Industrial Engineering is System Efficiency Engineering. It is Machine Effort and Human Effort Engineering. 2.26 Million Page View Blog. 193,075 visitors.
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It is important that industrial engineers have to recognize that scientific management was evaluated by Lilian Gilbreth, a psychologist from a human behavior perspective and a positive opinion was given. Industrial engineering, appeared as a part of the system of management and engineering developed to reduce cost of products made using engineering processes and methods.
After discussing the contribution of Taylor and Gilbreth in more detail, the contribution of many other industrial engineering researchers, professionals, consultants and authors are provided in a series of notes to introduce more industrial engineering concepts. These concepts and their applications will be discussed in more detail in various focus area modules of the course.
Find 5 new engineering developments every day in elements related to facilities, products and processes in your organization and assess their use. Best Practices in #IndustrialEngineering
Portable Danish Robot Expands Production with California Manufacturer
Universal Robots now performs machine tending at RSS Manufacturing & Phylrich in California. Deploying the robot arms from Denmark has vastly improved the company’s ability to stay competitive.
Productivity
August 1, 2016 | Lean, Continuous Improvement
The Benefits of Adopting a Continuous Improvement Approach.
For Waterstone Faucets, adopting a Lean and continuous improvement approach has made a positive impact on their business. Waterstone Faucets is a full line manufacturer and distributor of high quality kitchen faucets located in Murrieta, CA.
STONY BROOK, N.Y.--(BUSINESS WIRE)--Before the faucet maker RSS Manufacturing & Phylrich put the UR5 robot to work, bending 1500 units on a tube bender using manual labor would take 3 days. With the Universal Robot, the same job took four hours.
Industrial engineers (IE) are employed and productivity improvement and cost reduction are practiced in many companies using IE philosophy, principles, methods, techniques and tools. Apple Inc. - Industrial Engineering Activities and Jobs
Industrial engineers have to monitor technology developments and identify technologies that have application in the processes they are managing for productivity. They have to check technical feasibility and assure that the required quality of the output is achieved in their process. Then they have to check the economic benefit to the organization. It is termed IE economic analysis.
In 1977, I am given the assignment of writing a short essay on hybrid computer. The productivity aspect may not have been highlighted at that time. It was difficult to access journals and magazines also. Now access to the publications is more easy.
The reference given below provides the description of studies made to check whether there is feasibility of using hybrid computers for engineering problems and whether there is cost reduction benefit.
EVALUATION OF HYBRID COMPUTER PERFORMANCE ON A CROSS SECTION OF SCIENTIFIC PROBLEMS
R. D. Benham
ABSTRACT
Hybrid and small digital computers were evaluated on several types of technical problems. Comparisons with processing on a large digital computer were made for 12 scientific studies. Accuracy, time and cost (man and machine), convenience and flexibility, and computer requirements were evaluated by a cross section of scientists and engineers.
Illustration: Google's Engineering Productivity Department - Evolution of the Department through Automation of Testing. Emergence of Software Engineering Productivity Engineer & Specialist.
Mechanization refers to the replacement of human power with mechanical power of some form.
Automation and mechanization are often confused with each other; Mechanization saves the use of human muscles whereas automation saves the use of human judgement.
Atomation can be defined as the technology by which a process or procedure is performed without human assistance. Automation is done by using mechanical, hydraulic, pneumatic, electrical or electronic devices and computers. The obvious advantage of automation is requirement of human effort, hence high man's productivity. Automation also provides improvement in material handling, improvement in quality , accuracy and precision.
Low cost automation is a technology that automates some activities of the existing equipments, tools,
methods and people, using mostly standard automation components available in the market.
Jidoka - Automation and Mechanization - Process Engineering and Industrial Engineering in Toyota Production System
Jidoka, a pillar of Toyota Production Systems advocates automation with human touch in all operations of a process to increase productivity of operators as well as that of total systems.
Low-cost automation (LCA) involves the introduction of standard equipment, mechanisms, and devices to convert manual operations to automatic ones. Investment cost is low, as the term itself implies, and the ROI in terms of improved productivity and better work efficiency is high. In the workshop, participants see LCA as automation that assures quality, provides flexibility, increases productivity, and reduces cost. At the same time, it is easy to implement and affordable for small and medium enterprises (SMEs), the main users of LCA. Common areas in the manufacturing process for LCA application are machining, cold extrusion, grinding, material handling, quality inspection, dimensional accuracy, surface finishing, and assembly and packaging.
A workshop topics:
The different means of automation;
The concept and practice of LCA;
Problems relating to introducing LCA;
Planning and designing for LCA; Cost-benefit analysis of LCA: and
Process for implementing LCA.
The benefits of using LCA:
It contributes to process improvement, cutting machine downtime, cost reduction, better product quality, more precision manufacturing, on-time delivery, greater job safety, reduction in manpower requirements and human error, and environmental protection.
The key success factors for the implementation of LCA are: trained and skilled manpower, appropriate product types, availability of the requisite hardware and software,
CII National Competition on Low Cost Automation (LCA)
CII Institute of Quality, in 2018 eastablished National Competition on Low Cost Automation (LCA) to support the "Make-in-India" campaign by enhancing the competitiveness of Indian Industry in the global market. This competition catalyzes the wide spread adoption of LCA practices across Indian Industry through sharing best case studies. This competition focuses on core techninial concepts / inovative ideas resulted in improvement in PQCDSM (Productivity, Quality, Cost, Delivery, Safety & Morale). LCA Awards will be presented in six categories (Productivity Improvement, Karakuri Kaizen, Quality Improvement, Pokayoke, Set-up Change (SMED) and Safety & Energy).
My personal enquiry got the answer that for LCA, the ROI (payback period) has to be less than two years.
Padmatech Industries Pvt Ltd formally my known as Padmatech Engineering system provide Low cost industrial Automation, Since last decade. in process industry. PIPL optimize processes of client and results of this clients reduces there manufacturer cost, safety operation, less risk in operation, less manpower dependency. Padmatech Industries Pvt Ltd achieve pay back period from 28 days to 1 year/18 months depends upon automation cost and volume of work.
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Low Cost Intelligent Automation - increase productivity and flexibility and achieve Zero Defects -· AviasLCIA
Adopting conventional automation is still impractical in terms of return on investment (ROI usually requires 10 ~ 15 years). An automation, which consumes zero or very little power (eco-friendly), with zero or minimum actuators (safety), highly flexible & reliable in nature, which occupies less space (lean concept), that needs zero or minimum maintenance (high efficiency), with minimum investment and running cost, is termed as LCA.
Karakuri Automation
‘Karakuri’ is a Japanese word, which means achieving motion with no power or low power. It’s an ancient Japanese technique to move dolls without actuators or power. In Karakuri technique, different mechanisms like rope & pulley mechanism, counter weight mechanisms, cam & follower mechanisms, etc, are used to achieve unique motion or to convert one form of motion into another like vertical to horizontal and linear to rotary. Combining these motions together to form an automation solution requires an engineering approach.
Unlike conventional automation, Karakuri LCA provides safer, cost-effective, lean & maintenance-free flexible solutions with a target ROI of less than 2 years.
Video: “Jishuken” & “Low Cost Automation(Karakuri)” – Toyota Kirloskar Auto Parts
Oct 13, 2017 — Low Cost Automation Tutorial ... For example, to develop a device that is large and meets the high-speed and high-precision requirements, ...
PDF Low Cost Automation(LCA): A Case Study - ResearchGate
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Low-cost automation brings a breath of fresh air to medium-sized companies and ... Thus, for example, the linking between linear bearings, a corresponding ...
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May 26, 2016 — Keywords: low cost automation; productivity need analysis; PNA; heavy vehicle brake assembly; operator fatigue; productivity improvement.
An alternative of low-cost automation based on a ...
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Low Cost Automation for Manufacturing of Conveyor ... -
iosrjeniosrjen.org › Papers
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Abstract: - Low Cost Automation (popularly known as LCA) is the introduction of simple pneumatic, hydraulic, mechanical and electrical devices into the existing ...
Development of a Pneumatically Driven Cell for Low Cost ...
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by AC Valdiero · Cited by 1 — ... a pneumatically driven manufacturing cell for low cost automation applications. ... such as pneumatic servo position applications [1–5]; for example, Festo has ...
Pneumatic cylinder A: O1
Pneumatic cylinder C: O3
Pneumatic cylinder B: O2
Manual actuation button: I1
A review on low cost automation using pneumatic system
data.conferenceworld.in › BVCOE18
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This paper emphasizes on Low cost automation (LCA) using fluid power i.e. pneumatics. This paper also involves case studies of various industries which got ...
drylin® delta robots and robolink® DP robotic arms offer the same technical advantages as our gantries. Delta is available in two sizes and starts as low as $6,200. Countless component combinations are available for robolink® so you can design an individual solution that meets the needs of your business.
low cost automation using electro pneumatic system - IAARC
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robolink® Low Cost Automation - Igus
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Articles | Low Cost Automation: Retrofitting Old Machines
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The tetrahedron is the Best Simple & Low-Cost Automation Industry. It provides a solution for small & medium level companies. Automation in an assembly line.
Aug 11, 1998 — Tilt tables, turn tables, and lift tables are all examples of simple LCA.
Karakuri - Home
karakuri.item24.de › ...
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Low cost automation | INCIBE-CERT
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Case Study of Automation for Duplex Grinding ... - IJLTEMAS
www.ijltemas.in › DigitalLibrary
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Low cost automation is a technology that creates some ... In low cost automation using Robotic arm is generally ... Some examples of techniques for such.
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Karakuri - Low-Cost Automaiton | Haberkorn
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Low-cost automation 'on a shoestring' demos in action ...
Low-cost automation 'on a shoestring' demos in action. Leave a Comment / News / By admin. The Digital Manufacturing on a Shoestring project continued to ...
Cutting Costs with Pneumatics: Low-cost Automation from the ...
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... Costs with Pneumatics: Low-cost Automation from the Econom. and Techn. Perspectives Problem-solutions for Pract. Application Demonstrated by Examples.
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Low-cost automation (LCA) relieves strain on workers and boosts productivity without requiring complex control systems or drives. For example, by connecting ...
Karakuri | FlowStore Systems | Lean Manufacturing principles
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... rotating joints, pulleys, hinges, latches etc to help achieve low-cost automation. ... However, many examples are visible on digital media to provide inspiration.
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In this image you can notice that I only used two pins to connect 16 relays, which is made possible by MCP23017. You can see about this in the video, “IO ...
3.
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lean automation - DiVA
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by A Delkhosh · 2012 · Cited by 8 — At last some industrial and educational examples are reviewed to check the circumstances of ... Toyota have developed so-called low-cost automation. Lean.
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Global study and implementation of Karakuri
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by P Bellur Shashi Kumar · 2018 — studies, examples of low cost automation that can be used in further studies. The studies will also help understand the differences in continuous improvement ...
Laboratory automation - Wikipedia
en.wikipedia.org › wiki › Laboratory_automation
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May 9, 2020 — Justify with proper description why low cost automation is required to improve productivity in small scale industries. List out some examples. 1.
1 answer
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by HH Erbe — At a first glance low cost automation could be regarded as cheap hardware ... As an example one may consider Computer Integrated Manufacturing (CIM). The.
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Low Cost Automation (popularly known as LCA), is the introduction of simple pneumatic, hydraulic, mechanical and electrical devices into the existing production ...
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Low Cost Automation For Grinding Machine Ppt
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Low Cost Automated Systems
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Get familiar with low cost automation techniques like efficient material handling and inventory management. ... Analysis, Design Methods and. Worked Examples.
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PPT
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Give some example of engineering analysis software in common use on CAD ... Give specific examples of each. 12. ... 26 What is low cost automation? Discuss ...
With the theme Low-Cost Automation, the Symposium this year seeks to host a discourse on the application of automation to ... Examples & Case studies.
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... it is full of practical production examples of how Lean Thinking can be applied effectively ... Karakuri: The Application of Lean Thinking in Low-Cost Automation
Low-cost automation (LCA) relieves strain on workers and boosts productivity without requiring complex control systems or drives. For example, by connecting ...
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by S Seifermann · 2014 · Cited by 44 — Keywords: Low Cost Automation; Cellular Manufacturing; Work Measurement; Lean Machining. 1. ... MTM-1 for example shows a system-immanent deviation of.
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by E Hendrickson · 2001 · Cited by 4 — result, I have examples of good test automation stories. A tool that took a ... Further, otherwise low cost automation can become high cost as maintenance costs.
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Low-cost automation (LCA) relieves strain on workers and boosts productivity without requiring complex control systems or drives. For example, by connecting ...
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The following diagram shows an example executing the process of reading emails ... Smooth material flow & low cost automation Make material flow smooth ...
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A XYZ gantry from igus is a low-cost automation solution for loads up to 2.5kg. See how drylin® XYZ gantries boost efficient production for your application.
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(PTU, Dec. 2005) 4. Discuss the concept of low cost automation with the help of suitable examples. (PTU, May 2002) 5. What are the types of automation that can ...
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Low-cost automation is defined as a technology that creates some degree of automation around ... automated assembly lines are examples of such automation.
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A XYZ gantry from igus is a low-cost automation solution for loads up to 2.5kg. See how drylin® XYZ gantries boost efficient production for your application.
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Low cost automation on Quality function deployment, Jan, 3540/-, GGN ... of an Instructor-led presentation along with practical application examples will be given ...
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an example of mechanical automation in the general sense of replacing ... Chapter 7 shows how AutoIt can be used to integrate low-cost automation devices,.
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low cost automation for grinding machine ppt ... Examples of machine design are included including effects of cantilevered structure and closed structures.
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Feb 10, 2011 — ... amount of lights-out capacity, says Mr. Estes, typically a low-cost automation solution will do the job. For example, what about a bar feed?
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recent changes in industrial control panel standards, best practice examples ... The first book to combine all of the various topics relevant to low-cost automation.
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Examples &. Exercises. 50% hands- on. Expected Benefits. • Design of Low Cost Automation customized for specific needs. • Improved Minimal Material ...
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100) Low-cost Automation (max. = 100) For example, auto companies and their assembly plants may be compared and analyzed by using a set of variables that ...
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LOW- COST AUTOMATION The emergence of a new trend in automation is ... But I am convinced that these few examples of "low cost automation" herald a big ...
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Examples of low-cost automation include use of gravity conveyors versus powered conveyors, or use of lighter-weight, manually assembled supports versus ...
Allan R. Coletta · 2017 · Business & Economics
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In Japanese industrial engineering, Shigeo Shingo talks of flow of machines and flow of operators. The flow here describes the activities of machines and men. Can we reduce them to zero?
Like zero defect movement, can we launch zero flow processes movement and study the work of machines and men in the operations of processes to reduce them?
Machine vision increases hourly output of bottling line
March 2013
Machine vision in automated systems improves productivity, increases throughput, and eliminates human error.
Beer Bottles Inspection Case Study
Malted beverages are extremely popular in China, and 95% of all beer bottles are returned for recycling. They are inspected for damage, sterilized, and refilled. Bottle inspection is performed manually in most plants. There are roughly 3,000 bottling lines in China. They run at 18,000 to 24,000 bottles/hr and use human operators. Each line employs three shifts of 18 to 20 well-trained workers who inspect bottles on a fast-moving conveyor belt. The manual inspection is labor intensive and can cause eyestrain and fatigue.
Machine vision can be used to perform inspection tasks. Shangdong-based Mingjia Packaging Inspection Technology Co. Ltd. and Waterloo, Ontario-based Teledyne DALSA, a manufacturer of multicamera and digital-imaging products, are developing automated inspection systems for the Chinese-beer industry. “Checking that bottles are fit for reuse is a task that can be accomplished quickly and efficiently by machine vision according to Teledyne DALSA.
Some companies are already using machine- vision inspection systems purchased from abroad Mingjia was founded to design and develop affordable equipment to help beer producers adopt machine-vision inspection in place of manual bottles manually.
Mingjia started its relationship with Teledyne DALSA in 2008. Zhang had approached the Canadian firm for initial equipment development: The design called for a multicamera system capable of scanning bottles from multiple angles. Teledyne DALSA’s VA41 Vision Appliance is so used for its ability to survey many views simultaneously. This compact machine-vision controller supports up to six cameras — three analog and another three based on the IEEE 1394 serial-bus interface. Serial communications include RS-232, USB, and Ethernet for connecting the controller to the factory network. Mingjia’s configuration of the VA41 uses four analog cameras from a Japanese OEM, runs Teledyne DALSA’s Sherlock machine-vision software, and has enabled inspection rates of up to 42,000 bottles/hr.
Bottle-inspection System
The inspection equipment is placed immediately before the filling machines on a bottling line. Glass bottles, on a moving conveyor belt, pass through the equipment’s inspection chamber at high speed and each of the four cameras connected to the VA41 performs a specific task.
A camera positioned in the chamber at Stage 2 scans and checks the entire surface of the sidewall of an empty bottle, looking for defects, abrasions, and foreign matter. A similar process is repeated at Stage 5, once the bottle has been rotated through a 90° angle. Full-body scanning also makes use of mirrors to reduce the number of cameras required. A group of three mirrors, one behind the bottle and two oriented at 45° to the camera, enable 160% of the bottle’s body to be viewed and accurately checked. The camera at Stage 3, positioned above the bottle, scans the mouth for scratches, cracks, chips, and other irregularities, while the Stage 4 camera checks the base. “Inspecting the base is challenging because, when scanned, the nonslip surface texture molded into the glass bottom of each bottle generates unwanted signals and produces an image that is confusing to inspection algorithms.” Noise present in the image makes it difficult for the global-analysis software to distinguish between the ribbed background pattern and particles of dirt or other contamination adhering to the glass. To address the issue, optics and special lighting illuminate bottles from above and below, avoiding false alarms and preventing good bottles from being rejected.
The machine vision is also useful for detecting a bottle’s fill level and checking that labels have been applied correctly.
Upgrade to further increase productivity
Mingjia is developing an upgrade to the machine-vision hardware of its bottle inspection system by replacing the VA41 with a controller named GEVA. The Sherlock application software will be used. GEVA, Teledyne DALSA’s latest industrial controller, offers excellent cost savings for multicamera vision applications. Encased within an aluminum chassis, it provides the basis for a powerful industrial vision system. Unlike the VA41, which uses analog and IEEE 1394 serial-bus architectures, GEVA provides expandable Gigabit Ethernet (GigE) camera interfaces that significantly reduce cost. At the heart of the platform is a dualcore processor equipped with highspeed memory resources.
The controller has two camera ports that both support eight 640 × 480 mono cameras performing simultaneous inspection procedures. As part of the upgrade, Mingjia is also planning to replace third-party cameras with Teledyne DALSA’s Genie systems, which employ GigE technology and transmit data over standard CAT-5e and CAT-6 cables.
“GEVA is about two and a half times faster than VA41. This upgrade will enable Mingjia to substantially speed up inspections — to 64,000 bottles/hr, or possibly even 72,000.