Thursday, September 9, 2021

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

Lesson 104 of Industrial Engineering ONLINE Course.

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

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

Industrial Engineering

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

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


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

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

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




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

WORK MEASUREMENT APPROACH FOR PRODUCTIVITY IMPROVEMENT IN A HEAVY MACHINE SHOP 

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

Download the case study and go through it.

Figure 4 gives the elements in the original method.

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

Elements and Break Points

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

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

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


The operation time got reduced to 4.16 min.


2021

Evenly Spaced Radial-Force Vectors for Superior Gripping

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

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

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



Ud 9.9.2021
Pub 17.9.2020










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