Sunday, November 30, 2014

Productivity and Industrial Engineering in Bottled Water Manufacturing






Simulation and Control of Bottling Plant using First-order Hybrid Petri Nets


Positive Systems: Theory and Applications: Proceedings of the First Multidisciplinary International Symposium on Positive Systems: Theory and Applications (POSTA 2003), Rome, Italy, August 28-30, 2003.
http://books.google.co.in/books?id=jMDXlc-hC4IC&pg=PA79#v=onepage&q&f=false


Energy efficiency in Nestle  bottled water plants


Over the period 2005-2010, our energy use per litre has decreased by 22%.

Nestlé Waters has introduced many initiatives to optimise the energy efficiency of its plants, Including :
increasing line productivity,
investing in more energy-efficient machines,
heat recovery,
sharing expertise among the engineering community,
introducing new bottle blowing technologies.
While our production has increased, our energy use per litre has decreased by 22%.
http://www.nestle-waters.com/environment/bottled-water-manufacturing/energy-efficiency-water-plants





2001-2003


Productivity in Bottle Washing and Cost Reduction


Kolob Water Co. of Cedar City, UT, is a successful marketer of bottled spring water. Kolob’s customers get to have their “own” label on the PET water bottles they give to customers during office visits or at trade shows.

Martin Edgel, company manager,visited Pack Expo Las Vegas 2001 to view the latest technology and acquire it to improve the plant’s productivity. As a result of the show, Edgel purchased a 90-degree transfer turntable, a stainless-steel conveyor, and an automatic bottle washer—all from Accutek Packaging Equipment Co.

The bottle washer operates in a linear fashion. It has 10 rinse nozzles, an automatic bottle-indexing system, and a soft-grip bottle grabber. Photoeyes count the appropriate quantity of PET bottles into the work area. Additional containers are stopped automatically. A gripper arm then inverts the containers over a liquid-recovery basin as sanitizing liquid is sprayed into the bottles to remove any carton dust or particles. A no-clog spray and valve system allows the bottle washer to remain in operation when recycling rinse or sanitizing solution from the recovery basin.

After containers are rinsed and placed back onto the transport conveyor, they’re released from the work area and a new set of containers is indexed in for rinsing. The bottle washer cleans effectively at production rate speeds of up to 45 containers per minute (21,600 containers in 8 hour shift).

Prior to installing Accutek’s bottle washer, Kolob washed all of its bottles by hand.  With the new system installed, Kolob increased productivity by 300%, producing up to 400 cases per day. The manufacturing cost reduced by $1.50 per case.

http://www.packworld.com/machinery/tamper-evidence-machinery/back-vegas-more-gear
http://www.foodproductiondaily.com/Packaging/New-technologies-help-water-company-triple-productivity
http://www.accutekpackaging.com/
http://www.accutekpackaging.com/main.php?page_id=50  - Spring 44 bottling solution


Automatic water bottle washing, filling and capping
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Portable Water Bottle Production Systems - 125 liters per hour
http://www.bluspr.com/bottled_water_production.html
In an eight-hour session, up to 2,000 bottles of 500 ml size can be filled with a crew of two.
water purified by Blue Spring table-top bottled water production system costs as little as 1/8th penny (US$ 0.0013) per liter of product water.



Norland International.


Norland International, Inc. is your complete source for water bottling plants: complete bottled water production lines, water distillation systems; and related equipment for the water bottling industry, such as: commercial water distillers; carbon filters; ozone generating systems; bottle washers, fillers and cappers; case-packers and shrink-wrappers; and blow molding equipment for PET bottles.
In addition to its quality water bottling products, Norland is known worldwide for its industry-leading customer support, including pre-sale consultation and plant design, and after-sale service, including installation and maintenance.
http://www.norlandintl.com/



A project report on mineral water - location at Uruguay - 2011
Pack: 21 months;  IRR: 71.9%
http://www.pcoic.org.cn/uploadfiles/2011/11/15/20111115025258.pdf



Production and Packaging of Non-Carbonated Fruit Juices and Fruit Beverages


Philip R. Ashurst
Springer Science & Business Media, 30-Apr-1994 - Technology & Engineering - 429 pages

In the period of about five years since the first edition of this book appeared, many changes have occurred in the fruit juice and beverage markets. The growth of markets has continued, blunted to some extent, no doubt, by the recession that has featured prominently in the economies of the major consuming nations. But perhaps the most significant area that has affected juices in particular is the issue of authenticity. Commercial scandals of substantial proportions have been seen on both sides of the Atlantic because of fraudulent practice. Major strides have been made in the development of techniques to detect and measure adulterants in the major juices. A contribution to Chapter 1 describes one of the more important scientific techniques to have been developed as a routine test method to detect the addition of carbohydrates to juices. Another, and perhaps more welcome, development in non-carbonated beverages during the past few years is the rapid growth of sports drinks. Beverages based on glucose syrup have been popular for many years, and in some parts of the world isotonic products have long featured in the sports arena. A combination of benefits is now available from a wide range of preparations formulated and marketed as sports drinks and featuring widely in beverage markets world-wide. A new chapter reviews their formulation and performance characteristics. Another major trend in the area of fruit-containing non-carbonated beverages is the highly successful marketing of ready-to-drink products.




Top 10 - November 2014 - Blog Posts in Industrial Engineering

Thursday, November 27, 2014

Energy Efficiency and Productivity - International Events and Examples





2013

November

Alliance to Save Energy

250 energy experts, leaders and efficiency champions descended on Capitol Hill on November 20 to discuss and advocate for the Energy 2030 goal of doubling energy productivity by 2030.


Partnering with Efficiency Vermont, Grundfos shared how it increased market penetration for its circulator pumps which are over four times as efficient as traditional pumps.

Schneider Electric underscored its partnership with North Carolina State University that successfully saved that institution $1.5 million by reducing energy usage by 10 million kWh.

The Los Angeles Department of Water and Power plans to meet 45% of its 2025 power needs through energy efficiency and renewables

Massachusetts continues to lead the country in energy efficiency and to meet their goal to reduce energy use 35% by 2020.  On both coasts and in between, speakers emphasized the ability of governments to drive energy efficiency forward.

http://www.ase.org/events/2013-great-energy-efficiency-day


September

2013 ACEEE National Conference on Energy Efficiency as a Resource

http://www.aceee.org/proceedings


Massachusetts Most Energy-Efficient State in 2013 with California Close Behind at #2, Mississippi is Most Improved
http://www.aceee.org/press/2013/11/massachusetts-most-energy-efficient-




January

Energy Efficiency plans of Japan - Japan's Plans on Energy Conservation
http://eneken.ieej.or.jp/data/4749.pdf

Energy-Efficiency Policies in the Asia-Pacific: Can We Do Better?
Tilak K. Doshi and Nahim Bin Zahur
http://nbr.org/downloads/pdfs/ETA/PES_2013_summitpaper_Doshi_Zahur.pdf





Related Blog Posts by Me in This Blog


Energy Efficiency Conference - ECEEE

Energy Efficiency and Productivity - International Events and Examples

Industrial Engineering in Electical Engineering

Cost Reduction Opportunities in Power Plants and Distribution Systems

Economic Analysis - Clean Energy Investment Proposals

Energy Productivity - Efficiency Improvement

Energy Industrial Engineering

National Energy Conservation Day 

Wednesday, November 26, 2014

Industrial Efficiency and Energy Productivity Improvement



Industrial efficiency and low-cost energy resources are key components to increasing U.S. energy productivity and makes the U.S. manufacturing sector more competitive. Companies find a competitive advantage in implementing efficiency technologies and practices, and technologies developed and manufactured in the U.S. enable greater competitiveness economy-wide.


A video

http://energy.gov/eere/videos/clean-energy-manufacturing-initiative-industrial-efficiency-and-energy-productivity

Energy Efficiency Conference - ECEEE

Industrial Engineering is committed to energy efficiency.
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Building Regulations in England and Wales which now require a minimum number of fittings that will only accept low energy lamps (e.g. pin based CFLs) to be installed in all new homes. These regulations have made architects and builders reconsider the way they light the homes that they build.


2009 ACEEE Summer Study on Energy Efficiency in Industry
Timing is Everything: Moving Investment Decisions to Energy-Efficient Solutions
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Related Blog Posts by Me in This Blog


Energy Efficiency Conference - ECEEE

Energy Efficiency and Productivity - International Events and Examples

Industrial Engineering in Electical Engineering

Cost Reduction Opportunities in Power Plants and Distribution Systems

Economic Analysis - Clean Energy Investment Proposals

Energy Productivity - Efficiency Improvement

Energy Industrial Engineering

National Energy Conservation Day 

Sunday, November 16, 2014

Productivity and Competitiveness - Bibliography



Google search results


Productivity and Competitiveness: A Model for Developing Economies
C Bhaktavatsala Rao
Manager, (Corporate Planning), Ashok Leyland, Madras
ASCI  Journal of Management Volume 23, 1994
http://journal.asci.org.in/Vol.23(1994)/v23_2_bha.htm

332710G - Grinding - Productivity and Industrial Engineering



Productivity through Precision
The best grinders in the world use SBS Balancing and Acoustic Emission Monitoring to improve productivity. SBS is a world leader in grinding wheel balancing and process monitoring for the grinding industry. SBS dynamic balancing systems and acoustic emission monitoring solutions help you control the grinding process to improve part quality and increase productivity, thereby saving you time and money. Schmitt Balancing Systems are sold to machine tool manufacturers (OEMs), machine tool rebuilders, and grinding machine users worldwide. Schmitt’s SBS precision balancing systems are used by many of the world’s leading automotive, aerospace, steel, bearing, and machined parts manufacturers and in other industries where manufacturing tolerances are especially precise.
http://www.grindingcontrol.com/



2014

August

Determining Actual Grinding Productivity & Cost
August 26, 2014 by Debbie Gaspich
Debbie Gaspich is the director of product management for Thin Wheel and Construction Products at Norton | Saint-Gobain, 6600 Walmore Road, Niagara Falls, NY 14304, 716-731-7555, Debbie.A.Gaspich atr saint-gobain.com, www.nortonabrasives.com.
http://www.fabricatingandmetalworking.com/2014/08/determining-actual-grinding-productivity-cost/

May
Grinding - Technical Colloquium - 2014 - Technical Developments
http://www.grinding-symposium.com/technical-colloquium-ii-surface-and-profile-grinding-thursday-22-may-2014/

March
Handy Tips: Economical ways to improve grinding productivity
By Archana Tiwari-Nayudu, Mar 11, 2014
http://www.mmtonline.in/handy-tips-economical-ways-to-improve-grinding-productivity/


2013
GRINDING OPERATIONS: REAL WHEEL PRODUCTIVITY AND COST
By: Debbie Gaspich
http://www.metalformingmagazine.com/magazine/article.asp?aid=8273



Emage VLC 100 G vertical grinding center - for small chucked components with a maximum diameter of 100 mm,
The machine utilizes its onboard pick-up system to load itself,
Measuring process is integrated into the machine. The measuring probe is located between the machining area and pick-up station, where it is protected from contamination.
Two grinding spindles - One handles  rough- and the second finish-grinding work. This tooling combination can help to substantially reduce the grinding time of even very complex components.
http://www.productionmachining.com/articles/small-grinding-center-offers-big-productivity-boost


2010

Six Grinding Developments Providing Significant Productivity Gains

Ensure that you understand and implment the following six notable developments in grinding technology and practices for achieving significant productivity gains.

Multi-tasking
Wheels
Fixture sequencing and construction
Coolant and application
Application software
Reliability of machines
http://americanmachinist.com/machining-cutting/compelling-grinding-productivity

Saturday, November 15, 2014

327 - Nonmetallic Mineral Products - North American Industry Classification System - Nonmetallic Mineral Product Manufacturing

327 Nonmetallic Mineral Product Manufacturing


3271 Clay Product and Refractory ManufacturingT
32711 Pottery, Ceramics, and Plumbing Fixture ManufacturingT
327110 Pottery, Ceramics, and Plumbing Fixture Manufacturing
32712 Clay Building Material and Refractories ManufacturingT
327120 Clay Building Material and Refractories Manufacturing



3272 Glass and Glass Product ManufacturingT
32721 Glass and Glass Product ManufacturingT
327211 Flat Glass Manufacturing
327212 Other Pressed and Blown Glass and Glassware Manufacturing
327213 Glass Container Manufacturing
327215 Glass Product Manufacturing Made of Purchased Glass


3273 Cement and Concrete Product Manufacturing
32731 Cement ManufacturingT
327310 Cement Manufacturing
32732 Ready-Mix Concrete ManufacturingT
327320 Ready-Mix Concrete Manufacturing
32733 Concrete Pipe, Brick, and Block ManufacturingT
327331 Concrete Block and Brick Manufacturing
327332 Concrete Pipe Manufacturing
32739 Other Concrete Product ManufacturingT
327390 Other Concrete Product Manufacturing


3274 Lime and Gypsum Product ManufacturingT
32741 Lime ManufacturingT
327410 Lime Manufacturing
32742 Gypsum Product ManufacturingT
327420 Gypsum Product Manufacturing


3279 Other Nonmetallic Mineral Product Manufacturing

32791 Abrasive Product Manufacturing
Productivity and Industrial Engineering in Abrasive Product Manufacturing

327910 Abrasive Product Manufacturing
32799 All Other Nonmetallic Mineral Product ManufacturingT
327991 Cut Stone and Stone Product Manufacturing
327992 Ground or Treated Mineral and Earth Manufacturing
327993 Mineral Wool Manufacturing
327999 All Other Miscellaneous Nonmetallic Mineral Product Manufacturing






327 Nonmetallic Mineral Product ManufacturingT
3271 Clay Product and Refractory ManufacturingT
32711 Pottery, Ceramics, and Plumbing Fixture ManufacturingT
327110 Pottery, Ceramics, and Plumbing Fixture Manufacturing
32712 Clay Building Material and Refractories ManufacturingT
327120 Clay Building Material and Refractories Manufacturing
3272 Glass and Glass Product ManufacturingT
32721 Glass and Glass Product ManufacturingT
327211 Flat Glass Manufacturing
327212 Other Pressed and Blown Glass and Glassware Manufacturing
327213 Glass Container Manufacturing
327215 Glass Product Manufacturing Made of Purchased Glass
3273 Cement and Concrete Product ManufacturingT
32731 Cement ManufacturingT
327310 Cement Manufacturing
32732 Ready-Mix Concrete ManufacturingT
327320 Ready-Mix Concrete Manufacturing
32733 Concrete Pipe, Brick, and Block ManufacturingT
327331 Concrete Block and Brick Manufacturing
327332 Concrete Pipe Manufacturing
32739 Other Concrete Product ManufacturingT
327390 Other Concrete Product Manufacturing
3274 Lime and Gypsum Product ManufacturingT
32741 Lime ManufacturingT
327410 Lime Manufacturing
32742 Gypsum Product ManufacturingT
327420 Gypsum Product Manufacturing


3279 Other Nonmetallic Mineral Product Manufacturing
32791 Abrasive Product Manufacturing

327910 Abrasive Product Manufacturing
327910 Productivity and Industrial Engineering in Abrasive Product Manufacturing

32799 All Other Nonmetallic Mineral Product Manufacturing

327991 Cut Stone and Stone Product Manufacturing

327992 Ground or Treated Mineral and Earth Manufacturing

327993 Mineral Wool Manufacturing

327999 All Other Miscellaneous Nonmetallic Mineral Product Manufacturing 

Friday, November 14, 2014

336412 Productivity in Aircraft Engine and Engine Parts Manufacturing - Industrial Engineering and Lean Transformation


2015
GE Aviation’s newest facility in Lafayette, Indiana, will open in 2015. The 225,000-square-foot facility will assemble the new LEAP engine from CFM International, a 50/50 joint company between Snecma (Safran) and GE. With the capacity to perform final assembly of the engine and the engine’s core, the Lafayette facility will receive components from GE’s network of more than 80 facilities around the world and more than 1,500 domestic suppliers.


A facility of the future
The Lafayette facility will incorporate the latest technologies and innovations in engineering and workflow processes to enhance efficiency and productivity. By optimizing the way work is completed and by introducing new methods of manufacturing, we are making the future of engineering a reality today.
Automated vision
inspection systems
Integrated photo inspection systems to verify assembly quality
Integrated statistical
process control
Automated digital feedback to minimize process variation
Optimized assembly
workflow
Integration of LEAN flow and digital collaboration to maximize shop efficiency
Advanced torque
technologies
High-precision, specialized torque systems to ensure product reliability
High-tech rotor stacking
Patented predictive assembly process to improve engine performance
http://www.geaviation.com/manufacturing/advanced-manufacturing.html

2014
GE Aviation Bromont in Bromont, Que., is now  the most productive plant in the GE Aviation supply chain.

In 1989 it was a totally manual operation making 800,000 aircraft engine parts per year. Now it is  a highly automated advanced manufacturing and finishing plant producing almost three million parts per year — the most productive plant in the GE Aviation supply chain.
https://gereports.ca/advanced-manufacturing-boosts-productivity-at-ge-aviation-bromont/

2013
Pratt & Whitney assembly-floor transformation project
MIDDLETOWN, Conn., Wednesday, February 27, 2013
Pratt & Whitney completed the first phase of an assembly-floor transformation project at its Middletown, Conn., facility that prepares the Engine Center to produce its portion of PurePower® PW1100G-JM engines for the Airbus A320neo and increases production capacity for the F135 engine powering the F-35 Lightning II for the U.S. military.
This achievement was truly a team effort and signifies our ongoing investment to meeting our customer commitments by delivering game-changing engine technology within a lean manufacturing operation."
https://www.pw.utc.com/Press/Story/20130227-1500/2013/All%20Categories


Kennametal’s ToolBOSS® Management System.

Woodward’s Aircraft Engine Systems division in Rockford, Ill., develops and manufactures integrated turbine engine control and combustion systems, including fuel, combustion and electrical systems, as well as heat-management components. Their systems are used in high-thrust military engines such as the F135 and F136 that power the Joint Strike Fighter, and used in the GE turbine engines for the Black Hawk and Apache military helicopters. Among their commercial applications, Woodward systems are found in the GEnx™ engines that power the Boeing 787 Dreamliner and the 747-8, and in the Pratt & Whitney Canada PW600 family of engines for the revolutionary Eclipse 500 and Cessna Mustang VLJs (Very Light Jet) that recently entered the marketplace.

Cesar recommended that Woodward consider converting from the vending machines to Kennametal’s ToolBOSS® Management System. The ToolBOSS system integrates with a company’s supply-chain service to cut tooling inventory, decrease spending on tooling, reduce administrative costs, and gain continuous improvements by gathering and analyzing tool usage data.
http://www.kennametal.com/kennametal/en/about-us/company-profile/case-studies/reduce-costs-and-increases-productivity.html


2010
Process Improvements in Pratt and Whitney's Deficiency Report Investigation Process
http://lean.mit.edu/downloads/doc_download/2874-process-improvements-in-pratt-whitney-s-deficiency-report-investigation-process



An Exploration of Supply Chain Management Practices in the Aerospace Industry and in Rolls-Royce
by
Mohit Tiwari
Submitted to the Engineering Systems Division on May 6, 2005 in Partial Fulfillment of the
Requirements for the Degree of Master of Engineering in Logistics
http://dspace.mit.edu/bitstream/handle/1721.1/33373/62523032.pdf


Jet Engine manufacturing in New England
2001
http://www.massbenchmarks.org/publications/studies/pdf/jetengine01.pdf

1998
The Transition to Lean Manufacturing in Lynn Engine Assembly Operation GE Aircraft Engines
http://lean.mit.edu/component/docman/doc_download/2444-the-transition-to-lean-manufacturing-in-lynn-engine-assembly-operation-ge-aircraft-engines?Itemid=1193

Engine production systems in aircraft industry
1998
http://lean.mit.edu/downloads/doc_download/821-engine-production-systems-in-the-us-defense-aircraft-industry


1995
The Lean Transformation in Pratt and Whitney
http://nraomtr.blogspot.com/2014/02/the-lean-transformation-in-pratt-and.html


Manufacturers

Pratt and Whitney
GE Aircraft Engine Division
Rolls Royce
Boeing