Friday, April 6, 2012

Industrial Engineering Projects and Opportunities in Crankshaft Design and Production


IE Techniques

Human Effort Engineering
  1. Motion Study, Task Analysis
  2. Work Measurement: Time Study, PMTS, MTM, MOST
  3. Ergonomics: The Applied Science for Human Effort Engineering
  4. Wage Incentives and Job Evaluation
System Efficiency Engineering
  1. Method Study, Work Study, Methods Design
  2. Value Engineering

  3.  Statistics Based Techniques: SQC and IE of Quality Management and Process Control (SPC) - Six Sigma Projects

  4  .Operations Research and Quantitative Techniques

  5.   Plant Layout: Reduction of material movement, operator movement and movement of salesmen etc. 

  6.   Engineering Economics

  7.   IE Solutions in Various Functions: SMED and Lean Production Systems, Gantt Charts,

Visit for detailed articles on the above topics

The following subjects are foundation subjects for learning applying IE techniques.

Engineering disciplines based on the education and need of the process or system to be analyzed.

Principles of Management and Management Process to manage the IE studies, Projects and IE Department.

Management disciplines and Business processes based on the education and need of the process of system to be analyzed.

Anatomy, Physiology, Biomechanics, psychology, Sociology and Organization Behavior for Human Effort Engineering.

Mathematics, Statistics, Financial Accounting, Cost Accounting, and Management Accounting for help in efficiency techniques.


Value Engineering

Crankshaft machining - quotation from a specialist machining shop. L.D. Miles, Jan 14, 1949
Present cost of purchase $520 crankshaft made through  forging. New proposal maching of crankshaft by a specialist shop and crankshaft made from casting.
Plant Layout
For Plant Layout of Crankshaft Assembly as well as other shops of an Engine Unit of GM-Opel Plant Download (2009 file)
U-Shaped Cell at Kawasaki US Plant for Crankshaft Machining, 2003
Engineering Economics
For details of GM-Opel Engine Plant Download


Technical and Material Developments

Development of high strength cast steel for making crank throws 

High strength cast steel of 650 MPa class (Grade 5) was developed which was intended to have the fatigue strength equivalent to forged steel.
For the KAWASAKI-MAN B&W 12K98ME engine, one of the largest low speed diesel engines, a light-weight crankshaft was developed by using the crank throw made of the new high strength cast steel (the world first).

Reduction in Balancing Weights of Crankshafts 


A technology wherein the crankshaft is arranged at unequal angles (unequal ignition) which brings the effect of reduction of unbalance couple of forces is under rapid development. This technology has been applied to mainly 7-cylinder or 10-cylinder engines. With the recent progress of computers, a method that the optimum interval of unequal ignition is exactly calculated without regard to the specific cylinder number was made public. This may reduce requirement of balancing weights in crankshafts.

The New Holden V8 Engine - Technical Developments


The nodular iron cast crankshaft is internally balanced and fully counter weighted. It features variable radii undercuts which increase available bearing area; and rolled fillets for improved fatigue strength. The firing order was revised from the traditional set up to reduce crank arm stresses and to improve main bearing performance. Main journals 2,3,4 and 5 incorporate a drilled hole to enhance crank case breathing and to reduce mass.

Original knol - 2324

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