-to-end value chain from R&D to retail customers. Altogether, it has been improving productivity and enabling faster reaction to market needs while growing production capability.


492
Quaker Houghton - Industrial Engineering 4.0 - Intelligent Die Casting

493
Schneider Electric - Hyderabad

Over four years, the plant reduced its energy consumption by 59 per cent, improved waste optimisation by 64 per cent, decreased CO2 emissions by 61 per cent, and reduced water consumption by 57 per cent.

To improve energy efficiency and thereby reduce CO2 emissions, the Hyderabad team focused on the highest energy consumers in the plant: air compressors and chillers. An IoT-enabled device, Equaliser 4.0, was installed to regulate the compressors, thereby improving their efficiency. For the chillers, a data-driven energy management system with closed-loop control was fitted to constantly monitor and adjust energy consumption in real-time, optimising energy efficiency.

494
The Coca-Cola Company - Ballina

The site implemented digital, and analytics use cases. As a result, it improved cost by 16% while expanding its SKU portfolio by 30%

495
Unilever - Sonepat

Unilever Sonepat implemented 30+ Fourth Industrial Revolution use cases in its E2E supply chain. Top use cases included boiler and spray dryer process twins, as well as customer data-informed no-touch production planning and inventory optimization. 

This improved service by 18%, forecast accuracy by 53%, conversion cost by 40% and Scope 1 carbon footprint by 88%.

496
Western Digital - Bang Pa-In

497
Zymergen - Emeryville

Biotechnology firm Zymergen brought robotics and artificial intelligence (AI) to bioengineering labs, traditionally highly manual sites. 

Innovation rates soared, allowing Zymergen to use bioengineering for products previously were not feasible.



For Complete Coverage of Productivity Management Read Lessons.

Modern Industrial Engineering - Productivity Management Module - A Book of Online Readings




----------------------

Post Included In

Modern Industrial Engineering - LinkedIn News Letter - May 2025 Issue. 

Topic of Focus - Current Issues of Interest in Industrial Engineering to Make it Effective.

https://www.linkedin.com/pulse/current-issues-interest-industrial-engineering-may-2025-kvss-1hekc



Ud. 21.5.2025

Pub. 18.4.2025

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Tuesday, May 20, 2025

Novo Nordisk - Hillerød Plant - Industrial Engineering 4.0 - WEF - McKinsey Light House Plant

Industrial Engineering 4.0 - Computer Aided Industrial Engineering: Work Systems Analysis in Industry 4.0

Rao, Kambhampati Venkata Satya Surya Narayana; Rathod, Aniket.  IIE Annual Conference. Proceedings; Norcross (2021): 49-54.

https://www.proquest.com/openview/d32ef32bbaa911d170e046479790c035/1  


Novo Nordisk (Hillerød): Facing volume growth and rising complexities, Novo Nordisk has invested in digitalization, automation and advanced analytics, building a robust Industrial Internet of Things operating system to be scaled across their manufacturing footprint, increasing equipment efficiency and productivity by 30%.


Thank you to  @wef   for recognising our Hillerød, Denmark-based production facilities in its Global Lighthouse Network. Through digitalisation and advanced analytics in our factories, we serve the needs of 30 million people worldwide more efficiently and sustainably each year.


2025

https://www.novonordisk.com/careers/career-areas/manufacturing/novo-nordisk-hillerod.html

To drive the Industry 4.0 agenda forward and set new standards for pharma companies to be at the forefront of modern technology.

Automation Engineers and Process Digitalisation Specialists - Required

What does the Automation Engineer and Process Digitalisation Specialist roles entail?

Within Novo Nordisk's manufacturing arm, Product Supply, we are in the midst of an exciting digital transformation journey, and you can be part of it.

You will work alongside specialists from various fields within biotechnology, technology, and innovation, utilising your personal skills and experiences toward improving and innovating our production processes, benefiting our patients around the world that rely on our treatments.

In return, we give you the opportunity to make your mark and play an instrumental role in the development and scaling of technology across the production environment. Here you can use your sought-after skillset toward improving the lives of millions of people living with diabetes and other serious chronic diseases.

Modern technology plays a crucial role in our efforts to expand capacity – enabling us to serve even more patients with high quality products now and in the future. By implementing modern technologies and digitalising manual processes in our facilities, we are transforming the way we work by augmenting the skills of our employees and streamlining operations.

Using a collaborative approach, we partner with technology companies to drive the Industry 4.0 agenda forward and set new standards for pharma companies to be at the forefront of modern technology.

We need your talent and skillset to help us drive change and support our journey ahead!


2024














2007










Ud. 20.5.2025
Pub. 16.4.2024
















Posted by at 1 comment:
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Understanding and Developing Human Effort Productivity Science


2025 - A to Z Industrial Engineering - Blogging Theme - Industrial Engineering Benefits the Society and Organizations




Industrial Engineering - Systems/Processes/Methods Improvement Using Engineering solutions creatively.

Industrial Engineering - Prime focus - Productivity Improvement.

Productivity improvement gives National Prosperity and Organization Prosperity.



Source: https://www.linkedin.com/posts/national-productivity-council-gandhinagar_cartoonseriesabr10-productivity-economicgrowth-activity-7301162658278379520-eyyl




A to Z of Industrial Engineering - Blogging Challenge April 2025 - Proposed Posts

https://nraoiekc.blogspot.com/2025/02/a-to-z-of-industrial-engineering.html


Existing Collection of Articles

A to Z of Industrial Engineering - Principles, Methods, Techniques, Tools and Applications

https://nraoiekc.blogspot.com/2018/06/a-to-z-of-industrial-engineering.html


Modern Industrial Engineering - Summary Explanation.

https://www.linkedin.com/pulse/modern-industrial-engineering-summary-explanation-april-kvss-8hiyc

------------------------------------------


Understanding and Developing Human Effort Productivity Science


Industrial engineering has to use productivity science. Productivity science of machines and human effort productivity science are two important areas of productivity science that supports industrial engineering.

Industrial engineers have to understand and develop human effort productivity science further.


Understanding and Developing Machine Effort/Work Productivity Science is also equally important for industrial engineers.

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

https://nraoiekc.blogspot.com/2019/06/taylor-art-of-metal-cutting-important.html




Industrial and systems engineering (ISE)

Industrial and systems engineering (ISE) is defined as a discipline concerned with the design, improvement and installation of integrated systems of people, materials, information, equipment and energy. It draws upon specialised knowledge and skill in the mathematical, physical, and social sciences together with the principles and methods of engineering analysis and design, to specify, predict, and evaluate the results to be obtained from such systems (IISE 2024). 


The main components of ISE knowledge that reflect a categorisation of pertinent industrial and systems engineering theories and models include (1) work design & measurement, (2) operations research & analysis, (3) engineering economic analysis, (4) facilities engineering & energy management, (5) quality & reliability engineering, (6) ergonomics & human factors, (7) operations engineering & management, (8) supply chain management, (9) engineering management, (10) safety, (11) information engineering, (12) design and manufacturing engineering, (13) product design & development, and 14) system design & engineering.


Post Included In

Modern Industrial Engineering - LinkedIn News Letter - May 2025 Issue. 

Topic of Focus - Current Issues of Interest in Industrial Engineering to Make it Effective.

https://www.linkedin.com/pulse/current-issues-interest-industrial-engineering-may-2025-kvss-1hekc



Ud. 20.5.2025

Pub. 24.4.2025

Posted by at No comments:
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Department of Industrial Engineering - Value to be Created for the Organization and Society

 2025 - A to Z Industrial Engineering - Blogging Theme - Industrial Engineering Benefits the Society and Organizations




Industrial Engineering - Methods Improvement Using Engineering solutions creatively.

Industrial Engineering - Prime focus - Productivity Improvement.

Productivity improvement gives National Prosperity and Organization Prosperity.



Source: https://www.linkedin.com/posts/national-productivity-council-gandhinagar_cartoonseriesabr10-productivity-economicgrowth-activity-7301162658278379520-eyyl




A to Z of Industrial Engineering - Blogging Challenge April 2025 - Proposed Posts

https://nraoiekc.blogspot.com/2025/02/a-to-z-of-industrial-engineering.html


Existing Collection of Articles

A to Z of Industrial Engineering - Principles, Methods, Techniques, Tools and Applications

https://nraoiekc.blogspot.com/2018/06/a-to-z-of-industrial-engineering.html


Department of  Industrial Engineering - Value to be Created for the Organization and Society


Department of Industrial Engineering is an important department to be set in engineering organizations of all branches of engineering. It is of utility in all engineering tasks like design, manufacturing, construction, operation of power plants, telephone exchanges or mobile communication systems, rail transportation systems, air travel systems, information systems etc.

What is the purpose of industrial engineering department?

 It is primarily profit improvement through revenue growth and cost reductions achieved through productivity improvement of resources. 

From where does the productivity improvement come? 

From engineering and technology developments that keep appearing. From creative application of productivity science of machines, materials and human effort.


Advances in Engineering and Industrial Engineering.

Advances in Engineering facilitate  Industrial Engineering to increase productivity.

https://nraoiekc.blogspot.com/2025/04/advances-in-engineering-and-industrial.html


Understanding and Developing Human Effort Productivity Science



Industrial engineering is concerned with incremental improvements in processes, products and facilities. It also does productivity evaluation and improvement as the design stage of products and processes and selection of facilities.

What is the possible value addition?


Value Creation Model for Industrial Engineering

For $100 million cost, there can be one MS IE and 6 BSIEs. Value created: $3,600,000 per year on $100,000,000 cost of production per year.  Value to be created by IE department is 3.6% of the cost of production per year. Its cost of operating the department has to be 20% or one-fifth of the savings. Investment in improvement projects is addition to it.

Explanation
We start with a MS Industrial Engineer earning $12,000 per month. He is expected to have 6 BS industrial engineers under him. Each BS industrial engineer is earning a salary of $6000 per month.

Let us take a team of one  BS industrial engineer + Supervision by MSIE + staff support totaling $10,000 per month. which is equal to $120,000 per year.

This team is expected to generate a saving of $600,000 per year in 50 IE projects. That means each project has to save 12,000 dollars on average.

Let us assume each project is on an operator earning $3000 per month. The total cost of the work center can be taken as $30,000 per month. Which means $360,000 per year. Industrial engineers have to find $12,000 savings out of that expenditure every year assuming that a BSIE is responsible for work of 50 operators . Operation Analysis is used on One Machine + Operator combination. It is possible that multiple machines are operated by one operator in which case we may think of one machine + part operator.  Maynard and Stegemerten authored a full book on operation analysis and Niebel explained it well in a chapter in his book on Motion and Time Study.

The IE department's expenditure per month is $60,000 ((1 MSIE + 5 BSIEs + Staff)). They have to find savings of $300,000 per month. $3,600,000 per year on $100,000,000 cost of production per year.


Are they able to find such cost savings year after year and justify their compensation?



Breakup of Productivity Benefit  - Sharing Scheme


Savings of $300,000 per month

Benefit break up:

IE department staff: $60,000
Investment in projects: $60,000
Increase in benefits to other employees:$60,000
Benefit to customers: $60,000
Increase in profits of the company: $60,000

In the second year, the share of IE department staff and Investment in projects may get reduced to $30,000 and $90,000 may be given customers thus increasing the demand for the product to absorb the increased productivity.

An alternative benefit breakup model. Is it more sustainable?

Savings of $300,000 per month

Benefit break up:

IE department staff: $60,000

Increase in benefits to other employees:$30,000

Increase in profits of the company: $30,000
Investment in projects: $30,000  - This point needs to be discussed and understood better. Investment in IE or productivity projects can be in multiples $60,000 if you think it is contributing to the cost of capital of the company.

Benefit to customers: $150,000



Look forward to comments from Industrial Engineers on the feasibility of achieving productivity savings year after year and sharing them with other employees, shareholders and consumers apart from taking their compensation.



You can use the numbers in the model to calculate payback period and NPV


Let us say one BSIE IE team will have per annum $120,000 department expenses (personal sal + department office expenses)

Per annum investment in productivity projects is $120,000. So total investment in productivity improvement can be taken as $240,000.

While it gives savings of $600,000, from 2nd year onwards, $360,000 is shared with consumers. $120,000 is shared with employess. $120,000 is the return to capital invested.

Hence we can as investment: $240,000

From 2 year end every year there is cash inflow of $120,000. This will give payback period of 3 years because in the first year we are assuming that there is no cash inflow.

The NPV at the end of four years at a discount rate of 10% is $52,680.

As an Industrial Engineer, and IE manager are you following value addition and value allocation?

Taylor rubric: "an increase in productivity was allocated (1) one-third to the worker in the form of increased wages, (2) one-third to the owners in the form of stock dividends and capital investment, and (3) one-third to consumers in the form of lower prices for the products the company produced."

Source: https://nraoiekc.blogspot.com/2020/03/value-creation-model-for-industrial.html



Post Included In

Modern Industrial Engineering - LinkedIn News Letter - May 2025 Issue. 

Topic of Focus - Current Issues of Interest in Industrial Engineering to Make it Effective.

https://www.linkedin.com/pulse/current-issues-interest-industrial-engineering-may-2025-kvss-1hekc




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Ud. 20.5.2025

Pub. 4.4.2025



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Monday, May 19, 2025

IISE 2025 Atlanta Annual Conference - Information

 




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https://iise.secure-platform.com/annual/solicitations/102003/sessiongallery/schedule




Annual Conference Session Schedule

https://iise.secure-platform.com/annual/solicitations/102003/sessiongallery/schedule/items/94542


Manufacturing Systems Engineering 1


Manufacturing Systems Engineering 1





Title Presenting Author(s) Action

Designing Reverse Logistics Networks for Metal Remanufacturing with Cloud-Based Additive Manufacturing Systems Muyue Han, Muyue Han, Lingxiang Yun

Enhancing Disaster Supply Chain Resilience Through the Integration of Mobile Additive Manufacturing and Truck-Drone Delivery Systems Omid Abdolazimi, Junfeng Ma

Integrating Multi-Skill Assembly and Logistics Labor Scheduling Optimization Zhihan Liu, Wencang Bao, Benoit Montreuil, Louise Lacroix

Parallel Batch Scheduling With Incompatible Job Families Via Constraint Programming Jorge A Huertas, Pascal Van Hentenryck










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