Productivity Engineering of Material, Work Piece and Part Handling in Machining Operations

Lesson 104 of Industrial Engineering ONLINE Course.

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

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

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,  other machines and tools and accessories used along with the machines and machine tools are important components of engineering systems. Industrial engineers have to analyze the currently available machine tools & accessories in the market and the existing machine tools & accessories being used in the factory, plant and processes to identify more productive and profitable alternatives. F.W. Taylor advocated element level improvement in resources or inputs used in a process and operation and element level improvement in each operation. This is what Shigeo Shingo also explains as the difference between process and operation. In process analysis, you observe what are you are doing on the workpiece element by element. In operation analysis you observe each input and its activity. 

This collection offers you information on new workholding engineering improvements,  to increase productivity to help you in giving ideas and directions in searching for new workholding devices and their creative application. Engineering has to be learned from examples also. This is also termed as discovery learning. 

Case Study - Method Study - Handling Parts for Radial Drilling Machine - 2020

Download paper from
http://www.jetir.org/view?paper=JETIREA06026

A conveyor was proposed to reduce time and fatigue.
“Productivity Improvement For Machining Process By Using Time & Motion Study”
Ketan K. Tonpe, Ram R. Wayzode, Mahesh Makode, Saurabh Patte, Suraj Deshmukh,

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

WORK MEASUREMENT APPROACH FOR PRODUCTIVITY IMPROVEMENT IN A HEAVY MACHINE SHOP 

Ishwar Bhiradi and B.K.Singh
5th International & 26th All India Manufacturing Technology, Design and Research Conference (AIMTDR 2014) December 12th–14th, 2014,
IIT Guwahati, Assam, India
http://www.iitg.ac.in/aimtdr2014/PROCEEDINGS/papers/570.pdf

Download the case study and go through it.

Figure 4 gives the elements in the original method.

Part: Differential Housing
Material: Cast iron Gr 25
Operation: SIDE FACE DRILLING OPERATION
Machine: 475.01(BFW-1)

Elements and Break Points

a. Pickup casting from input conveyor, place it on Hydraulic lifter.
Breakpoint: Improper tackling
b. Increase hydraulic pressure, Hydraulic lifter  lifts the component and places it on fixture
Breakpoint: Hydraulic. Oil not available.

Table 1 gives the time for each element and total operation time 6.78 minutes

In the revised procedure, the operator was asked to directly pickup and the put the casting in fixture. The hydraulic lifter mechanism was removed.
This practice is initially monitored for process
disturbances, manual fatigue conditions and quality
parameters. No changes are observed after change in
machine setup. Figure 5 gives the elements of the revised method and Table 2 gives elemental times.


The operation time got reduced to 4.16 min.

2021

Evenly Spaced Radial-Force Vectors for Superior Gripping

Get-A-Grip multi-axis workholding will not distort, deform the workpiece

AMT INNOVATIONS’ new workholding product, Get-A-Grip® has a “cutting-edge triangular dovetail” design that will not distort or deform the workpiece. The dovetail provides three, evenly spaced radial-force vectors for superior gripping. Through carefully developed triangular contact geometry, it reportedly eliminates the need for an indexing pen. The novel internal clamping geometry reduces material preparation area and can be strategically placed where the finished part may have a pocket which greatly reduces secondary operations.

Get-A-Grip “revolutionizes traditional workholding products for multi-axis CNC machining,” according to the developer. Stainless steel materials and innovative design elements bring flexibility and time-saving advantages that will result in a dramatic increase in production and profits.

https://www.americanmachinist.com/machining-cutting/media-gallery/21901481/8-new-machining-technologies-you-should-know/slideshow?slide=2

Ud 9.9.2021

Pub 17.9.2020

Toyota - Human Resource Management and Human Effort Industrial Engineering Practices

INDUSTRIAL ENGINEERING is redesign (engineering) of Products, Facilities and Processes for Productivity increase.
Productivity Management Imperative for USA - McKinsey. Returning US productivity to its long-term trend of 2.2 percent annual growth would add $10 trillion in cumulative GDP over the next ten years (2023 - 2030).

INTRODUCTION TO MODERN INDUSTRIAL ENGINEERING. E-Book FREE Download. 

https://academia.edu/103626052/INTRODUCTION_TO_MODERN_INDUSTRIAL_ENGINEERING_Version_3_0 

Creating Toyota cultures around the world

John Shook

Sep 6, 2021

https://planet-lean.com/nate-furuta-book/

TOYOTA KATA SUMMARY – 13 MINUTES TO FULL-ON KATA

https://impruver.com/toyota-kata-summary/

Machining Cutting Temperatures Reduction - Productivity Engineering and Optimization

 Lesson 108 of Industrial Engineering ONLINE Course.

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

Lesson 111. F.W. Taylor - Productivity Engineering of Belting - 1893

Complete analysis of the mechanics of cutting have to use temperature-dependent constitutive models of cutting conditions. Cutting temperatures increase with cutting speed. As temperature in the primary deformation zone increases,  temperature on the rake face of the tool increases and tool life decreases. At  high cutting speeds, the tool-chip interface temperature approaches the melting temperature of the work material and chip starts melting.

The rise in machining temperature is different for different materials. Cutting temperatures are higher for harder materials at the same cutting speeds. For materials of similar hardness, cutting temperatures increase with ductility.

MANAGING THERMAL LOADS IN MILLING PROCESSES

https://www.secotools.com/article/21483?language=en

Effective Ways to Reduce Heat Generation

October 25, 2018

https://www.harveyperformance.com/in-the-loupe/reduce-heat-generation/

Makino's Research and Development Work in the Area

Makino, the machine tool builder made special studies in the area of cutting temperature to use the results in productivity engineering.

2013 Cutting Speed Maximization subject to temperature constraint

In the paper "MODEL DEVELOPMENT FOR CUTTING OPTIMIZATION IN HIGH-PERFORMANCE TITANIUM MACHINING" by DR. ZHIGANG WANG, SENIOR PROCESS DEVELOPMENT ENGINEER, MAKINO INC. and MARK LARSON, MANAGER OF TITANIUM PROCESS DEVELOPMENT, © 2013 Makino, Inc., the following conclusions were made.

An analytical cutting-force model for milling processes in Ti64 has been developed that provides good accuracy in predicting the cutting forces when compared to experimental cutting data.

• Numerical simulation was performed to estimate the temperature distribution at the tool/chip interface. 

Cutting speeds and radial depth of cut have more dominant effects on cutting temperatures than do feed rates.

• Average cutting temperature at the tool/chip interface was measured in experimental testing and was found to be controlled within the characteristic temperature of WC material to maintain reasonable tool life in a stable finishing operation optimized to achieve high productivity as well as long tool life.

• Physical experimentation has verified that the proposed theoretical modeling approach can achieve high-performance machining of titanium alloys.

For a test job, test cuts were conducted at 1,174 rpm (optimal according to model) to check surface finish and tool wear under actual cutting conditions.  During testing, the average temperature at the tool/chip interface reached 650°C (1202°F), below the 800°C (1472°F) critical temperature threshold, and the flank tool wear was less than 0.1 mm after 16 passes.

Makino FB127 Thermal Control Features

To ensure consistent accuracy over long cycle times, the FB127 machine is equipped with the following features:

Core-cooled ballscrews on all axes, including temperature control of the bearings support bracket area and motor mounting area, to maintain component temperatures.

Temperature control of the machine saddle and spindle carrier using oil passageways and temperature-controlled oil, ensuring tight control over saddle and carrier temperatures.

Addition of a separate oilmatic unit for tight temperature control of the machine elements.

Guideway hydraulic circuit (Nano slideway) on the X-axis to reduce friction and heat generation, yet also maintain stringent control over geometries and accuracies.

The FB127 spindle features Makino’s unique core-cooling and under-race lubrication system, minimizing thermal distortion at high spindle speeds.

https://www.makino.com/machine-technology/machines/vertical-machining-centers-3-axis/fb127

Parametric Optimization of Heat Generation during Turning Operation, 

Journal of Mechanical Engineering and Automation, 2016;  6(5A): 117-120

http://article.sapub.org/10.5923.c.jmea.201601.22.html

Optimization of Cutting Parameters on Tool Wear, Workpiece Surface Temperature and Material Removal Rate During Turning of AISI D2 Steel

IJERT,   Volume 01, Issue 05 (July 2012)

https://www.ijert.org/optimization-of-cutting-parameters-on-tool-wear-workpiece-surface-temperature-and-material-removal-rate-during-turning-of-aisi-d2-steel

Ud 4.9.2021

Pub 17.9.2020

TOTAL QUALITY MANAGEMENT IN HIGHER EDUCATION INSTITUTE OPERATIONS

Georgia Tech's goal is to become the premier technological university of the 21st Century.

We want to  transform our organizational culture, policies and processes from ones that largely are focused internally to ones that are dedicated to identifying customers, ascertaining their needs, developing processes that meet those needs, defining realizable measurements of customer satisfaction, and empowering faculty and staff to create, maintain and strengthen those processes in pursuit of continuous improvement. 

A PROPOSAL FOR THE INTEGRATION OF  TOTAL QUALITY MANAGEMENT

INTO INSTITUTE CURRICULUM, RESEARCH, AND OPERATIONS

Gilmour, Joseph E.; Amons, Jane C.

Georgia Inst. of Tech., Atlanta.

30 Apr 92

Report

http://files.eric.ed.gov/fulltext/ED356706.pdf

Ud 4.9.2021

Pub 6.11.2014

IISE Course - MATERIALS HANDLING ANALYSIS

Ubiquity of Industrial Engineering Principle of  Industrial Engineering

Industrial Engineering is applicable to all branches of engineering.

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

SYSTEMATIC MATERIALS HANDLING ANALYSIS & SYSTEMATIC CONTAINER PLANNING

2 days, 1.4 CEUs

Note: This course is only offered by our qualified training provider in Turkey.

Overview

No operation can be performed without transportation! 

Materials handling methods link layout operations to a functioning manufacturing system. Depending on the nature of your facility, materials handling costs account for 10 to 30 percent of your total operating cost, which may be even higher in case of distribution facilities. Most facilities have not yet been referenced to a materials handling plan. Methods have mostly developed spontaneously or been projected by equipment suppliers and consultants. Likewise, the individuals appointed as materials handling engineer are mostly individuals without as formal education in this field. In the absence of analyses, many of them adopt the approach “me too” based on what others have done.

Our materials handling course is based on Systematic Handling Analysis (SHA), which is the most organized approach designed to analyze and evaluate materials handling methods. Developed by Richard Muther and Knut Haganas and refined through an application history of more than 40 years, Systematic Handling Analysis accompanies Systematic Layout Planning (SLP). SHA is available in printed form and is used by thousands of planners worldwide.

Our course on SHA methods give equal weight to facility and warehouse subjects. It is needed by those who have to apply the following procedures:

Replace materials handling equipment, improve or add to their specifications.

Replace materials handling methods, or evaluate alternative methods.

Reorganize for a better flow of materials and movement of products.

Reduce costs through better materials handling methods.

Topic Highlights 

• Classify the materials
• Analyze the moves
• Quantified flow diagram
• Set handling equipment and container plans and adjust
• Evaluate alternative plans
• Detail the selected plan

What You Will Learn 

• To improve the performance of facility.
• To decrease the materials handling cost.
• To provide the flexibility, harmony and quantity incrementation.
• To save time and prevent oversights.
• To improve the use of space

Course Content 

Systematic Planning of Industrial Facilities

Anatomy of an industrial plant

Layout, materials handling, communications and controls, utilities, building

Systematic Materials Handling Analysis (SHA)

How to apply systematic materials handling analysis (SHA)?

Four phases of materials handling

What is materials handling?

Steps of systematic handling analysis

Key inputs

Materials Classification

Determine the characteristics of materials

Classification of materials – sample case evaluation

Materials Movement Analysis – Sample Case Evaluation

What unit do you use to measure intensity of flow?

Flow analysis: Equivalent movement multipliers

Measuring diverse material movements

Route-product movement summary

How to prepare a quantified flow diagram?

Distance-intensity diagram and what it tells to us?

Flow intensity, effort and cost

Visualization of flow and materials handling effort

How to Plan an Effective Materials Handling Method?

Methods, plans and systems

Materials handling equipment types and their uses

Elements of materials handling cost

Real-world materials handling

Materials handling equipment classified by cost data

What the distance-intensity chart tells us about handling equipment?

Selection guide of materials handling equipment by quantified flow diagram

Pick-up and set-down devices and transport units

What the distance-intensity chart tells us about layout and handling system?

Classical materials handling systems

How to decide on the handling equipment, transport unit and system?  

Case Study: Preliminary Handling Plan

Case Study: Overall Materials Handling Analysis

Developing and Evaluating Alternative Handling Plans

Evaluation of alternatives – sample case evaluation

Select the best handling plan

Detail Handling Plan and Implementation Phases

The pattern repeats

Forms of waste and relationship to material handling

Elimination of waste

Principles of lean materials handling

Basic good practices of materials handling

Implementation worksheet

Case Study: Challenging Layout Plan 

Case Study: Overall Materials Handling Analysis

Systematic Container Planning (SCP)

How to implement Systematic Container Planning (SCP)?

Framework of phases

Three fundamentals in SCP

Procedure of SCP

Material Classification – Sample Case Evaluation 

Industrial Container Types 

Functions of Industrial Containers 

Container Requirements and Guidelines – Sample Case Evaluation 

Overall Container Plan – Sample Case Evaluation

Detail Container Plan – Sample Case Evaluation 

Container Process Chart 

Wooden Pallet Designs 

Fork-liftable Container Features 

Hand-liftable Container Considerations 

Container Selection Factors 

Who will benefit:

• Plant and Production Managers/Engineers
• Warehouse, Distribution and Logistics Managers
• Industrial and Process Engineers and Systems Analysts
• Materials Handling Engineers and Equipment Suppliers
• Technicians and Lead Operators

 

https://www.iise.org/Details.aspx?id=33490

News - Information for Material Handling and Transport Operation Analysis

Productivity Measurement - Principle of Industrial Engineering

TAYLOR - NARAYANA RAO PRINCIPLES OF INDUSTRIAL ENGINEERING
https://www.proquest.com/docview/1951119980

20-Productivity Measurement

Productivity measures at the enterprise level, process level, operation and work station level are required. It is important to highlight that productivity measurement is required for each input into the operation. For instance, you have measure productivity of cutting fluid in machining. Industrial have to assess the productivity of each element or input.

To maintain system level focus, productivity measures at system level have to be developed and used.

The relation between productivity measures at the enterprise level, process level, and work station level have to be established to facilitate decision making.

______________________________________________

Principles of Industrial Engineering - Presentation 

by Dr. K.V.S.S. Narayana Rao in the 2017Annual Conference of IISE (Institute of Industrial and Systems Engineering) at Pittsburgh, USA on 23 May 2017

___________________

___________________

Principles of Industrial Engineering - Narayana Rao - Detailed List

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

1. Productivity science

2. Productivity engineering

3. Industrial Engineering is applicable to all branches of engineering

4. Principles of (machine) utilization economy to be developed for all resources used in engineering systems.

5. Industrial engineering optimization

6. Industrial engineering economics

7. Implementation team membership and leadership

8. Human effort engineering for increasing productivity

9. Principles of motion economy to be used in all IE studies in the area of human effort engineering

10. Operator comfort and health are to be taken care of.

11. Work measurement

12. Selection of operators

13. Training of operators, supervisors and engineers

14. Productivity training and education to all

15. Employee involvement in continuous improvement of processes and products for productivity improvement.

16. Productivity incentives

17. Hearty cooperation

18. Productivity Management

19. System level focus for productivity

20. Productivity measurement

21. Cost measurement

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

https://www.proquest.com/docview/1951119980

Updated on  29 Aug 2021, 4 June 2019, 28 June 2917

Takt Time - Assembly and Production Line Balancing for JIT Production

The classic calculation for takt time is:

Available Minutes for Production / Required Units of Production = Takt Time

 The “pure” definition is usually to take the total shift time(s) and subtract breaks, meetings, and other administrative non-working time. This is the way Shingijutsu teaches it.

The Purpose of Takt Time

Running to takt time is not necessary for moving towards lean. Many factories operate just fine without even knowing what it is. What is needed is some way to determine the minimum resource necessary to get the job done (eliminating muda), and a way to continuously compare what is actually happening vs. what should be happening, and then a process to immediately act on any difference (jidoka). 

Takt time is  a tool for doing it in JIT.  It is a very effective tool and  it is largely considered a necessary fundamental. 

http://theleanthinker.com/2010/04/28/takt-time-cycle-time/

https://lecturenotesblog.wordpress.com/2013/07/04/takt-time-target-manpower-and-line-balancing/

Takt and Line Balancing

https://www.allaboutlean.com/line-balancing-1/   (Total 6 articles)

https://www.coursera.org/lecture/wharton-operations/takt-time-Z5Vif

https://blogs.sap.com/2014/11/20/operations-management-basics-takt-time-target-manpower-and-line-balancing/

https://hal.archives-ouvertes.fr/hal-01094679/file/HAL_APMS%2714_Dynamic_Reconfiguration.pdf

https://www.sciencedirect.com/science/article/pii/S2351978917303578/pdf?md5=cbce08810f00108629eac7601730e7e7&pid=1-s2.0-S2351978917303578-main.pdf

https://globaljournals.org/GJRE_Volume14/4-Assembly-Line-Balancing.pdf

http://www.ieomsociety.org/paris2018/papers/471.pdf

https://inpressco.com/wp-content/uploads/2016/09/Paper2102-106.pdf

https://www.ijtra.com/view/information-by-the-people-for-the-people-for-development.pdf

https://www.ijraset.com/fileserve.php?FID=4630

https://industrial-excellence-award.eu/fileadmin/data/pdf/Publications/Case_Article_The_Fendt_VarioTak-Revolutionizing_Mixed-Model_AssemblyLine_Production.pdf

https://nandiniananthula.com/line-balancing/

http://psrcentre.org/images/extraimages/22%20813523.pdf

Ud 29.8.2021

Pub 23.9.2012