MIT - LAI Self Assessment Tool (LESAT) - Website Page Information

http://lean.mit.edu/products/lai-self-assessment-tool-lesat-2



LAI Self Assessment Tool (LESAT)
The LAI Self-Assessment Tool (LESAT) 2.0 is now available.

LESAT is a tool for self-assessing the current state of an enterprise and its readiness to change. The tool is organized into three assessment sections:

Lean transformation/leadership: lean practices pertinent to the lean transformation process with an emphasis on enterprise leadership and change management.
Life cycle processes: lean practices related to the "life cycle processes of an enterprise, i.e., those processes involved in product realization.
Enabling infrastructure: lean practices applicable to infrastructure support units.
Each section contains diagnostic questions, lean practices, five capability levels, and lean indicators. Each of the practices are focused at the enterprise assessment level, and the tool is supported by a Facilitator's Guide as well as a LESAT calculator.

MIT - Lean Enterprise Product Development for Practitioners - Website Information

http://lean.mit.edu/products/lean-enterprise-product-development-for-practitioners

Drs. Josef Oehmen and Eric Rebentisch have come out with  a new series of whitepapers, Lean Product Development for Practitioners in 2011.

 LAI on Program Management for Large Scale Engineering Programs

Dr. Josef Oehmen, Dr. Eric Rebentisch, and Kristian Kinscher, LAI Whitepaper Series: Lean Product Development for Practitioners, Version 1.0, December 2011.

 This paper addresses Enterprise, Program and Multi-Project Management.

Risk Management in Lean Enterprise Product Development 

Dr. Josef Oehmen and Dr. Eric Rebentisch, LAI Paper Series: Lean Enterprise Product Development for Practitioners, Version 1.0, March 2010.

The paper follows LAI´s understanding and Risk Management in Lean Product Development philosophy regarding Lean Management concepts and especially their integration into large and complex Enterprise settings.

The papers draw mainly on the research done by LAI. Where necessary to ensure a comprehensive presentation of a topic, findings of other researchers and research groups from the field of Lean Product Development are integrated into the papers.  This paper addresses topic 9, Risk Management.

The two core challenges of risk management are finding the optimum balance a) between the cost of carrying risks vs. the cost of mitigating risks and b) between a risk that is taken with a certain development project and the return that is expected from the project.

Waste in Lean Enterprise Product Development 

Josef Oehmen and Eric Rebentisch, LAI Paper Series: Lean Product Development for Practitioners, Version 1.1, July 2010.

The main objective of this paper is to make the work that has been done at LAI in the area of waste in product development easily accessible to the consortium members. The focus of the discussion in this paper is therefore on past LAI work. Non-LAI work is integrated into the presentation where it is necessary to complete the picture.

The intended readership is engineers and managers in the areas of product development, product design, systems engineering and program management. The paper is also intended to provide a first overview to students and others interested in the field.

Reading this whitepaper provides a concise overview of the most important waste drivers in product development, that is, the most common project deficiencies that lead to cost and schedule overrun, as well as to performance issues. It will enable those involved in process improvement initiatives to include specific lean-related factors into their process analysis. It provides both managers and engineers with a common language and concepts to enhance the efficiency of their product development projects.

The Innovative Lean Enterprise - Anthony Sgroi, Jr. - Book Information

The Innovative Lean Enterprise: Using the Principles of Lean to Create and Deliver Innovation to Customers
Anthony Sgroi, Jr.
CRC Press, 19-Aug-2013 - Business & Economics - 315 pages


Explaining how to use Lean principles to drive innovation and strategic portfolio planning, The Innovative Lean Enterprise: Using the Principles of Lean to Create and Deliver Innovation to Customers outlines simple, yet powerful, visual Lean tools that can enhance idea generation and product development. It starts with a discussion of Lean principles and then identifies the applicable portions of Lean that can drive customer value.

The book discusses customer value in the form of the benefits your customers desire. It walks you through the processes of using Lean techniques to effectively evaluate the quality of any prospective marketing opportunity and includes examples from a variety of industries, including healthcare.

The text discusses value creation, reduction of waste, entrepreneurial system designer, set-based concurrent engineering, and Lean project management. It also includes numerous examples of visual management tools as they apply to innovation to help you develop the understanding required to achieve a competitive advantage for your brand, division, or company through Lean.
http://books.google.co.in/books?id=iSAbAAAAQBAJ



Table of Contents


Visual Strategy
The First Parameter of Strategy
     Utility
     Emotion
The Second Parameter of Strategy
The Third Parameter of Strategy
The Fourth Parameter of Strategy
The Strategy Icon
Conclusion
Chapter Overviews
     Chapter 2: Understanding the Current State
     Chapter 3: Opportunity Identification
     Chapter 4: Idea Generation
     Chapter 5: Delivering Profitable Innovation to Targeted Customers
     Chapter 6: Barriers to Imitation
     Chapter 7: Applications of Graphical Strategy Tools
     Chapter 8: Ranking Offerings
     Chapter 9: The Strategy Transformation Process
     Chapter 10: Strategy Transformation Example
     Chapter 11: Alignment and Position Statements

Understanding the Current State
The 2-D Perceptual Map
The 2-D Map
The Utility Knife Industry
     First Innovation: The Retractable Utility Knife
     Second Innovation: Quick Blade Change
     Third Innovation: Folding Utility Knives
     The Switchback Knife
     Product Features: Lock-Back-Style Folding Utility Knives
     Product Features: Folding Retractable Utility Knife with Blade Storage
     Product Features: Fast-Open Gravity Utility Knife
Conclusion

Opportunity Identification
Must-Be Requirements
One-Dimensional Requirements
Attractive Requirements
Top Portion of Product Fulfillment Map
     Acquisition
     Product Use
     Barriers to Use
     Product Robustness
     End of Life
Left-Side Portion of Product Fulfillment Map
     Utility: Product Function Category
     Risk: Category in Which Customers Seek Risk Avoidance
     Simplicity or Convenience
     Emotional Well-Being or Social Well-Being
     Supports the Green Movement
     Financial
Product Fulfillment Map Example
Opportunity Scores
Conclusion

Idea Generation
Internal Perspective Techniques
     Surveys
     Focus Groups
     One-on-One Interview
     Intercepts
     Product User Testing
     Customer Feedback and Complaints
     Ethnographic Research
     Idea Generation
     The Problem Solution Statement
     Job Mapping
Internal Ideation Methods
     Brain Writing
     Brain Walking
     Worst Idea
     Patent Prompts
     Picture Prompts
     White Board Technique
External Perspective Techniques
     Looking to Alternative Industries
     Looking to Alternate Strategic Groups
     Looking at Different Buyer Groups
     Looking to Complementary Product and Service Offerings
     Adding or Removing Functional or Emotional Characteristics
     Identifying New Trends
Conclusion

Delivering Profitable Innovation to Targeted Customers
Utility
Emotion
Conclusion

Barriers to Imitation
Brand Power
Firm’s Knowledge
Customer Relationships
Supplier Relationships
High-Efficiency Operations
Skill of People
Processes
Technology and Money
Regulatory Pioneering
Economies of Scale
Switching Cost of the Consumer
Intellectual Property
     Patents
     Types of Patents
     Patent Claims
     The Power of Patent Pending (a defensive tool)
     Trademarks
     Trade Dress as an IP Tool
     Copyrights as an IP Tool
     Trade Secrets as an IP Tool
Conclusion

Applications of Graphical Strategy Tools
SWOT Analysis
     Strength
     Weakness
     Opportunities
     Threats
Balanced Scorecard Approach
     The Learning and Growth Perspective
     The Business Process Perspective
     The Customer Perspective
     The Financial Perspective
Disruptive Innovation
     New Market Disruptions
     Low-End Disruptions
Conclusion

Ranking Offerings
Conclusion

The Strategy Transformation Process

Strategy Transformation Example
Conclusion

Alignment and Position Statements
Conclusion

Epilogue

Bibliography

Lean Systems: Applications and Case Studies in Manufacturing, Service, and Healthcare - Book Information

Lean Systems: Applications and Case Studies in Manufacturing, Service, and Healthcare
Elizabeth A. Cudney, Sandra Furterer, David Dietrich
CRC Press, 16-Oct-2013 - Business & Economics - 533 pages


Lean Systems: Applications and Case Studies in Manufacturing, Service, and Healthcare details the various Lean techniques and numerous real-world Lean projects drawn from a wide variety of manufacturing, healthcare, and service processes, demonstrating how to apply the Lean philosophy.

The book facilitates Lean instruction by supplying interactive case studies that enable readers to apply the various Lean techniques. It provides an in-depth discussion of the Lean tools (i.e., VSM, standard work, 5S, etc.) and several real-world case studies and applications of Lean that have shown significant improvement in meeting customer requirements. The case studies follow the Six Sigma framework of Define, Measure, Analyze, Improve, and Control (DMAIC) structure for process improvement. The authors include detailed descriptions of each Lean tool and examples of how each Lean technique was applied to a wide variety of manufacturing, service, and healthcare processes.

These in-depth descriptions and cases studies can be used by industry professionals and academics to learn how to apply Lean. They provide a detailed, step-by-step approach to Lean and demonstrate how to integrate Lean tools for process improvement and to sustain improvements. But more than this, the approach taken in this book gives readers the tools to effectively apply Lean techniques.



Table of Contents

Overview and Introduction to Lean
Instructional Strategies for Using This Book, Elizabeth A. Cudney, Sandra L. Furterer, and David M. Dietrich
Lean Six Sigma Roadmap Overview, Sandra L. Furterer

Lean Tools and Step-by-Step Implementation

Value Stream Mapping, Elizabeth A. Cudney
Using 5S and Visual Management to Create a Clean and Manageable Work Environment, Elizabeth A. Cudney
Using Single-Minute Exchange of Dies and Total Productive Maintenance to Reduce Setup Time and Downtime, Elizabeth A. Cudney
Flow, Pull, and Kanban, Elizabeth A. Cudney
Mistake Proofing (aka Poka-Yoke): Preventing Defects by Monitoring Process Conditions and Correcting Errors at the Source, Elizabeth A. Cudney
Standard Work: Documenting the Interaction between People and Their Environment, Elizabeth A. Cudney
Systems Thinking and Theory of Constraints, Elizabeth A. Cudney, David M. Dietrich, and Sandra L. Furterer
Hoshin Kanri, Elizabeth A. Cudney

Manufacturing, Service, and Healthcare Case Studies

Lean Restaurant, Corbin LeGrand, Neha Pawar, Snehal Digraskar, Sneha Mahajan, Sukhada Mishra, and Susan Polson|
Achieving Flow in a Rapid Prototyping Laboratory, Shirish Sreedharan, Elizabeth A. Cudney, and Frank Liou
Implementing Lean Manufacturing Techniques to Achieve Six Sigma, Elizabeth A. Cudney
Pump Teardown Review Process Improvement, Shrey Arora and Rodney Ewing
Improving Women’s Healthcare Center Service Processes, Sandra L. Furterer
Application of Lean Tools in a Medical Device Company, Kelly M. Davis, Elizabeth A. Cudney, and Scott E. Grasman
Motor Grader Assembly Line Modification, Mujahid Abjul, Charlie Barclay, Nanday K. Dey, Amita Ghanekar, and Lynda Melgarejo
Sunshine High School Discipline Process Improvement: A Lean Six Sigma Case Study, Marcela Bernardinez, Khalid Buradha, Kevin S. Cochie, Jose Saenz, and Sandra L. Furterer
Financial Services Improvement in a City Government: A Lean Six Sigma Case Study, Sandra L. Furterer
Application of Lean Tools in a Hospital Pharmacy, Seth Langston, Jason Park, and Raj Vemulapally
Using Value Stream Mapping to Identify Performance Gaps for Hoshin Planning, Elizabeth A. Cudney

Planning and Implementation Strategies for Lean Initiatives

Planning and Executing a Kaizen Workshop, David M. Dietrich
Prioritizing the Lean Initiatives, Sandra L. Furterer
Emerging Technologies Influencing Lean, David M. Dietrich, Elizabeth A. Cudney, and Sandra L. Furterer
Future and Challenges of Lean: Engagement and Success Factors, Elizabeth A. Cudney and Sandra L. Furterer
Glossary
Index


http://books.google.co.in/books?id=VUnGAAAAQBAJ

Robotic Applications in Indian Companies - Engineering Economic Analysis

Sai Surface Coating Technologies Pvt. Ltd is using Roboruka supplied by Jay Robotix.

The deployment of RoboRuka™ 2.0 will enhance productivity by over 15 - 25% by ensuring less wastage of raw materials and maintaining the consistency in the product's quality. It will also reduce cost of production by 10% (approx) including savings in labor cost. Moreover the biggest advantage with RoboRuka™ 2.0 is that of easy accessibility to spare parts. Companies will be able to achieve greater precision and flexibility and faster production cycles as well. Companies can expect ROI within 6 - 10 months.

http://www.prlog.org/12208096-jay-robotix-gains-traction-in-their-industrial-solution-segment-with-roboruka-orders.html

http://metroindia.com/Details.aspx?id=2066

http://www.supportbiz.com/articles/top-story/low-cost-robotics-lends-helping-hand-indian-smes.html

Lean Enterprise - The Machine That Changed the World - Book Summary and Excerpts

Preface

Chapter 1 The Industry of Industries in Transition


Chapter 2. The Rise and Fall of Mass Production

Chapter 3. The Rise of Lean Production

Example of Lean Production

In American Companies, die changes required a full day. The American companies dedicated die presses to each part. To Ohno of Toyota, that was not the solution. He has to stamp all the parts he needed from only few press lines. Hence he decided to decrease the die change time and he went on decreasing the die change time to 3 minutes and he also eliminated the need for die change specialists. The operators only will change the die. In the process he made the unexpected discovery - it actually cost less per part to make small batches of stampings than to run off enormous lots (due to  small setup costs).

Making only a few parts before assembling them into a car cause stamping mistakes to show up instantly. It made the production people more concerned about quality and that eliminated defectives significantly. But to make the system a success, Ohno needed both an extremely skilled and a highly motivated work force. Workers have take the initiative to maintain quality production. Otherwise, the whole factory will come to a halt.

Ohno organized his assembly workers into teams. The teams were given a set of assembly steps, their piece of line and told to work together on how best to perform the necessary operations. They work under a team leader, who would do assembly tasks, as well as coordinate the team and would  fill in for any absent worker. In mass production plans there were foremen and utility workers used to take the place of absentees. Ohno next gave the teams the job of housekeeping, minor tool repair, and quality checking. Finally, he gave them responsibility for process improvement also. This continuous, incremental improvement process, kaizen in Japanese, took place in collaboration with the industrial engineers, who still existed in much small number.

Ohno reasoned that rework at the end of assembly due to finding errors in final inspection is a waste. He wanted even assembly workers to pass on the work only if it is defect free and in case there is a defect which they could not rectify, they can stop the line and take the time to rectify the defect even with the help of other workers. Also, problem solving through 5 Whys methods is also used to avoid recurrence of the problem. In the initial days of this practice, the line was stopped  many times and workers got frustrated, with practice, the stoppages decreased significantly. Today, in Toyota plants,  yields approach 100 percent. That is the line practically never stops.  The extra benefit due to this method was that quality of shipped cars steadily improved. You cannot build quality by inspection, you have to build quality at the production centers only.  Today, Toyota assembly plant have practically no rework areas and perform almost no rework on assembled cars. In contrast, mass-production plants devote 20 percent of plant area and 25 percent of their total hours of final-assembly effort to fixing mistakes. American buyers report that Toyota's vehicles have among the lowest number of defects of any in the world, comparable to the very best of the German luxury car producers, who devote  many hours of assembly effort to rectification.

Supply Chain to Support Lean Production

The production of a car involves enginering and fabricating more than 10,000 major components and assembling them inot around 100 major subassemblies - engines, transmissions, steering gears, suspensions, and so on.

Toyota took a new approach to organize this supply 10,000 major components. It termed the suppliers of complete sub-assemblies  as first tier suppliers. These first-tier suppliers form an integral part of the new product development team. They are given responsibility for detail engineering the sub-assembly. They are given the performance specification of the subassembly, which is developed with them as a part of the team developing the new car. The supplier has to deliver the prototype for testing and once approved, the production order was given. Thus the detailed engineering of the subassembly was done by the tier 1 supplier.  The tier 1 suppliers were encouraged to talk among themselves about ways to improve the design process.  Each first- tier supplier formed a second tier of suppliers for components.

Toyota takes some equity in some supplier companies and these companies are encouraged to take equity in Toyota. Toyota also acts as banker for its supplier group providing loans to finance the machinery for new products.

Toyota share personnel also with suppliers. It provides work-force when load surges and also deputes its managers. Toyota encourages its suppliers to produce for other companies also.

Kanban system: Kanban system is used in Toyota production system to implement Just-in-time (JIT). As a container of parts was used up, it was sent back to the previous step or the supplier and this becomes the signal to make one more container of parts. Reduction of inventories in the JIT system means any error will disrupt the production. But the power of JIT idea is to involve everybody in quality and timely production by removing safety stocks or nets.

It took Eiji Toyoda and Ohno more than twenty years to fully implement JIT within the Toyota supply chain. They succeeded and created a highly productive, high quality, responsive supply chain.

Product Development and Engineering in Lean Enterprise

Ohno and Toyoda decided early that product engineering inherently encompassed both process and industrial engineering.. They formed product design teams with experts from process and industrial engineering teams. Career paths were structured so that rewards went to strong team players without regard to their function. The consequence of lean engineering  was a dramatic leap in productivity, product quality and responsiveness.

Lean Production and Changing Consumer Demand

Toyota's flexible production system and its low cost and time product engineering let the company supply the product variety that buyers wanted with little cost penalty. In 1990, Toyota offered consumers around the world as many products as General Motors even though Toyota was only half of GM's size. Toyota requires only half the time and effort required by GM to design and produce a new car. So Toyota can offer twice as many vehicles with the same development budget.  Japanes car makers offer as many models as all of the Western firms combined.  The product variety offered by Japanese is growing where that offered by Western companies is shrinking.

Japanese on an average are producing 500,000 copies in four years, whereas western companies making 2 million copies in 10 years.

Toyota is making profit by producing only two-thirds of the life-of-the-model production volume of European specialist firms and therefore it can attack the craft-based niche producers like Aston Martin and Ferrari. American mass producers could not attack them due to insufficient volume.

Lean Production: Dealing with Customers

Toyota in its initial days only developed a build-to-order system in which the dealer sent orders for presold car to the factory for delivery to specific customers in two to three weeks. The salesmen at the dealer went directly to customers making house calls. When demand began to droop, they worked more house and also they visited households they knew more likely to buy Toyota cars. This door-to-door selling of cars is termed as aggressive selling.  Toyota built a massive data base on households and their buying preferences for Toyota products.

The Toyota sales system incorporates the buyer into the product development process. In Japan vehicle inspection take place frequently and buyers change cars after six years.  Toyota minimize the chances of losing a Toyota user by using its consumer data base to predict what buyers want next as their incomes, family size, driving patterns and tastes changed.  Thus Toyota directly goes to existing customers in planning new products.


Chapter 4 Running the Factory


Chapter 5 Designing the Car

Chapter 6 Coordinating the Supply Chain

Chapter 7 Dealing with the customers

Chapter 8 Managing the Lean Enterprise

Related Reading


Are Japanese car building techniques the best?
http://auto.howstuffworks.com/under-the-hood/auto-manufacturing/japanese-car-building-techniques.htm

Machining Solutions

http://www.distinct.in/Brake_Cam.html

Component : Brake Cam
Sector : Two Wheeler
Operation : Profile Milling
Machine : Vertical Machining Center

http://www.distinct.in/Brake_Spider.html

Component : Brake Spider
Sector : Auto Components
Operation : ID , Facing & Back Facing
Machine : CNC Turning Center

Industrial Engineering - Productivity Enhancing Technology Development

1000th Published Post in Industrial Engineering Knowledge Center Blog

What is Industrial Engineering?

Industrial Engineering is Human Effort Engineering and System Efficiency Engineering.

Technology is a subsystem in the Systems made efficient by industrial engineers. Hence creating efficient technology or more productive technology is a task of industrial engineering. So we can say one task of industrial engineering is productivity enhancing technology development. Technology mean products and processes. Industrial engineers need to specialise. Industrial engineers with mechanical engineering background will work primarily on mechanical engineering products and processes and make them more efficient. Civil engineers with industrial engineering specialisation will primarily work on structures and construction processes.

Industrial engineering has techniques like value engineering (product design efficiency engineering), methods efficiency engineering, optimization techniques, six sigma and simulation which facilitate efficiency/productivity improvement. All these techniques help industrial engineers to systematically identify efficient engineering alternatives. Hence engineers in various branches are to be given industrial engineering education to develop the capabilities in them to develop more productive technologies in their branch of engineering.


While industrial engineers keep working towards making technologies more productive, there are other engineers who are making new product, who are improving products by adding more features and engineers who are guiding operators in using the technology.

The data bases of industrial engineers are more cost oriented and efficient oriented. An vendor trying to sell a more efficient technical device in a company should visit industrial engineers and industrial engineer has to welcome him. Engineering economic analysis is the discipline that helps industrial engineers to do economic feasibility analysis of the new device. His engineering background helps him to do the technical analysis.

Industrial Engineers have to develop special purpose machines that have more productivity than general purpose machines.

They have to develop jigs and fixtures which help in improving productivity.

They have to select tools and design special tools to improve productivity.

Material handling is another area ripe for productivity improvement.

Inspection tools also can be made more efficient.

Special Purpose Machines

SPMs are very useful for producing large quantities of high quality products at low costs. These machines can also be altered to produce similar components when necessary as modular components and systems are now available to develop SPMs. High accuracy, uniform quality, and large production quantities are important characteristics of SPMs. However, the inadequate knowledge of machining specialists with this technology has resulted in its low utilization in manufacturing firms.

In this article a detailed discussion of SPMs, their capabilities and accessories have been described. It also explained the development of a KBES to assist SPM users in deciding whether or not to make use of SPMs for a given production task. An  analysis was made on the basis of technical and economical considerations. In a  case study  presented in the paper for the given production task SPM would result in a significant 59% reduction of costs when compared to CNC, and an unbelievable 95.5% cost reduction was achieved when compared to traditional lathe.

https://nraoiekc.blogspot.com/2013/12/special-purpose-machines-for-increased.html

( http://www.intechopen.com/download/get/type/pdfs/id/30663 )

Industrial engineers have to take the responsibility for development of special purpose machines.

Operation Analysis described H.B. Maynard clearly brought the role of industrial engineering in analysing material, equipment, cutting tools, jigs and fixtures, material handling and work station design.

Updated on 5 June 2019

Productivity and IE in Plastics Bottle Manufacturing

2014

Raising productivity and protecting worker health through ABB Robot

Packing 60,000 plastic bottles a day by hand was taking a high toll in labor costs and operator health for an Australian plastics company. A single ABB robot not only solved the problem, it increased productivity by up to 40 percent.
Power Plastics is a Sydney-based manufacturer of plastic bottles and containers for customers in the food, pharmaceuticals, personal care, househould and industrial segments.

Skyrocketing raw material prices and the operational and human costs of hand-packing 60,000 bottles a day were the key reasons behind the company's decision to switch from manual to robot-based production in its labor-intensive squeezable bottle line.

The final decision to automate was made after a particularly bad year with workers' compensation claims from RSI (repetitive strain injury).
Prior to the installation of the ABB robot, two operators spent each shift putting the bottles into cardboard boxes, sealing the boxes and stacking them on pallets. Now a single ABB IRB 4400L robot, with a 2.43 meter reach and a 30kg payload, picks up eight to ten bottles at a time (depending on bottle size) from two production lines. A single operator is required to seal the boxes and palletize them.
http://www.abb.com/cawp/seitp202/76b0a1b4c85d7a1ec1257736002801f7.aspx

2012

COMPRESSION BLOW FORMING PROCESS NOW IN COMMERCIAL PRODUCTION

Close Up: Blow Molding
By Matthew H. Naitove, Executive Editor
Share on twitterShare on facebookShare on printShare on gmailMore Sharing Services
13
From: Plastics Technology
Issue: July 2012
Expectations of higher productivity, improved quality, and energy savings for a novel blow molding process are now being realized in commercial production at Amcor Rigid Plastics in Youngsville, N.C.
Based in Ann Arbor, Mich., Amcor (amcor.com) is producing 75-cc HDPE pharmaceutical bottles for one customer and also plans stock bottles of 150 and 300 cc. The machine is suitable for the pharmaceutical packaging range of 60 to 300 cc. “For the pharmaceutical industry, compression blow forming is one of the most significant technological developments for rigid packaging in decades. It’s a game-changer for an industry that demands risk-free performance,
CBF is said to have several advantages over injection-blow molding (IBM) of small HDPE bottles:
Amcor says the 12-station CBF machine can run at up to 6000 bottles/hr and a 20-station model (coming later this year) could produce 10,000/hr, depending on bottle size and weight. Productivity is enhanced by the continuous rotary motion of the cam-operated process, eliminating station-to-station indexing time.
http://www.ptonline.com/articles/compression-blow-forming-process-now-in-commercial-production

Plastics manufacturer improves safety and ergonomics while increasing productivity with the Motion Controls Robotics “Robotic SUBTA” 

Challenge
A national manufacturer of stock and custom plastic packaging solutions for the food packaging, chemical, automotive and household industries faced the challenge of improving its safety and ergonomics associated with its manual system of unloading its Nissei Bottle Making Machine at its manufacturing facility.

Motion Controls Robotics’ created the Robotic SUBTA system, a pre-engineered robotic system designed for PET blow-molded bottle handling. The system uses different robotic units depending on the type of machine that is being unloaded. The Robotic SUBTA system grabs and sets the bottles on a conveyor, standing up, acting as a takeaway unit. The system provides increased throughput due to high reliability and
uptime and cycle times faster than most mold machine rates. The Robotic SUBTA system also requires a minimum of floor space, a high priced commodity in a manufacturing facility.
http://www.motioncontrolsrobotics.com/downloads/Robotic%20SUBTA%20Case%20Study.pdf

Productivity and IE in Plastics Pipe and Pipe Fitting Manufacturing

2011

Pipe extrusion: Internal cooling system boosts productivity
Published: February 11th, 2011

Plastics pipe extruders are offered a new tool to help increase their lines' efficiency when processing polyolefins. Developed and manufactured by KraussMaffei Berstorff, this new internal pipe cooling (IPC) system is said to dramatically reduce the initial cost and space requirements for a new pipe extrusion line, while also helping increase the productivity of already-installed pipe extrusion lines.
http://www.plasticstoday.com/mpw/product-watch/plastic-pipe-extrusion-internal-cooling-system


2010

HOW TO GET PEAK PERFORMANCE & EFFICIENCY OUT OF YOUR EXTRUSION LINE, PART I
http://www.ptonline.com/articles/how-to-get-peak-performance-efficiency-out-of-your-extrusion-line---part-i

BOOSTING EXTRUSION PRODUCTIVITY-PART II OF III: OPTIMIZE PRODUCT CHANGEOVER & PURGING
http://www.ptonline.com/articles/boosting-extrusion-productivitypart-ii-of-iii-optimize-product-changeover-purging

TIPS AND TECHNIQUES: BOOSTING EXTRUSION PRODUCTIVITY - PART III OF III: TRIM YOUR MATERIAL & ENERGY COSTS
http://www.ptonline.com/articles/tips-and-techniques-boosting-extrusion-productivitypart-iii-of-iii-trim-your-material-energy-costs

Productivity and IE in Plastics Packaging Film and Sheet Manufacturing

ERP for Plastic Industry

CyFrame.com We are the leading international provider of Best-of-Breed ERPII business software solutions (ERP Softwares and MRP Softwares) dedicated to improve productivity exclusively for the plastic industry : Plastic inventory, planning and packaging software, injection blow moulding, extrusion blow moulding and blown film softwares and management systems.
http://www.cyframe.com/



2012
Napco Modern Plastic Products Company – Technical Division installs additional slitter machine at Dammam-based plant to increase productivity and plant output. The co–extruded plastic film manufacturer produces flexible barrier films, as well as polypropelyne (PP)/polyehthylene (PE), cast polypropylene (CPP), and PE films for the food and medical sectors.
http://news.indevcogroup.com/en/April2012/Plastics/166/New-Machine-at-Napco-Modern-Plastic-Products-Company-%E2%80%93-Technical-Division-Increases-Productivity-co-extruded-PE-Films-Dammam-Napco-Modern-Technical-new-machine-Saudi-Arabia.htm

2011
Performance: Plastic Packaging Materials and Unlaminated Film and Sheet Manufacturing (NAICS 32611) - Canada
https://www.ic.gc.ca/app/scr/sbms/sbb/cis/performance.html?code=32611&lang=eng


Quality Claims

If you want to save money and gain efficiencies with your film packaging, you need the flattest, most consistent film available. And with state-of-the-art technologies that controls gauge variances, we can offer you just that.
http://www.haremar.com/advantages/productivity

Productivity and IE in Sheet Metal Work Manufacturing

Sheet Metal Processes
http://www.ic.polyu.edu.hk/student_net/training_materials/IC%20Learning%20Series%202013%20-%20Sheet%20Metal%20Fabrication.pdf



2013
Lean Manufacturing
http://www.danserinc.com/more-than-metal/lean-manufacturing.shtml


Enhancement in productivity in sheet metal industry through
Lean Principles
Gaurav Kumar*, Rajender Kumar** and S.K. Gupta***
*M. Tech. Student, Department of Mechanical Engineering, FET, MRIU, Faridabad, (HR) India
**Asst. Prof., Department of Mechanical Engineering, FET, MRIU, Faridabad, (HR) India
***Asso. Prof., Department of Mechanical Engineering, FET, MRIU, Faridabad, (HR) India
http://researchtrend.net/ijet41/30%20RAJINDER%202.pdf

Creo™ Elements/Direct™ Sheet Metal Productivity Package
ACCElErATE ShEET METAl DESign USing ThE lEADing DirECT 3D CAD SySTEM, PlUS ShEET METAl TOOlS,
wiTh FUll DATA MAnAgEMEnT
http://www.ptc.com/WCMS/files/127616/en/6619_Creo_Elements_Direct_Sheet_Metal_Pkg_DS_EN.pdf

2012
Two processes, one laser — that makes for productivity”

Cutting and welding
http://www.mastersofsheetmetal.com/masters/two-processes-one-laser-that-makes-for-productivity_3311/


2007
Sheet-Metal Productivity (On the Edge Solid Edge Tutorial)
http://www.cadalyst.com/manufacturing/sheet-metal-productivity-on-edge-solid-edge-tutorial-10949

Productivity and IE in Boiler and Heat Exchanger Manufacturing

North American Industry Classification System - Fabricated Metal Product Manufacturing - 332

Automated Welding machine influences productivity, health and safety, improve quality and increase business opportunity..
increase productivity by increase the welding rate, cost of consumables, and the cost of machinery. The time spent on joint preparation and time spent on job preparation is also decrease..
For example compare to manual operations, 70-80% of the cost for completing  welding is typically attributed to humanpower (the cost of labor

With automated welding operations, these figures decrease as the output per workers increases. Usually it means lower unit costs.  Increased output is due to:
- Improved the control of weld result to improv weld quality and minimized over-welding, weld mistakes and weld variation. You will  control of the process reduces processing time, reduces scrap and may virtually eliminate the weld process
- Increased the speed resulting in greater welding rates. It ‘s limited in manual welding by the operator’s tolerance to heat with the welding machine torch may use higher currents than manual torches. The speed can be higher in mechanized welding

CMF is a french company manufacturing machines specialized in boilers’industry. We already have worked closely with our clients, we design and create the right automated machines for boiler’s manufacturer. With 20years experience in this field we have delivered more than 50 machines to different customers in the world.
http://www.cmfgroupe.com/news/optimization-of-your-boiler-production/


Manufacturers

American Boiler Manufacturers Association
http://www.abma.com/

http://www.bemz.by/en/

http://www.victoryenergy.com/industrial-boiler-manufacturer/




L&T-MHI Boilers
has established state of art manufacturing facility for Pressure Parts and Pulverisers for super critical boilers at Hazira in Gujarat. The current installed capacity is 4000 MW per year. The facility has systems, processes, machinery, manufacturing capabilities which are the best in its class. Today we can boast of creating such a facility in India which is unique and augurs well for the Indian Power Equipment requirement.

In Pulveriser manufacturing facility, the plant layout is designed for optimum movement of material. Also many of the production accessories are designed and facilitated to achieve the ergonomic workstation design to reduce the fatigue of the people working in the area.      

There has been lot of thrust and emphasis on system driven approach since inception and MHI has put lot of emphasis on training and development of workforce skill development.

This has lead to development of a strong technical team with proficiency in super critical boiler fabrication. Along with MHI, we have run various training and skill development programs.   More than 400 people have been trained in their areas of activities with the active participation of MHI experts, this covered detail Manufacturing Procedure for Header, Pipe, Panel and Coils.

For the on job Shop Floor experience a MHI Technical Advisory Team has been placed at L&T-MHI Boilers Hazira Manufacturing Complex to assist the Engineers and Supervisors in fabrication activities. With their in depth knowledge and proficiency in manufacturing of Super critical boilers, we have been able to develop our workforce too.

After starting the full load production a Quality Patrol Team has been formed including the MHI and L&T-MHI Boilers persons. This team takes in frequent visits in fabrication shops and suggests various measures for improvement. These suggestions are related to safety, improving productivity and quality of products.
http://www.larsentoubro.com/lntcorporate/common/ui_templates/HtmlContainer.aspx?res=P_MHI_DMAN_AOVR

Productivity and IE in Metal Tank (Heavy Gauge) Manufacturing

Comprehensive Software for Vessel Design

AutoPIPE Vessel powered by Microprotol enables fully automatic workflows, including complete global codes and applied loadings for pressure vessels, heat exchangers, tanks, and air coolers, to deliver greater productivity, safer designs, cost effective manufacturing, and improved project collaboration.

It is the only application to perform truly optimized vessel design in minutes. AutoPIPE Vessel creates fully detailed engineering drawings and cost estimates in less than five minutes.
http://www.bentley.com/en-US/Products/Bentley+AutoPIPE+Vessel/

Boilers, metal containers and steam generators production statistics - NACE Rev. 1.1
2009
http://epp.eurostat.ec.europa.eu/statistics_explained/index.php/Boilers,_metal_containers_and_steam_generators_production_statistics_-_NACE_Rev._1.1


Pressure Vessel Welding Solutions
http://www.lincolnelectric.com/en-us/industries/Documents/gsm0807.pdf

Manufacturers


Spectac International has been in business for more than 25 years and is a leading manufacturer of Stainless Steel vessels, tanks and equipment. The company specialises in relevant sectors i.e. Food & Beverages, Pharmaceutical, Chemical, Brewing and Dairy.
http://www.spectac.ie/profile/

Productivity and IE in Metal Container Manufacturing

Canada 2011 productivity related information
https://www.ic.gc.ca/app/scr/sbms/sbb/cis/performance.html?code=33243&lang=eng


Sheet metal bending processes
http://thelibraryofmanufacturing.com/sheetmetal_bending.html



Manufacturers

Takshing Metal Can Manufacturing Co., Ltd.
http://takshing.gmc.globalmarket.com/

Productivity and IE in Metal Heat Treating

2012
Improving Productivity in a Heat Treatment Shop
for Piston Pins
Sandeep K.1
, Ajit Kumar 2
, Mahesh N. S.3
 1- M. Sc. [Engg.] Student, 2- Professor, 3- Head of Dept.
 Mechanical and Manufacturing Engineering Dept.
M. S. Ramaiah School of Advanced Studies, Bangalore 560 058

http://www.msrsas.org/docs/sastech_journals/archives/Sept2012/6.pdf

2007

Developing an Advanced Control Strategy 

to Optimize Heat-Treating Processes

Jake Fotopoulos – Air Products and Chemicals, Inc., Allentown, Pa.

Optimization of a facility using automation and advanced controls can improve 

productivity and reduce costs. A fi ve-step process to accomplish this is discussed. 

Help exists for companies desiring an analysis of their entire process.

https://www.airproducts.com/~/media/Files/PDF/industries/metals-developing-advanced-control-strategy-optimize-heat-treating.pdf

2006

Development of Computer Aided Heat Treatment Planning System for 

Quenching & Tempering (CHT – q/t) and Industrial Application of 

CHT-bf & CHT-cf 

 

A Thesis Submitted to the faculty of the  

WORCESTER POLYTECHNIC INSTITUTE  

In partial fulfillment of the requirements for the  

Degree of Master of Science  

In  Mechanical Engineering  

By  Amarjit Kumar Singh 

http://www.wpi.edu/Pubs/ETD/Available/etd-050306-224714/unrestricted/singh.pdf

Productivity and IE in Metal Valve Manufacturing

Further productivity gains at DFC
2013
Aveng Manufacturing DFC has further upgraded factory facilities to maintain a competitive advantage in quality and productivity.
An automated welding line has been installed at the company’s Vent-O-Mat valve plant to improve the execution of welding sequences on stainless steel components used in the manufacture of guides and airtight thin-walled floats

Cleaning Units Help Valve Manufacturer Improve Productivity
This company manufactures high-pressure globe valves, which are mainly used in the power generating industry.
2005
http://www.mmsonline.com/articles/cleaning-units-help-valve-manufacturer-improve-productivity

Productivity and IE in Ball and Roller Bearing Manufacturing

A leading ball bearing manufacturing customer wanted to improve the machine cycle time for the flashing operation. So, Castrol was requested to provide a solution.
• The operation requires high metal
 removal within a few hours of grinding.
• Operators have to work over machines
 without suffering objectionable odour
 problems.
• A total manufacturing cycle should be
 completed in 4 - 5 hours removing 200
 microns of material.
• The grinding fluid operates at 3 - 4%
 concentration.
http://www.castrol.com/liveassets/bp_internet/castrol/castrol_advantage/STAGING/local_assets/downloads/b/ball_bearing_case_studies_EN.pdf



Products
Ball Bearings Ceramic Hybrid Bearing Roller Wheel
http://www.bearingworks.com/ball_bearings.html

http://www.timken.com/en-in/products/Documents/Timken-Ball-Bearing-HU-Catalog.pdf

http://www.zysbearing.com/precision-bearings/hybrid-ceramic-ball-bearings.html

Manufacturers

The SNR
The SNR story begins in Oerlikon, Switzerland, where Jacques Schmidt made the first rings and balls of the future tempered steel bearings. He named his company SRO (S for Schmidt; R for Roost, his wife’s surname; and O for Oerlikon) and, in 1894, registered his SRO ball bearing patent and made SRO the only ball bearing supplier in France.
http://www.ntnamericas.com/en/about-ntn/brands/snr




The Bearings Division of Tata Steel is the first in the category to have successfully challenged the TPM Award from Japan Institute of Plant Maintenance, Tokyo in 2004. It is the only bearings manufacturer in India to have won this recognition till date.
http://www.tatabearings.in/about-us/manufacturing-units.asp


India Manufacturers

1. Associated Bearing Company Ltd., Pune (Maharashtra)
2. Asian Bearings Company Ltd., Hosur (Tamil Nadu)
3. Karnataka Ball Bearing Corporation Ltd., Mysore
(Karnataka)
4. HMT Ltd., Hyderabad (Andhra Pradesh)
5. Tata Iron and Steel Company Ltd., (Bearings Division)
Kharagpur (West Bengal)
6. Shriram Bearings Ltd., Ranchi (Bihar)
7. National Engineering Industries Ltd., Jaipur (Rajasthan)
8. FAG Precision Bearings Ltd., Vadodara (Gujarat)
9. Antifriction Bearing Company Ltd. Bharuch (Gujarat)
Lonavala (Maharashtra)
10. Union Bearings Manufacturing Co., Porbunder (Gujarat)
11. Needle Roller Bearing Co. Ltd., Thana/Jalna (Maharashtra)
12. Shriram Needle Industries Ltd., Ranchi (Bihar)
13. Deepak Insulated Cables Ltd., Mysore (Karnataka) (Needle
Bearings Division)
14. Austin Engg Co., Gujarat
15. Karnataka Ball Bearing Co Ltd., Mysore
16. Mysore Kirloskar Ltd, Harihar (Karnataka)
17. Needle Roller Bearings Ltd, Thane
18. Needle Roller Bearings Ltd., Waluj
19. Ruby Bearings Pvt Ltd., Rajkot

Bearing Industry in India - Report
http://www.dsir.gov.in/reports/techreps/tsr047.pdf

Productivity and IE in Farm Machinery and Equipment Manufacturing

Manufacturers


Manufacturers

http://www.cema-agri.org/

The specialist for professional farming
As manufacturers of machinery for soil cultivation, sowing and plant protection, LEMKEN currently employs approximately 1,000 people worldwide. The company is in the sixth and seventh generation of ownership by the LEMKEN family. LEMKEN’s headquarters

are located in Alpen, a town in the Lower Rhine area of Germany, 50 km north-west of Düsseldorf. LEMKEN produces about 15,000 machines per year with a turnover of 340 million € in 2012. Thus LEMKEN is one of the leading

companies in Europe. With a market share of more than 40 % for reversible ploughs and cultivators LEMKEN is established as German market leader.
http://www.lemken.in/

Farm Equipment Manufacturers Association

This Association represents manufacturers of specialized agricultural equipment, their suppliers and their distributors.

We understand their needs and work hard to be the voice of a specialized industry that continues to bring choice, value and innovation to agriculture.

The Farm Equipment Manufacturers Association reaches out and connects small manufacturers, suppliers and distributors, giving them the advantage over their competitors.
http://www.farmequip.org/


Escorts has played a pivotal role in the agricultural growth of India for over six decades. Having pioneered farm mechanization in the country, we have been developing solutions to enhance agricultural productivity and improve quality of life in rural India. Taking a step forward, the company launched the 'Jai Kisan' initiative, a unifying platform to empower the Indian farmer and to make him self-reliant.
http://www.escortsgroup.com/businesses/agri-machinery.html

Productivity and IE in Construction Machinery Manufacturing

2012
China's Largest Construction Machinery Manufacturer Xugong Group Construction Machinery Co Turns to Process Simulation to Validate and Optimize Productivity
http://news.thomasnet.com/companystory/China-s-Largest-Construction-Machinery-Manufacturer-Xugong-Group-Construction-Machinery-Co-Turns-to-Process-Simulation-to-Validate-and-Optimize-Productivity-850707


Top 100 Construction Equipment
http://www.constructionequipment.com/products/top-100/2012

Manufacturers

Hitachi Construction Machinery Europe NV
http://www.hcme.com/

Productivity and IE in Mining Machinery and Equipment Manufacturing

MAJOR MINING EQUIPMENT MANUFACTURER INCREASES PRODUCTIVITY

Lincoln Electric Developed Custom Automated Robotic Welding Solution for Bit Block Assembly
at Joy Mining’s Franklin, PA, Plant

System specification
After reviewing the results of their metric evaluation, Cerminara and his team decided to replace nine semi-automatic Lincoln Electric Idealarc® DC-655/LN-10 stations used for bit block-to-pedestal assemblies and install two automated welding stations in their place. The custom-designed solutions feature Power Wave® 455M high performance, inverted-based welding power sources, FANUC ARC Mate® 100iC robotic arms, and Harris® Preheat Torch systems and temperature-sensing devices. The systems use Lincoln Electric SuperArc® L-56 premium mild steel MIG wire in .045 (1.1 mm) inch diameter.

Productivity
The same number of assemblies are being welded with one operator running both stations per shift.  In the past they  needed between 6 and 8 welders to manually produce the same number of parts.  With automation, now they  need only 3 operators per day vs. the 18 to 24 required in the past,” “Automation has made the difference.  When you look at the productivity increase, the return on investment and other numbers, all of those metrics have been met or exceeded with the installation of the automation equipment. Overall, the results have been spectacular.”
http://www.lincolnelectric.com/en-us/support/application-stories/Pages/joy-mining-automated-welding.aspx


Manufacturers

http://www.dovemining.com/

http://eimcoelecon.in/

http://www.joy.com/

Productivity and IE in Oil and Gas Field Machinery and Equipment Manufacturing

Manufacturers


http://www.nov.com/drilling/rigs.aspx

http://www.rigzone.com/search/sites/BHL_International_Inc9848.asp



Stewart & Stevenson
designs, manufactures and markets equipment for U.S. and international oilfield service providers and drilling and worker contractors, as well as national oil companies that require integrated and customized product solutions. We manufacture equipment specifically for hydraulic fracturing, well stimulation, well worker, intervention and drilling operations. Our manufacturing segment benefits from our long-standing relationships with our globally recognized OEMs. We have five main manufacturing facilities across North America, comprising more than 600,000 square fee of space, that are strategically located to effectively service our customers' needs.

Oilfield Equipment

Oilfield equipment manufactured by Stewart & Stevenson has supported the worldwide oil and gas industry since the 1950s. Today, well stimulation equipment, intervention equipment, power generation equipment and specialized controls for all of Stewart & Stevenson’s oilfield equipment are manufactured at Stewart & Stevenson’s Houston, Texas and Calgary, Alberta manufacturing facilities and dedicated branch facilities. Stewart & Stevenson is a single source supplier of all individual well stimulation and intervention equipment, complete with technically advanced controls, enabling customers to obtain a fully integrated system ready for immediate operation at delivery.

Rig Systems
Stewart & Stevenson’s drilling, workover and well servicing equipment serves the global oilfield service industry. From Stewart & Stevenson’s rig manufacturing facilities in Calgary, Alberta; Edmond, Oklahoma; Casper, Wyoming; Houston, Odessa and Victoria, Texas, we deliver ready-to-operate oilfield drilling, workover and well servicing rigs that meet the rigorous standards established by the American Petroleum Institute and the International Standards Organization. Field-experienced personnel work with customers to develop the best concept for their application. In-house engineers and drafting teams use the latest software to design each rig. Fabrication and assembly capabilities include in-house machine shop, electrical research and development, advanced welding and inspection technologies, and on-site sandblasting and painting. Quality control is involved in every step of the process, and extensive operational testing is available at our 8000-foot test well. Stewart & Stevenson manufactures rig components, including masts, substructures, drawworks, controls, power generation and support units.US Rig facilities manufacture rigs and rig components and provide rig-up and testing before shipping rigs to customers. Our Odessa and Victoria, TX, Edmond, OK and Casper, WY facilities provide rig refurbishment and service to rigs at work in the US and international locations. The Houston Rig facility develops and manufactures advanced controls for rig and other oil and gas equipment manufactured by Stewart & Stevenson.
http://www.stewartandstevenson.com/about-us/divisions/manufacturing

Productivity and IE in Food Product Machinery Manufacturing

Manufacturers


ABOUT ECONOMODE
IndiaMART TrustSealIn a short period, Economode has carved a niche for itself in the Snack Food Industry. This young organization was born in 2001 and ever since has acquired enviable mind space in an industry teeming with competition and marked by a high degree of disorganization. Beginning with developing snack food equipment, Economode has now broached out into multiple forays such as product and Process consulting, Innovation in Technology and facilities (plants), product development, new product line concepts and more.
http://www.economode.in/


We manufacture and export a qualitative range of food procession machines like Snacks Machine, Noodles Machine, Rotary Roster Machine. Continuous Conveyor Dryers (Diesel & Electric) Oven Tray Dryers Machine and Fryums Machine.

S. K. Engineering has proved as a sterling name in the field of food processing machineries. We have taken the food processing by storm for the last 8 years. Today we have emerged as a prominent manufacturer and exporter of numerous
food processing machines.

The company represents a qualified team of designers, engineers and manufacturers of the entire spectrum of food machines. We process all the skills, knowledge and infrastructure to produce, nothing, but the best services. Company has its regular range of machines for regular applications and arrangements to design and manufacture machines according to customers specific need within a specific time frame.

Our efficient team of experts keep a strict vigil on every aspect of manufacturing of these machines until it’s final dispatch. Our team also offers a comprehensive guideline to our clients and thereby helping them to choose the right kind of machines. Periodic quality checks are also done by them to guarantee an authentic and efficient delivery of our product.

http://www.foodextruder.com/

Orbital Food Machinery, over the years, have become the global leader in supplying and buying quality used food processing and packaging machinery to the food industry.
Within our extensive 100,000 square foot factory, we have over 2300 machines in stock from primary, secondary processing, packaging and end of line machines.
http://www.orbitalfoods.com/

Productivity and IE in Semiconductor Machinery Manufacturing

Semiconductor machinery manufacturing encompasses the necessary equipment for semiconductor production, including wafer-processing, assembly and packaging.
_____________

_____________


Manufacturers


USA Manufacturers state survey - 2006
http://www.usitc.gov/publications/332/pub3868.pdf


Nikon is a world leader in the development and manufacture of optical and digital imaging technology for semiconductor and industrial applications. Established in 1917, the Company provides complete optical systems that offer optimal versatility, performance and productivity. Nikon has shown its commitment to the future of the semiconductor industry through its aggressive product development, superior training and technical support.
http://www.nikonmetrology.com/en_EU/Products/Semiconductor-Systems/Semiconductor-Equipment

Productivity and IE in Paper Machinery Manufacturing

Manufacturers

http://www.hitechengg.com/aboutus.html
For more than 15 years Devraj Papertech Machinery is a leading Pulp and Paper Mill Machinery supplier. Devraj Papertech Machinerycommit to build only the highest quality machinery; we have earned the reputation of being the longest lasting and most trouble free machinery provider. We have also earned the reputation for offering new and innovative solution for pulp and paper applications.


http://www.jmcmachines.com/

JMC Papertech Pvt Ltd was formerly known as jmc engineers and promoted by group of expirenced technocrates with succesfull track record and reputation.the company was incorporated as partnership firm in year of 2002 to set up most advanced composites engineering unit equiped with sophesticated equipments using state of art technology for machinery manufacturing and fabrication works of paper plants , cement plants, chemical &fertilizer plants and dairy plants giving it an competitive edge in this age of globalization. in the year of 2011 our company has taken shape of corporate entity and during the process of transformation our firm has been converted into a privatelimited company with a new name of jmc papertech private limited.

http://www.papermachineries.com/
S. L. Exports
We at S.L Industries, have always endeavored to go beyond boundaries and scale newer peaks of excellence. Our name has become synonymous with Pulp & Paper Machinery Manufacturers that is based on a very unique fundamental Machineries that can produce High Quality Paper by recycling waste. This pulp, and has enhanced and propelled out vision at S.L Industries - 'On a mission for a greener world'.

http://www.saspapercupmachines.com/
SAS Industries is a 10 year old engineering company based out of Pudukottai in Tamilnadu, manufacturing high quality automatic Paper cup manufacturing machines. Our Paper Cup Machine, the SAS PC1000i was one of the earliest machines in India that was fully automatic and manufactured indigenously in India using Indian components only. Over the years, we have done hundreds of Installations all over India with a trail of happy cutomers. Our wide service network available all over India to reach even the remote corners of the country helps our customers with low downtime and increased productivity.

Printing Presses - Productivity and Industrial Engineering

A Methodology for Implementing Total Productive
Maintenance in Manufacturing Industries–A Case Study of Printing Press
2012
http://www.ijerd.com/paper/vol5-issue2/F05023239.pdf

Chicago Tribune Recycles Production Waste and Cuts Costs
2010
http://www.piworld.com/aggregatedcontent/chicago-tribune-recycles-printing-production-waste-cuts-costs

Step by Step - Standard Work Reduces Errors & Downtime
http://www.piworld.com/aggregatedcontent/step-step-standard-work-reduces-errors-downtime-printing


For More article Visit
http://www.piworld.com/industrycenter/productivity-process-improvement

Productivity and IE in Printing Machinery and Equipment Manufacturing

Manufacturers

http://www.abhishekprintline.com/
Screen Printing Machines
•  Fully Auto Screen Printing Machine • Flat Screen Printing Machines • Round Screen Printing Machines • Flat Screen Printing Machines
• Round Screen Printing Machines •  Round Screen Printing Machines

Pad Printing Machines
• Manual Pad Printing Machine • Manual Round Printing Machine

UV Curing Systems
• Online UV Curing Systems • Offline UV Curing Systems • UV Control Panels • UV Curing Lamps

UV Coating Machines
• Manual Full Coater Machines • Fully Automatic Spot and Full Coater and Curing System

http://www.technoprint.co.in/

In 2005, “TECHNO INDUSTRRIES” Was Established At Vasai Near Mumbai With A Full Fledged And Self Sufficient Tool Room, Manufacturing Machinery And Quality Control Setup. The Company Now Employs Technical Manpower, R&D Engineers, Printing Technologists, Cad Engineers And Service Personnel. After Sales Service Provided By The Company Is Among The Best In The Printing Industry And Our Service Engineers Attend To Machine Installation & Commissioning, Trouble Shooting And Training Client Personnel To Handle Our Machines To Optimum. We Remain Till Date The Only Printing Machinery Manufacturers In India To Have Developed And Installed Fully Automatic, High Speed, Multicolour, Multistation Screen Printing Machine With Online Flame Treatment And U.V. Drying For Cylindrical Bottles Upto 1 Liter Capacity.

We Have Been Pioneer In Modification And Customization Of Printing Machine As Per Requirement Of Our Customers. One Of Such Effort Is Designing And Manufacturing Of 8 Color Screen Printing Machine For HONDA. Over All These Years We Have Been Modifying Our Machines To Make It More Reliable, Enhance Quality Of Printing To Satisfy Our Customers.


High Precision Bearings for Printing Machinery
http://www.schaeffler.com/remotemedien/media/_shared_media/08_media_library/01_publications/schaeffler_2/tpi/downloads_8/tpi_222_de_en.pdf

Productivity and IE in Optical Instrument and Lens Manufacturing

Optical Instruments Manufacturer - Kaizen Activities

Planning and setting of semi-annual improvement targets
Monthly analysis on current situation: issues, kaizen proposals, results.
Daily Improvement tasks by Supervision Personnel
Lay-out design review
Workbench, parts, jig and tool placement review. Reduction of worker motion, process review.
http://www.genbakaizen.com/consulting/kaizenexamples.html


Optical Tooling Theory & Applications
40-Hour Theory & Applications Course
http://www.brunson.us/metrology-3d-measurement-alignment-optical-tooling-training-courses/metrology-optical-tooling-theory-applications-course/

Harnessing Light: Optical Science and Engineering for the 21st Century ( 1998 )
http://www.nap.edu/openbook.php?record_id=5954&page=235


Products

Microscopes
http://www.qualitydigest.com/june04/articles/02_article.shtml

Manufacturers

Bay Optical Instrument
is a leading innovator in the development of microscope ergonomics.

Established in 1983, Bay Optical Instrument is the inventor of the ErgoAdapter(TM) a workplace-inspired device that has revolutionized the use of stereomicroscopes in laboratories and manufacturing facilities across the United States.

Bay Optical designers bring more than 20 years of on-site experience with microscopes and applied optics to product development. Actively involved in microscope ergonomics in the industrial, medical and education sectors for more than a decade, they have developed high quality technologies that directly address real workplace problems. In fact, years of industrial usage by technicians in major corporations such as Boeing Aerospace, Hewlett­Packard and IBM have significantly reduced cumulative stress disorders and set new standards for company ergonomic programs.
http://bayoptical.com/

Productivity and IE in Photographic and Photocopying Equipment Manufacturing

Canon EOS: Quantitative & Qualitative Analysis on Product & Services
http://atw223om-canon.blogspot.in/2011/03/83-total-quality-management.html

Continuous improvement at Canon
The TQM Magazine, Vol. 1 Iss: 1
Author(s): Japan Management Association
The Canon Production System formed the framework for the TQM programme and has been instrumental in the Company's spectacular success.
http://www.emeraldinsight.com/journals.htm?articleid=1712387&show=pdf


Productivity in Photographic Equipment
1987
http://www.bls.gov/mlr/1990/06/art3full.pdf



Manufacturers

Canon
http://atw223om-canon.blogspot.in/2011/03/50-introduction.html

Productivity and IE in Metalworking Machinery - Machine Tool Manufacturing

Productivity improvement with Gear machine configuration (Gear production line system): Machine Tool

This section provides an example of solution achieved by the "Gear Production Line System" consisting of gear cutting machines that contributes to productivity improvement.
http://www.mhi.co.jp/en/products/detail/ind_mt_sol_manufacturing_line.html





Using Incentive Plans to Boost Productivity in Manufacturing
1998
http://www.tms.org/pubs/journals/jom/matters/matters-9811.html



Manufacturers


India

http://www.imtma.in/


The Indian Machine-Tool Industry
A Benchmarking Study


John Sutton


This report sets out some benchmarking results on productivity
and quality for CNC (computer numerically controlled)
machine tools produced by leading Indian manufacturers. The
study was carried out by Professor J. Sutton of the London
School of Economics, with the assistance of Mr. G. Doshi, on
behalf of the World Bank, during the period December 1999 to
August 2000.
http://personal.lse.ac.uk/sutton/benchmarking_machine_tools.pdf

Productivity and IE in Engine, Turbine, and Power Transmission Equipment Manufacturing

Turbine Design, Manufacturing and Quality Assurance
Geomagic® is making turbine design and evaluation smarter.

Geomagic’s 3D scanning and analysis capabilities are being used to enhance the process of creating efficient, high-performing turbines for power grid applications, compression equipment and aeronautical propulsion.

Geomagic’s products combine perfectly to give engine and turbine blade designers and manufacturers the ability to rapidly model, design, check precise part positions and verify as-built structures. The advanced 3D modeling capabilities of Geomagic Studio® dovetail perfectly with the airfoil/turbine blade analysis tools offered by Geomagic Qualify®, together building higher accuracy, automation and productivity in turbine engineering and inspection. For repair and retrofit needs, Geomagic allows engineers to accurately reverse engineer aging or undocumented blade, blisk and turbine assemblies
http://geomagic.com/en/industries/turbine


2011
Researchers at Iowa State University’s new Wind Energy Manufacturing Laboratory are on a mission to lower the price of wind power down to six cents per kilowatt hour by 2020, and they are taking a somewhat unusual path to get there. Instead of focusing on new wind turbine technology, the research team is working behind the scenes to bring down the cost of manufacturing turbine blades, with the goal of developing new manufacturing systems that could improve productivity by 35 percent.
http://cleantechnica.com/2011/10/29/wind-power-at-bargain-basement-prices-by-2020/

Equipois's zeroG arm dramatically boosts productivity by solving common manufacturing problems caused by fatigue and exertion:
http://www.equipoisinc.com/why/productivity/

ABB robotics makes wind turbine manufacturing more efficient
2010-12-20 - ABB’s robot-based surface finishing concept for wind turbine rotor blades reduces paint shop energy consumption by up to 60 percent and paint consumption by 25 percent compared to alternative methods of applying surface coatings. Most importantly, it provides a perfectly applied layer of protection for one of the most demanding operating environments on earth.
http://www.abb.co.in/cawp/seitp202/50a263c7fa5d15c5c12577ff0044d2e9.aspx

Productivity and IE in Pump and Compressor Manufacturing

Robotic Success Story
OEM Pump Manufacturer

Product(s) Used:
FANUC M16iT Top-loader robot
Nakamura-Tome STW-40 CNC lathes
Servo-driven Door Operators
Robotic 2D Vision System
Automatic end-effector changer
http://www.productivity.com/content/customer/docs/1_oem_pump_mftg.pdf




The Aqua Group consists of Aquasub Engineering and Aquapump Industries. As a leading manufacturer with more than 50 years of experience in the pump industry, the firm has a widely distributed network of 1,000 exclusive dealers and 18 branches across India

Leveraging legacy data
Aquasub Engineering uses NX™ software from Siemens PLM Software to ensure that it continues to meets customers’ requirements, in spite of an increasing workload. The company uses NX for both computeraided design (CAD) and computer-aided manufacturing (CAM).

One of the reasons NX was chosen was its ability to work with data created in other CAD systems, including the company’s own legacy data. “The NX digital product development solution from Siemens PLM Software gave us the option of transferring all of our history,” says N. Purushottama, general manager of the foundry at Aquasub Engineering. “We are using our legacy 2D drawings with NX for developing pump designs in 3D. The ability to reuse our legacy data saves design time.”
http://community.plm.automation.siemens.com/t5/News-NX-Manufacturing/NX-helps-pump-manufacturer-increase-productivity-by-50-percent/ba-p/1481



THE FEASIBILITY OF MANUFACTURING PUMPS
IN SAVANNAH, GEORGIA

1965

https://smartech.gatech.edu/bitstream/handle/1853/43252/a-787_327255.pdf

Productivity and IE in Material Handling Equipment Manufacturing

Products

http://www.ise.ncsu.edu/kay/Material_Handling_Equipment.pdf
67 page note by Prof Kay

Manufacturers


Bulk Material Handling Equipment

Production Handling Systems DBA Hovair Automotive is a full service supplier specializing in bulk material handling equipment and is a major material handling equipment manufacturing company located in Franklin, Indiana.
http://www.hovairauto.com/





Starke Material Handling Group, Canada
http://www.ic.gc.ca/app/ccc/srch/nvgt.do?lang=eng&prtl=1&sbPrtl=&estblmntNo=234567133440&profile=cmpltPrfl&profileId=441&app=sold

Productivity and IE in Elevator and Moving Stairway Manufacturing

Waste elimination to improve productivity by using Value Stream Mapping (VSM) in the factory
Tay, Kwai Fui (2010) Waste elimination to improve productivity by using Value Stream Mapping (VSM) in the factory. Masters thesis, Universiti Malaysia Sabah.
http://eprints.ums.edu.my/3609/


Manaufacturers

Fujitec Singapore

Fujitec Singapore Corporation Ltd, a subsidiary of Fujitec Co. Ltd (Japan), is the first lift manufacturing company in South Asia.

Since establishing Southeast Asia’s largest elevator manufacturing base in Singapore in 1972, Fujitec has installed more than 20,000 elevators in high- rise apartment buildings, major commercial projects as well as Industrial buildings in Singapore. As a major player in the lift industry in Singapore, the company has supplied to majority of public housing (HDB) in the country. Through the combined strength of its South Asia subsidiary, Fujitec Singapore presently manufactures approximately 1,000 units annually; and employs nearly 1100 people.
http://www.fujitecsg.com/about.html

Productivity and IE in Conveyor and Conveying Equipment Manufacturing

OPTIMIZING BELT CONVEYOR MANUFACTURING
Thesis
Honghong Chen
Degree Programme in Industrial Management
2010
http://www.theseus.fi/bitstream/handle/10024/24201/Chen_Honghong.pdf?sequence=1



Manufacturers
Goessling

Magnetic Slide Conveyors, commonly referred to as Beltless Magnetic Conveyors, are typically used to convey a wide variety of ferrous materials ranging from machine chips and scrap to parts, fasteners and stamping fall-off. For applications that demand high reliability and very low maintenance a magnetic slide conveyor is a wise choice.
Goessling magnetic slide conveyors are designed with all moving parts completely enclosed, meaning there’s no external belt to jam, tear, or wear out from carrying sharp, abrasive parts and scrap. No external moving parts to fail also results in practically maintenance-free operation, therefore eliminating the b possibility to compromise productivity or worker safety.
Construction features include a wear-resistant chain guide runner system which requires no lubrication, an automatic die spring tensioning device, a 304 stainless steel bed, and permanent-powerful rare earth magnets.
http://www.goesslingusa.com/magnetic-slide-conveyors-understanding-benefits-applications/



Conveyor Manufacturing, Customization, and Support From MHE, a Leader in Service Excellence Service Excellence in Conveyor Customization

For over 80 years, MHE has been dedicated to providing you with durable, dependable conveyors specifically designed to withstand and resist abrasion, corrosion, and high temperatures.  Whether you’re looking for a drag conveyor to transport heavy-duty loads or a bucket elevator for your cement mill, MHE can provide a custom solution to meet your requirements.  We stand by our selection of long-lasting conveyors and their ability to boost productivity, raise profits, and reduce labor costs
http://www.mheus.com/service-excellence.html

Productivity and IE in Power-Driven Handtool Manufacturing

Handtool Ergonomics

Poor hand tool design results in:
– Lost productivity (slower work, more errors)
– More injuries (increased WRMSD risk)
– More illness (increased long term illness e.g. vibration syndrome)
– More accidents (9% of all disabling injuries related to poor hand tool
design)
– More costs (worker’s compensation, litigation)

http://www.cdc.gov/niosh/docs/2004-164/pdfs/2004-164.pdf

http://ergo.human.cornell.edu/studentdownloads/DEA3250pdfs/Hand%20Tools.pdf

Manufacturers

http://www.apextoolgroup.com/

http://www.greatnecksaw.com/


India
http://www.eastmanhandtools.com/

Productivity and IE in Welding and Soldering Equipment Manufacturing

Lean Welding Case Study


Vermeer Manufacturing Company of Pella, Iowa, and Miller Electric Mfg. Co. of Appleton, Wis., have agreed to share information from their lean welding journey. Vermeer’s results speak volumes to the power of lean welding. Here are just a few examples:

A production rate increase of 37.5 percent on its “lean model line” (the line that best exemplifies lean principles. It produces brush chippers).
The ability to turn raw materials into finished goods in days, not weeks. Vermeer has demonstrated year-after-year improvements of 200 to 300 percent for four consecutive years on some lines.
Year-after-year safety incident and severity rate reductions of 10 to 15 percent.
Zero long-term corporate debt. The company paid cash for more than 300 Axcess® multi-MIG welding systems from Miller.
After implementing Axcess Systems and lean principles on its terrain leveler line, the number of non-conforming welds caught by internal audits dropped by 500 percent, from 6.68 to 1.36 welds per measurement period.

http://www.millerwelds.com/resources/articles/Lean-Welding-Offers-Robust-Results

Manufacturers


http://www.millerwelds.com/

http://www.scottgross.com/WeldingMachines.htm

Productivity and IE in Packaging Machinery Manufacturing

Manufacturers


http://www.cermex.com/


India


Akash Packtech (P) Ltd. is a leading company engaged in the manufacturing, supplying and exporting Packaging Machines for diverse industries like Pharmaceutical, Food Processing and others.
http://www.akashpack.com/


The Institute of Packaging Machinery Manufacturers of India (IPMMI)
The Institute of Packaging Machinery Manufacturers of India (IPMMI) is the exclusive national body representing the  Packaging machinery manufacturers  in the country. They  cater  to the need of the packaging industry covering –package conversion , packaging line operations, packaging systems, online and end of line systems, ancillary machinery and equipments besides testing and quality control equipments.
http://www.ipmmi.org/