Tuesday, March 29, 2022

The Platino Fiber: Laser Cutting Machine.

 


The Platino Fiber: Productive, efficient, and easy-to-use fiber laser cutting machine.

https://www.thefabricator.com/directory/showroom/prima-power-north-america-inc



The Platino Fiber represents a fully tested platform that combines reliability and flexibility with state of the art efficient laser technology. Profitable for production with all materials and thicknesses, including highly-reflective metals and high thickness mild steel. Ready for round, square, or rectangular tubes. Available in laser powers ranging from 2-6 kW. The Platino Fiber has low operating costs thanks to its energy efficiency and reduced maintenance. Thanks to a wide range of automation solutions, Platino Fiber can grow with your company from a stand-alone machine to a 24/7 operating FMS. A single focusing lens system with automatic nozzle changer makes this laser user friendly. The Platino Fiber also features easy to use programming software and Prima power operator interface.

Fully-tested and reliable thanks to the 20 years of experience with the Platino platform.


https://www.pesmedia.com/new-laser-provides-cutting-edge/

Learning Theories - Instructional Design


Different kinds of learning

What are different kinds of learning?

The most basic distinction is Benjamin Bloom's three domains:

Cognitive learning (thoughts), such as teaching someone to add fractions.

Affective learning (feelings, values), such as teaching someone to not want to smoke.

Physical or motor learning (actions), such as teaching someone to touch type.

https://idtheory.sitehost.iu.edu/methods/m1c.html


Levels of Cognitive Learning

The major levels of cognitive learning can be classified as memorizing, understanding, and applying. 

Memorization.   In this kind of learning, learning is said to occur when the learner states or remembers facts or taught material verbatim. It entails learners encoding facts or information in the form of an association between a stimulus and a response (For a given stimulus the response is given). Examples: Columbus discovered America in 1492, Pi = 3.1417,  "B" for Bush etc.  

Understanding. The learners relate a new idea to relevant prior knowledge. The behaviors that indicate that this kind of learning has occurred include comparing and contrasting, making analogies.   He can tell similar concepts and concepts which are opposite without being first told about them. It also involves making inferences whether it is present or not present in a given situation. Elaborating the issues, and analyzing the issue (as to parts and/or kinds), are also part of understanding. 

Application. At this level of learning, the knowledge can be used in new situations. It entails learners identifying critical commonalities on the topic taught and determining whether these conditions are present  in a diversity of previously unencountered situations.

Memorization, though sometimes very important, is greatly overused. Understanding and Application are important but complex.  

https://idtheory.sitehost.iu.edu/methods/m1d.html


Dave Merrill has proposed that it is useful to think of three types of content that can be learned.

Concepts
Procedures
Principles

A concept is a group or class of particulars which have something in common. These are concepts:
Shoe, Resistor etc.

A procedure is an ordered sequence of steps for accomplishing some goal. These are procedures:

How to write a paragraph.

 A principle is a relationship between two or more changes. It can be a causal, correlational, or natural-order relationship. 

An increase in price causes a decrease in demand.
https://idtheory.sitehost.iu.edu/methods/m1e.html
https://idtheory.sitehost.iu.edu/methods/m1f.html

Resources

Ausubel, D.P. (1968). Educational Psychology: A Cognitive View. New York: Holt, Rinehart & Winston.

Ausubel, D.P., Hanesian, & Novak, (1978) Educational Psychology: A Cognitive View (2nd ed.). New York: Holt, Rinehart & Winston. 

Bloom, B.S. (1976). Human Characteristics and School Learning. New York: McGraw-Hill. 

Gagné, R.M. (1985). The Conditions of Learning and Theory of Instruction (4th ed.). New York: Holt, Rinehart & Winston. 

Kaufman, R. (1979). Needs Assessment: Concept and Application. Englewood Cliffs, NJ: Educational Technology Publications. 

Keller, J. (October 1987). Strategies for stimulating the motivation to learn. Performance and Instruction, 1-7. 

Kulhavy, R. (1977). Feedback in written instruction. Review of Educational Research, 47, 211-232. 

Miller, G. (1956). The magical number seven, plus or minus two: Some limits on our capacity to process information. Psychological Review, 63, 81-97. 

Thorndike, E.M. (1913). Educational Psychology. Volume II. The Psychology of Learning. New York: Teachers College, Columbia University. 

Resources

To acquire skills in designing memorization-level instruction:

Reigeluth, C.M. Memorization. An interactive lesson under development for this site. 

To see an example of a computer-based lesson for a memorization task, look at:

Siegel, M., et al Bones? Learn the Bones of the Body. Novanet. 

To learn more about the drill-and-practice model of instruction, especially as it applies to computer-based instruction:

Salisbury, D.F. Cognitive psychology and its implications for designing drill and practice programs for computers. Journal of Computer-Based Instruction, 17(1), 23-30.
https://idtheory.sitehost.iu.edu/methods/m2h.html

Instructional Theory and Technology for the New Paradigm of Education
Charles M. Reigeluth
Indiana University
RED. Revista de Educación a Distancia. Núm. 50. Art. 1b. 15-Jul-2016 
DOI: http://dx.doi.org/10.6018/red/50/1b
http://www.um.es/ead/red/50/reigeluth_eng.pdf

https://sites.google.com/a/nau.edu/educationallearningtheories/home/charles-reigeluth


There are two kinds of knowledge that are needed to help school systems transform: The ends and the means.  Also, a different kind of research is needed to advance each of these two kinds of knowledge.

Charles M. Reigeluth

https://www.reigeluth.net/

Books


Instructional Design - Step by Step: Nine Easy Steps for Designing Lean, Effective, and Motivational Instruction


John S. Hoffman

iUniverse, 2013 - Education - 566 pages


Learn a simple, proven, step-by-step method for designing lean, eff ective, and motivational education and training from author Dr. John S. Hoff man, a thirty-year training veteran. A practitioner’s guide geared toward the newcomer to professional instructional design, Instructional Design—Step by Step presents an easy-to-understand process that includes these features:


• A primer on understanding how humans learn and the twelve principles of adult learning

• Ten key teaching principles and twenty common training mistakes

• Instruction on how to design computer application training complete with numerous examples illustrating new concepts and techniques

• Simple principles and practical advice laid out in bulleted lists and tables that can be immediately applied to training projects

• Follow-up questions at the end of every chapter with answers to test understanding of key concepts

• A broad range of examples across subject areas gathered by assessing real-life situations

• Sidebars containing recommendations for further reading

• A bibliography and extensive index for locating specific information Instructional Design—Step by Step and its companion volume, Instructional Development—Step by Step, provide a complete A-to-Z guide on how to design and develop instructional and educational materials—from short presentations to entire courses and curricula.

https://books.google.co.in/books?id=3SqOvnNpyOQC

Instructional-design Theories and Models: A New Paradigm of Instructional Theory, Volume II, Volume 2


Charles M. Reigeluth

Routledge, 13-May-2013 - Education - 728 pages


Instructional theory describes a variety of methods of instruction (different ways of facilitating human learning and development) and when to use--and not use--each of those methods. It is about how to help people learn better.


This volume provides a concise summary of a broad sampling of new methods of instruction currently under development, helps show the interrelationships among these diverse theories, and highlights current issues and trends in instructional design. It is a sequel to Instructional-Design Theories and Models: An Overview of Their Current Status, which provided a "snapshot in time" of the status of instructional theory in the early 1980s. Dramatic changes in the nature of instructional theory have occurred since then, partly in response to advances in knowledge about the human brain and learning theory, partly due to shifts in educational philosophies and beliefs, and partly in response to advances in information technologies. These changes have made new methods of instruction not only possible, but also necessary in order to take advantage of new instructional capabilities offered by the new technologies. These changes are so dramatic that many argue they constitute a new paradigm of instruction, which requires a new paradigm of instructional theory.


In short, there is a clear need for this Volume II of Instructional Design Theories and Models. To attain the broad sampling of methods and theories it presents, and to make this book more useful for practitioners as well as graduate students interested in education and training, this volume contains twice as many chapters, but each half as long as the ones in Volume I, and the descriptions are generally less technical. Several unique features are provided by the editor to help readers understand and compare the theories in this book:

https://books.google.co.in/books?id=FW9BA3c_VRkC


http://www.trainingshare.com/resources/
http://curtbonk.com/streamed.html

Monday, March 28, 2022

Statistics and Industrial Engineering


Lesson 401   of  Industrial Engineering ONLINE Course -  IE Statistic and IE Six Sigma Module.

Statistics and Industrial Engineering
Author: Narayana Rao

F.W. Taylor himself advocated maintaining of records and data for decision making. The other industrial engineering pioneers also promoted record keeping and data analysis. As sampling based  decision making became more robust, industrial engineers promoted it as a productivity improvement initiative and imperative. One of the prominent areas of application is statistical quality control. Sampling was also used in work measurement and work sampling technique was developed in industrial engineering. Now six sigma, a statistics based technique is being promoted by the IE profession.




F.W. Taylor has indicated that data collected for machine shop will be in thousands of pages. Harrington Emerson included records in his book 12 Principles of Efficiency. Their contemporary, professor of industrial engineering, Diemer wrote:

Department of Records.
"It is primarily a research and advisory department the results of  whose investigations and whose recommendations are brought up  at such meetings of department heads and others as may have been  predetermined. It is the duty of the record department to see that  records kept by various departments are not merely kept and stored  away, but that from each set of records is secured a method of most effective analysis so that the records of the past may be compared  with records of the present and conclusions may be drawn as to future  action. The individuals engaged in this department must be experts  in theory of accounts, the science of statistics, the art of graphical  presentation and cost accounting. The tendencies and facts indicated by an analysis of the records must be brought forcibly  to the attention of all individuals whose actions based on experience  and intuition differ from the action indicated by an analysis of figures,  records and statistics."

Reference: Factory Organization in Relation to Industrial Education
Author(s): Hugo Diemer
Source: The Annals of the American Academy of Political and Social Science, Vol. 44, The
Outlook for Industrial Peace (Nov., 1912), pp. 130-140

Industrial engineering has taken up the responsibility of using statistics to make processes in organizations efficient. May be Walter Shewart is the first statistician to develop a systematic method for applying the concepts and methods of statistics to industrial process control problems and industrial engineering has adopted statistical process control as a method to be installed in companies through IE department.

The role of statistics as a tool of management
J. M. Juran
Statistica Merlandica
Volume 4, Issue 1‐2, February 1950, Pages 69-79
First published: February 1950 
† *Paper presented at the 26th session of the International Statistical Institute in Bern, September 1949. Reprinted with permission of the author and of the ISI.

Growth of the mass production industries has posed new and complex problems in industrial management. Scientific solution of these problems necessitates statistical analysis of the vast quantities of data generated in these industries as a by‐product.

Improvements bordering on the spectacular have been achieved in selected instances of industrial applications of statistical analysis. Quality control and market research afford two such instances.

The professional statistical societies can do much to aid the greater utilization of statistics in industry by:

(a). organizing in each society a major division to deal with the problems of statistics in industry.

(b). sponsoring joint meetings with societies of managers, industrial engineers, and others interested in industrial statistics.

Important applications of statistics in industrial engineering: Work Sampling, Statistical Quality Control, Design of Experiments to improve productivity, Six Sigma
_______________________________________________________________________

Variability

No  two objects in the world around us, nor any two actions performed by the same or by different individuals, are exactly identical. Precision machine parts produced in quantity by the same operator busing identical tools and equipment will, upon examination show a definite variability.

Manufacturers try to reduce the variability of their output. The complete elimination of  variability in production is usually not feasible, and would be entirely uneconomical even if feasible. Instead, the manufacturer's philosophy is based on a tolerable, statistically predictable, level of imperfect product.

Source:   Siegmund Halpern, The Assurance Sciences, Prentice-Hall, Inc,. Englewood Cliffs, New Jersey, 1978,p.66.

Quality control enables us to ascertain sudden or gradual changes in product variability (or establish trends) to permit the institution of timely corrective action that will avoid production of costly scrap.

________________________





Remembering Walter Shewhart (Quality Magazine, March 2, 2009)
http://www.qualitymag.com/Articles/Web_Exclusive/BNP_GUID_9-5-2006_A_10000000000000540505

THE PHILOSOPHY OF SHEWHART'S THEORY OF PREDICTION
Dr Mark Wilcox, Centre for Business Performance; Cranfield School of Management, Cranfield University, Cranfield, United Kingdom. MK430AL
http://www.flowmap.com/documents/shewhart.pdf

Multivariate Quality Control - Historical Perspective
http://www.opf.slu.cz/vvr/akce/turecko/pdf/Firat.pdf

Shewhart’s Charts and the Probability Approach
Henry R. Neave and Donald J. Wheeler
© 1996
http://www.spcpress.com/pdf/Wheeler_Neave.pdf


Variation through Ages,  Quality Progress, Dec 1990 (interesting article)
http://www.apiweb.org/VariationThroughAges.pdf



Book: Industrial Statistics: Practical Methods and Guidance for Improved Performance

Anand M. Joglekar

ISBN: 978-0-470-49716-6 April 2010 288 Pages

TABLE OF CONTENTS
PREFACE.
1. BASIC STATISTICS: HOW TO REDUCE FINANCIAL RISK?

1.1. Capital Market Returns.

1.2. Sample Statistics.

1.3. Population Parameters.

1.4. Confidence Intervals and Sample Sizes.

1.5. Correlation.

1.6. Portfolio Optimization.

1.7. Questions to Ask.

2. WHY NOT TO DO THE USUAL t-TEST AND WHAT TO REPLACE IT WITH?

2.1. What is a t-Test and what is Wrong with It?

2.2. Confidence Interval is Better Than a t-Test.

2.3. How Much Data to Collect?

2.4. Reducing Sample Size.

2.5. Paired Comparison.

2.6. Comparing Two Standard Deviations.

2.7. Recommended Design and Analysis Procedure.

2.8. Questions to Ask.

3. DESIGN OF EXPERIMENTS: IS IT NOT GOING TO COST TOO MUCH AND TAKE TOO LONG?

3.1. Why Design Experiments?

3.2. Factorial Designs.

3.3. Success Factors.

3.4. Fractional Factorial Designs.

3.5. Plackett–Burman Designs.

3.6. Applications.

3.7. Optimization Designs.

3.8. Questions to Ask.

4. WHAT IS THE KEY TO DESIGNING ROBUST PRODUCTS AND PROCESSES?

4.1. The Key to Robustness.

4.2. Robust Design Method.

4.3. Signal-to-Noise Ratios.

4.4. Achieving Additivity.

4.5. Alternate Analysis Procedure.

4.6. Implications for R&D.

4.7. Questions to Ask.

5. SETTING SPECIFICATIONS: ARBITRARY OR IS THERE A METHOD TO IT?

5.1. Understanding Specifications.

5.2. Empirical Approach.

5.3. Functional Approach.

5.4. Minimum Life Cycle Cost Approach.

5.5. Questions to Ask.

6. HOW TO DESIGN PRACTICAL ACCEPTANCE SAMPLING PLANS AND PROCESS VALIDATION STUDIES?

6.1. Single-Sample Attribute Plans.

6.2. Selecting AQL and RQL.

6.3. Other Acceptance Sampling Plans.

6.4. Designing Validation Studies.

6.5. Questions to Ask.

7. MANAGING AND IMPROVING PROCESSES: HOW TO USE AN AT-A-GLANCE-DISPLAY?

7.1. Statistical Logic of Control Limits.

7.2. Selecting Subgroup Size.

7.3. Selecting Sampling Interval.

7.4. Out-of-Control Rules.

7.5. Process Capability and Performance Indices.

7.6. At-A-Glance-Display.

7.7. Questions to Ask.

8. HOW TO FIND CAUSES OF VARIATION BY JUST LOOKING SYSTEMATICALLY?

8.1. Manufacturing Application.

8.2. Variance Components Analysis.

8.3. Planning for Quality Improvement.

8.4. Structured Studies.

8.5. Questions to Ask.

9. IS MY MEASUREMENT SYSTEM ACCEPTABLE AND HOW TO DESIGN, VALIDATE, AND IMPROVE IT?

9.1. Acceptance Criteria.

9.2. Designing Cost-Effective Sampling Schemes.

9.3. Designing a Robust Measurement System.

9.4. Measurement System Validation.

9.5. Repeatability and Reproducibility (R&R) Study.

9.6. Questions to Ask.

10. HOW TO USE THEORY EFFECTIVELY?

10.1. Empirical Models.

10.2. Mechanistic Models.

10.3. Mechanistic Model for Coat Weight CV.

10.4. Questions to Ask.

11. QUESTIONS AND ANSWERS.

11.1. Questions.

11.2. Answers.

APPENDIX: TABLES.

REFERENCES.

INDEX.

https://www.wiley.com/en-us/Industrial+Statistics%3A+Practical+Methods+and+Guidance+for+Improved+Performance-p-9780470497166

INDUSTRIAL STATISTICS

Course Developers
D. K. Jain & R. Malhotra
http://ecoursesonline.iasri.res.in/course/view.php?id=484

Industrial Statistics - Guidelines and Methodology - Unido
https://www.unido.org/resources/publications/cross-cutting-services/industrial-statistics-guidelines-and-methodology

Last edited on Knol: 22 Jul 2010
Exported : 26 Nov 2011 to this blog

Original URL: http://knol.google.com/k/-/-/  2utb2lsm2k7a/ 2768


Key Words: Statistics, Industrial Engineering and Efficiency
__________________________________________________________________________


Updated 28.3.2022,   9 August 2021,  4 August 2019,  14 July 2016,  23 July 2012

Sunday, March 27, 2022

Value Engineering at the Design and Development Stage - Examples: Tata Nano

Value Engineering
Value Engineering (VE) can be applied during product development to reduce costs maintaining the quality designed in by form and strength designers. Value analysis is a systematic analysis with a series of questions answered by utilizing existing engineering knowledge and knowledge of suppliers' capabilities by engineers training to collect relevant engineering knowledge for value analysis as well as by all engineers inside the company and invited engineering consultants and supplier personnel.  This takes place before any capital is invested in tooling, plant or equipment.

Up to 80% of a product’s costs (throughout the rest of its life-cycle), are locked in at the design development stage according to some scientific studies,  The design and development of any product determines and develops many factors, such as tooling, plant and equipment, labor and skills, training required, materials, shipping, installation, maintenance, as well as decommissioning and recycle procedures. Thus it designs many cost related factors right at the beginning. Value engineering has the ability to modify some of these factors in the beneficial direction. Value engineering should be considered an important  activity in the product development process and it is certainly a value increasing investment. Value engineering section in new product development process has to be created and used for sound commercial reasons.


Technical Paper
Value Engineering Factors with an Impact on Design Management Performance of Construction Projects
Murat Gunduz, Ph.D., A.M.ASCE; Aly A. Aly; and Tarek El Mekkawy, Ph.D.
Journal of Management in Engineering
Vol. 38, Issue 3 (May 2022)
American Society of Civil Engineers
https://ascelibrary.org/doi/abs/10.1061/%28ASCE%29ME.1943-5479.0001026

Value to the customer, through of benefits to the customer, is initially created in the product/project or service concept phase of a project when the product case is first produced and the direction of a project is agreed. The project design should be tested to ensure it will create value for the organisation andother  stakeholders apart from the customer.  The engineering options chosen to deliver the benefits need to be tested to ensure they  give the best value for money: There are generally a number of different ways of delivering the benefits and one is likely to provide better value than another. Benefits delivered or to be delivered should be stated with clarity in a measureable form so that other alternative options to deliver the benefit can be identified or developed by value analysis team.

VALUE ENGINEERING
January 29, 2017
Vijay Sharma
Independent Consultant

August 6, 2018

Use Value Improvement Methods and Reduce Capital Costs of Projects and Products Produced Using Projects.

Project value improvement (PVI) rigorously identifies tools, management practices, and capabilities that optimize a project’s financial value.  PVI integration could recover trillions over time for the world.
McKinsey analysis estimates that global capital spending will total $77 trillion between 2018 and 2023, which places the annual value of that spending at more than $10 trillion. Historically, owners that rigorously integrate PVI have realized in excess of 10 percent of project value in savings. 

PVI’s origins and evolution
PVI began in the 1950s as “value engineering,” where an engineering department’s technical solution aligned seamlessly with the cost data of the input markets.  With both working in concert, efficiencies were achieved.










Design to cost and target costing are applied in a good manner in the development of Tata Nano car. Value engineering states that designers and managers of design do not make use of all value opportunities or low cost opportunities in the early stages of product life cycle. Design to cost and target costing force design department to make greater use of value opportunities in the early stages. Value engineers are being associated with design teams to incorporate value opportunities. Tata Nano is a good example of use of target costing and value engineering.

Number of authors and journalists have contributed to document the cost reduction activities undertaken in Nano development. This article highlights some of them.

___________________________________

Overdrive Team, Network 18, 19th March 2009

ECU
The ECU, or engine control unit is a small computer that controls all aspects of engine operation. It is  expensive, but, it is needed because an engine today must satisfy emissions norms, sound norms, produce an acceptable spread of power, return an acceptable level of economy and still more.  Tata worked with Bosch to take the ECU down to an unprecedented price by reducing the sensors used by the ECU to govern the engine  down to half the usual number.

Wiper
Only one wiper is provided

Small wheels and mounting
Small wheels are lighter, which positively impacts economy.  Further, these wheels were mounted with only three lugs resulting in lower costs but it is modification done to a feature which became automatic in car design to improve economy. There is no power steering in the car. Further, the design team split the tyre sizes to give the front a slightly thinner spec, while keeping the driven wheels fatter. This balances the impact of the wider track at the front, and in driving terms should endow the car with mild understeer at the limit - which is a safety feature.  The engineered understeer helpsin developoing a balanced, neutral car. But smaller tyres mean less rubber, so they should be cheaper as well.

The non-opening hatch also provides cost reduction. It means no costs in terms of beading, hinges and locks, and that the whole panel can be a relatively cheap addition to the monocoque which will add to the strength of the chassis without adding cost.

Light body
Nano uses a light gauge metal body and the production process will aim for minimum wastage.

Engine format/placement
The four-stroke parallel twin 624cc engine has number of patented invention of Tata company. The single-counterbalancer equipped motor is being labelled as a world first for a car application. The engine is fuel-injected and  it is a two-valve single overhead cam design.


Placement of engine at the rear

The rear-engine, rear-wheel drive format eliminates the driveshaft and saves some money. The engine is packaged in a stunning way. The motor is behind and under the rear seats. The hatch does not open. The engine is accessed by flipping the rear seats forward. The engine could be pretty reliable. The engine's non-intrusion into the passenger cabin  liberates  interior space - 21 per cent more interior space than the Maruti 800.

Central instruments and dashboard
The central meters and the dash on the Nano  eliminates the need to adapt that large plastic assembly for right- and left-hand drive markets. Tata will offer a speedometer, odometer and a digital fuel gauge plus lights that are spartan, but complete instrumentation. There is no glove box.

Filler cap and single mirror
The filler cap is actually located under the nose. On the cost front, this means that body does not need to a hole in it at someplace for the filler cap. There will be only right side mirror and left side mirror may be an optional extra.
Source:
___________________________________

Rediff Article on 12.1.2008

The 623 cc two-cylinder petrol engine from aluminum. Conventional engines are made from cast iron, adding weight as well as cost to the car. Being smaller and lighter, the cost was lower. 
The engine being lighter and placed at the rear of the car put less pressure on the steering systems, which allowed for more cost savings. As a result, there was no requirement for a link between the engine and the rear wheels. 
The tubular design of the car instead of the conventional 'rod' design definitely helped cut costs, particularly the processes involved.
Costs were  cut by using regular bulbs that meet the regulations instead of long life bulbs.  
Source
_____________________________________

Cost-effective emission reduction solutions
For example, BASF Catalysts has developed a catalytic converter for the Nano to meet India’s current emission standards. BASF local experts in India are supported by colleagues from the USA to achieve this cost-effective regulatory compliance. BASF operates a catalyst manufacturing plant in Chennai, India.

Weight savings for better fuel efficiency- Plastic air intake manifold
The Nano’s plastic air intake manifold will be produced by Tata Visteon and employs BASF’s Ultramid® glass-fiber reinforced engineering plastic. Generally, air intake manifolds supply the engine with the air it needs for combustion and was traditionally made from aluminium. By replacing it with Ultramid leads to 40% weight saving which in turn leads to better fuel efficiency and lesser emission, essential features for the Nano.
Source:
_____________________________________
_____________________________________
More Articles for Study
Engineering the Nano

Presentation
Value Engineering of Nano

How_Tata_has_built_a_car_that_costs_less_than_a_motorbike

New Product Development Process - Tata Nano
Tata Motors Commecial Launch and Some Component Suppliers details
Wharton article on Nano
_____________________________________
Original Knol
http://knol.google.com/k/narayana-rao/ value-engineering-at-the-design-and/ 2utb2lsm2k7a/  2320


Ud. 27.3.2022, 23.1.2020
Pub 10.3.2012

Saturday, March 26, 2022

Jig and Fixture Design - Principles and Explanation


Industrial engineers have to be well versed in the possibilities of designing jigs and fixtures for increasing productivity of material processing or parts processing and assembling using machines or men. They may do the design of the jigs and fixtures internally in the IE department, or assign the work to the engineering departments or the tool-room or give it to the outside designers. But it is their responsibility to identify the opportunity and initiate the activity to assess it to take it forward. Industrial engineer must have the capability to identify the any engineering way to improve material processing, inspection, material handling and transport and storage in each process used in the organization. They have to monitor the developments in engineering and technology on a continuous basis to keep themselves up-to-date in engineering.

PRINCIPLES OF JIG DESIGN

Jigs and fixtures may be defined as devices used in the manufacture of duplicate parts of machines and intended to make possible interchangeable work at a reduced cost, as compared with the cost of producing each machine detail individually.

Jigs and fixtures serve the purpose of holding and properly locating a piece of work while machined, and are provided with necessary, appliances for guiding, supporting, setting, and gaging the tools in such a manner that all the work produced in the same jig or fixture will be alike in all respects, even with the employment of unskilled labor. When using the expression "alike," it implies, of course, simply that the pieces will be near enough alike for the purposes for which the work being machined is intended. Thus, for certain classes of work, wider limits of variation will be permissible without affecting the proper use
of the piece machined, while in other cases the limits of variation will be so small as to make the expression "perfectly alike" literally true.

Objects of Jigs and Fixtures. The main object of using jigs and fixtures is the reduction of the cost of machines or machine details made in great numbers. This reduction of cost is obtained in consequence of the increased rapidity with which the machines may be built and the employment of cheaper labor,
which is possible when using tools for interchangeable manufacturing. Another object, not less important, is the accuracy with which the work can be produced, making it possible to assemble the pieces produced in jigs without any great amount of fitting in the assembling department, thus also effecting a great saving in this respect. The use of jigs and fixtures practically does away with the fitting, as this expression was understood in the old-time shop; it eliminates cut-and-try methods, and does away with so-called "patch- work" in the production of machinery. It makes it possible to have all the machines built in the shop according to the drawings, a thing which is rather difficult to do if each individual machine in a large lot is built without reference to the other machines in the same lot.

The interchangeability obtained by the use of jigs and fixtures makes it also an easy matter to quickly replace broken or wornout parts without great additional cost and trouble. When machines are built on the individual plan, it is necessary to fit the part replacing the broken or worn-out piece, in place, involving considerable extra expense, not to mention the delay and the difficulties occasioned thereby.

As mentioned, jigs and fixtures permit the employment of practically unskilled labor. There are many operations in the building of a machine, which, if each machine were built individually, without the use of special tools, would require the work of expert machinists and toolmakers. Special tools, in the form
of jigs and fixtures, permit equally good, or, in some cases, even better results to be obtained by a much cheaper class of labor, provided the jigs and fixtures are properly designed and correctly made. Another possibility for saving, particularly in the case of drill and boring jigs provided with guide bushings in the
same plane, is met with in the fact that such jigs are adapted to be used in multiple-spindle drills, thereby still more increasing the rapidity with which the work may be produced. In shops where a great many duplicate parts are made, containing a number of drilled holes, multiple-spindle drills of complicated design, which may be rather expensive as regards first cost, are really cheaper, by far, than ordinary simple drill presses.

Another advantage which has been gained by the use of jigs and fixtures, and which should not be lost sight of in the enumeration of the points in favor of building machinery by the use of special tools, is that the details of a machine that has been provided with a complete equipment of accurate and durable
jigs and fixtures can all be finished simultaneously in different departments of a large factory, without inconvenience, thus making it possible to assemble the machine at once after receiving the parts from the different departments; and there is no need of waiting for the completion of one part into which another is required to fit, before making this latter part. This gain in time means a great deal in manufacturing, and was entirely impossible under the old-time system of machine building, when each part had to be made in the order in which it went to the finished machine, and each consecutive part had to be lined up with each one of the previously made and assembled details. Brackets, bearings, etc., had to be drilled in place, often with ratchet drills, which is a slow and always inconvenient operation.

Difference between Jigs and Fixtures. To exactly define the word "jig, " as considered apart from the word "fixture," is difficult, as the difference between a jig and a fixture is oftentimes not very easy to decide. The word jig is frequently, although incorrectly, applied to any kind of a work-holding appliance used in the building of machinery, the same as, in some shops, the word fixture is applied to all kinds of special tools. As a general rule, however, a jig is a special tool, which, while it holds the work, or is held onto the work, also contains guides for the respective tools to be used; whereas a fixture is only holding the work while the cutting tools are performing the operation on the piece, without containing any special arrangements for guiding these tools. The fixture, therefore, must, itself, be securely held or fixed to the machine on which the operation is performed; hence the name. A fixture, however, may sometimes be provided with a number of gages and stops, although it does not contain any special devices for the guiding of the tools.

The definition given, in a general way, would therefore classify jigs as special tools used particularly in drilling and boring operations, while fixtures, in particular, would be those special tools used on milling machines, and, in some cases, on planers, shapers, and slotting machines. Special tools used on the lathe
may be either of the nature of jigs or fixtures, and sometimes the special tool is actually a combination of both, in which case the term drilling fixture, boring fixture, etc., is suitable.

Fundamental Principles of Jig Design. Before entering upon a discussion of the minor details of the design of jigs and fixtures, the fundamental principles of jig and fixture design will be briefly outlined. Whenever a jig is made for a component part of a machine, it is almost always required that a corresponding jig be made up for the place on the machine, or other part, where the first-mentioned detail is to be attached. It is, of course, absolutely necessary that these two jigs be perfectly alike as to the location of guides and gage points. In order 'to have the holes and guides in the two jigs in alignment, it is advisable, and almost always cheaper and quicker, to transfer the holes or the gage points from the first jig made to the other. In many instances, it is possible to use the same jig for both parts.
Cases where the one or the other of these principles is applicable will be shown in the following chapters in the detailed descriptions of drill and boring jigs.

There are some cases where it is not advisable to make two jigs, one for each of the two parts which are to fit together. It may be impossible to properly locate the jig on one of the parts to be drilled, or, if the jig were made, it may be so complicated that it would not be economical. Under such conditions the component part itself may be used as a jig, and the respective holes in this part used as guides for the tools when machining the machine details into which it fits. Guide bushings for the drills and boring bars may then be placed in the holes in the component part itself. In many cases, drilling and boring operations are also done, to great advantage, by using the brackets and bearings already assembled and fastened to the machine body as guides.

One of the most important questions to be decided before making a jig is the amount of money which can be expended on a special tool for the operation required. In many cases, it is possible to get a highly efficient tool by making it more complicated and more expensive, whereas a less efficient tool may be produced at very small expense. To decide which of these two types of jigs and fixtures should be designed in each individual case depends entirely upon the circumstances. There should be a careful comparison of the present cost of carrying out a certain operation, the expected cost of carrying out the same operation with an efficient tool, and the cost of building that tool itself. Unless this is done, it is likely that the shop is burdened with a great number of special tools and fixtures which, while they may be very useful for the production of the parts for which they are intended, actually involve a loss. It is readily seen how uneconomical it would be to make an expensive jig and fixture for a machine or a part of a machine that would only have to be duplicated a few times. In some cases, of course, there may be a gain in using special devices in order to get extremely good and accurate results.

Locating Points. The most important requirements in the design of jigs are that good facilities be provided for locating the work, and that the piece to be machined may be easily inserted and quickly taken out of the jig, so that no time is wasted in placing the work in position on the machine performing the work. In some cases, a longer time is required for locating and clamping the piece to be worked upon than is required for the actual machine operation itself. In all such cases the machine performing the work is actually idle the greater part of the time, and, added to the loss of the operator's time, is the increased expense for machine cost incurred by such a condition. For this reason, the locating and clamping of the work in place quickly and accurately should be carefully studied by the designer before
any attempt is made to design the tool. In choosing the locating surface or points of the piece or part, consideration must be given to the facilities for locating the corresponding part of the machine in a similar manner. It is highly important that this be done, as otherwise, although the jigs may be alike, as far as their guiding appliances are concerned, there may be no facility for locating the corresponding part in the same manner as the one already drilled, and while the holes drilled may coincide, other surfaces, also required to coincide, may be considerably out of line. One of the main principles of location, therefore, is that two component parts of the machine should be located from corresponding points and surfaces.

If possible, special arrangements should be made in the design of the jig so that it is impossible to insert the piece in any but the correct way. Mistakes are often made on this account in shops where a great deal of cheap help is used, pieces being placed in jigs upside down, or in some way other than the correct one, and work that has been previously machined at the expenditure of a great deal of time is entirely spoiled. Therefore, whenever possible, a jig should be made " fool-proof ."

When the work to be machined varies in shape and size, as, for instance, in the case of rough castings, it is necessary to have at least some of the locating points adjustable and placed so that they can be easily reached for adjustment, but, at the same time, so fastened that they are, to a certain extent, positive. In the following chapters different kinds of adjustable locating points will be described in detail.

Clamping Devices. The strapping or clamping arrangements should be as simple as possible, without sacrificing effectiveness, and the strength of the clamps should be such as to not only hold the piece firmly in place, but also to take the strain of the cutting tools without springing or " giving." When designing the jig, the direction in which the strain of the tool or cutters acts upon the work should always be considered, and the clamps so placed that they will have the highest degree of strength to resist the pressure of the cut.

The main principles in the application of clamps to a jig or fixture are that  they should be convenient for the operator, quickly operated, and, when detached from the work, still connected with the jig or fixture itself, so as to prevent the operator from losing them. Many a time, looking for lost straps, clamps, screws, etc., causes more delay in shops than the extra cost incurred in designing a jig or fixture somewhat more complicated, in order to make the binding arrangement an integral part of the fixture itself. Great complication in the clamping arrangements, however, is not advisable. Usually clamping
arrangements of this kind work well when the fixture is new, but, as the various parts become worn, complicated arrangements are more likely to get out of order, and the extra cost incurred in repairing often outweighs the temporary gain in quickness of operation.


The judgment of the designer is, in every case, the most important point in the design of jigs and fixtures. Definite rules for all cases cannot be given. General principles can be studied, but the efficiency of the individual tool will depend entirely upon the judgment of the tool designer in applying the general principles of tool design to the case in hand.

When designing the jig or fixture, the locating and bearing points for the work and the location of the clamps must also be so selected that there is as little liability as possible of springing the piece or jig, or both, out of shape, when applying the clamps. The springing of either the one or the other part will cause incorrect results, as the work surfaces will be out of alignment with the holes drilled or the faces milled. The clamps or straps should therefore, as far as possible, be so placed that they are exactly opposite some bearing point or surface on the work.

Weight of Jigs. The designer must use his judgment in regard to the amount of metal put into the jig or fixture. It is desirable to make these tools as light as possible, in order that they may be easily handled, be of smaller size, and cost less in regard to the amount of material used for their making, but, at
the same time, it is poor economy to sacrifice any of the rigidity and stiffness of the tool, as this is one of the main considerations in obtaining efficient results. On large-sized jigs and fixtures, it is possible to core out the metal in a number of places, without decreasing, in the least, the strength of the jig itself. The corners of jigs and fixtures should always be well rounded, and all burrs and sharp edges filed off, so as to make them convenient and pleasant for handling. Smaller jigs should also be made with handles in proper places, so that they may be held in position while working, as in the case of drilling jigs, and also for convenience in moving the jig about.

Jigs Provided with Feet. Ordinary drill jigs should always be provided with feet or legs on all sides which are opposite the holes for the bushings, so that the jig can be placed level on the
table of the machine. These feet also greatly facilitate the making of the jig, making it easier to lay out and plane the different finished surfaces. On the sides of the jig where no feet are required, if the body is made from a casting, it is of advantage to have small projecting lugs for bearing surfaces when laying
out and planing. While jigs are most commonly provided with four feet on each side, in some cases it is sufficient to provide the tool with only three feet, but care should be taken in either case that all bushings and places where pressure will be applied to the tool are placed inside of the geometrical figure obtained by connecting, by lines, the points of location for the feet.

While it may seem that three feet are preferable to use, because the jig will then always obtain a bearing on all the three feet, which it would not with four feet, if the table of the machine were not absolutely plane, it is not quite safe to use the smaller number of supports, because a chip or some other object is liable to come under one foot and throw the jig and the piece out of line, without this being noticed by the operator. If the same thing happens to a jig with four feet, it will rock and invariably cause the operator to notice the defect. If the table is out of true, this defect, too, will be noticed for the same reason.

Jig feet are generally cast solid with the jig frame. When the jig frame is made from machine steel, and sometimes in the case of cast-iron jigs, detachable feet are used.

Materials for Jigs. Opinions differ as to the relative merits of cast iron and steel as materials from which to construct the jig and fixture bodies. The decision on this point should depend to a great extent upon the usage to which the fixture is to be put and the character of the work which it is to handle. For small and medium sized work, such as typewriter, sewing machine, gun, adding machine, cash register, phonograph, and similar parts, the steel jig offers decided advantages, but for larger work, such as that encountered in automobile, engine, and machine tool fixtures, the cast-iron jig is undoubtedly the cheaper and more advisable to use. The steel jig should be left soft in order that at any future time additional holes may be added, or the existing bushings changed as required. With a cast-iron jig this adding of bushings is a difficult matter, as the frame is usually bossed and "spot finished" at the point where the bushings are located, and it is very difficult to build up on the jig frame in order to locate or change the bushings. When designing the jig, these points should be remembered and provision made for them, where possible.

General Remarks on Jig Design. One mistake, quite frequently made, is that of giving too little clearance between the piece to be machined and the walls or sides of the jig used for it. Plenty of clearance should always be allowed, particularly when rough castings are being drilled or machined in the jigs; besides,
those surfaces in the jig which do not actually bear upon the work do not always come exactly to the dimensions indicated on the drawing, particularly in a cast-iron jig, and allowance ought to be made for such differences.

In regard to the locating points, it ought to be remarked that, in all instances, these should be visible to the operator when placing the work in position, so that he may be enabled to see that the work really is in its right place. At times the construction of the piece to be worked upon may prevent a full view of
the locating points. In such a case a cored or drilled hole in the jig, near the locating seat, will enable a view of same, so that the operator may either see that the work rests upon the locating point, or so that he can place a feeler or thickness gage between the work and the locating surface, to make sure that he has the work in its correct position. Another point that should not be overlooked is that jigs and fixtures should be designed with a view of making them easily cleaned from the chips, and provision should also be made so that the chips, as far as possible, may fall out of the jig and not accumulate on or about the locating points, where they are liable to throw the work out of its correct position and consequently spoil the piece.

The principles so far referred to have all been in relation to the holding of the work in the jig, and the general design of the jig for producing accurate work. Provisions, however, should also be made for clamping the jig or fixture to the table of the machine, in cases where it is necessary to have the tool fixed while in operation. Small drilling jigs are not clamped to the table, but boring jigs and milling and planing fixtures invariably must be firmly secured to the machine on which they are used. Plain lugs, projecting out in the same plane as the bottom of the jig, or lugs with a slot in them to fit the body of T-bolts, are the common means for clamping fixtures to the table. For boring jigs, it is unnecessary to provide more than three such clamping points, as a greater number is likely to cause some springing action in the fixture. A slight springing effect is almost unavoidable, no matter how strong and heavy the jig is, but, by properly applying the clamps, it is possible to confine this springing within commercial limits.

Jigs should always be tested before they are used, so as to make sure that the guiding provisions are placed in the right relation to the locating points and in proper relation to each other.

Summary of Principles of Jig Design. Summarizing the principles referred to, the following rules may be given as the main points to be considered in the designing of jigs and fixtures:

1. Before planning the design of a tool, compare the cost of production of the work with present tools with the expected cost of production, using the tool to be made, and see that the cost of building is not in excess of expected gain.

2. Before laying out the jig or fixture, decide upon the locating points and outline a clamping arrangement.

3. Make all clamping and binding devices as quick-acting as possible.

4. In selecting locating points, see that two component parts of a machine can be located from corresponding points and surfaces.

5. Make the jig " fool-proof "; that is, arrange it so that the work cannot be inserted except in the correct way.

6. For rough castings, make some of the locating points adjustable.

7. Locate clamps so that they will be in the best position to resist the pressure of the cutting tool when at work.

8. Make, if possible, all clamps integral parts of the jig or fixture.

9. Avoid complicated clamping arrangements, which are liable to wear or get out of order.

10. Place all clamps as nearly as possible opposite some bearing point of the work, to avoid springing.

11. Core out all unnecessary metal, making the tools as light as possible, consistent with rigidity and stiffness.

12. Round all corners.

13. Provide handles wherever these will make the handling of the jig more convenient.

14. Provide feet, preferably four, opposite all surfaces containing guide bushings in drilling and boring jigs.

15. Place all bushings inside of the geometrical figure formed by connecting the points of location of the feet.

1 6. Provide abundant clearance, particularly for rough castings.

17. Make, if possible, all locating points visible to the operator when placing the work in position.

18. Provide holes or escapes for the chips.

19. Provide clamping lugs, located so as to prevent springing of the fixture, on all tools which must be held to the table of the machine while in use, and tongues for the slots in the tables in all milling and planing fixtures.

20. Before using in the shop, for commercial purposes, test all jigs as soon as made.

Types of Jigs. The two principal classes of jigs are drill jigs and boring jigs. Fixtures may be grouped as milling, planing, and splining fixtures, although there are a number of special fixtures which could not be classified under any special head.

Drill jigs are intended exclusively for drilling, reaming, tapping, and facing. Whenever these four operations are required on a piece of work, it is, as a rule, possible to provide the necessary arrangements for performing all these operations in one and the same jig. Sometimes separate jigs are made for each one of these operations, but it is doubtless more convenient and cheaper to have one jig do for all, as the design of the jig will not be much more complicated. Although it may be possible to make a distinction between a number of different types of drill jigs, it is almost impossible to define and to get proper names for the various classes, owing to the great variety of shapes of the work to be drilled. There are, however, two general types that are most commonly used, the difference between them being very marked. These types may be classified as open jigs and closed jigs, or box jigs. Sometimes the open jigs are called clamping jigs. The open jigs usually have all the drill bushings in the same plane, parallel with one another, and are not provided with loose or removable walls or leaves, thereby making it possible to insert the piece to be drilled without any manipulation of the parts of the jig. These jigs are often of such a construction that they are applied to the work to be drilled, the jig being placed on the work, rather than the work being placed in the jig. The jig may be held to the work by straps, bolts, or clamps, but in many cases the jig fits into or over some finished part of the work and in this way the jig is located and held in position.

The closed drill jigs, or box jigs, frequently resemble some form of a box and are intended for pieces where the holes are to be drilled at various angles to one another. As a rule, the piece to be drilled can be inserted in the jig only after one or more leaves or covers have been swung out of the way. Sometimes it is necessary to remove a loose wall, which is held by bolts and dowel pins, in order to locate the piece in the jig. The work in the closed drill jig may be held in place by set-screws, screw bushings, straps, or hook-bolts.

The combination drilling and boring jig is another type of closed jig designed to serve both for drilling and boring operations. Before designing a combination drill and boring jig, the relation between, and number of, the drilled and bored holes must be taken into consideration, and also the size of the piece to be machined. In case there is a great number of holes, it may be of advantage to have two or even more jigs for the same piece, because it makes it easier to design and make the jig, and very likely will give a better result. The holes drilled or bored in the first jig may be used as a means for locating the
piece in the jigs used later on. Combination drill and boring jigs are not very well adapted for pieces of large size.

Open Jigs. Open jigs of the simpler forms are simply plates provided with bushed holes which are located to correspond with the required locations for the drilled holes. While holes are sometimes drilled by first laying out the holes directly upon the work, it is quite evident that this method of drilling
would not be efficient if a large number of duplicate parts had to be drilled accurately, as there is likely to be more or less variation in the location of the holes, and considerable loss of time. In the first place, a certain amount of time is required for laying out these holes preparatory to drilling. The operator, when starting the drill, must also be careful to make it cut concentric with the scribed circle, which requires extra time, and there will necessarily be more or less variation. To over-come these objections, jigs are almost universally used for holding the work and guiding the drill, when drilling duplicate parts,
especially when quite a large number of duplicate pieces must be drilled.

The ring-shaped jig shown at A in Fig. i is used for drilling the stud bolt holes in a cylinder flange and also for drilling the cylinder head, which is bolted to the cylinder. The position of the jig when the cylinder flange is being drilled is shown at B. An annular projection on the jig fits closely in the cylinder
counterbore, as the illustration shows, to locate the jig concentric with the bore. As the holes in the cylinder are to be tapped or threaded for studs, a "tap drill," which is smaller in diameter than the bolt body, is used and the drill is guided by a removable bushing b of the proper size. Jigs of this type are often held in position by inserting an accurately fitting plug through the jig and into the first hole drilled, which prevents the jig from turning with relation to the cylinder, when drilling the other holes. When the jig is used for drilling the head, the opposite side is placed next to the work, as shown at C. This side
has a circular recess or counterbore, which fits the projection on the head to properly locate the jig. As the holes in the head must be slightly larger in diameter than the studs, another sized drill and a guide bushing of corresponding size are used. The cylinder is, of course, bored and the head turned before the drilling is done.

Jigs of the open class, as well as those of other types, are made in a great variety of shapes, and, when in use, they are either applied to the work or the latter is placed in the jig. When the work is quite large, the jig is frequently placed on it, whereas small parts are more often held in the jig, which is so designed that the work can be clamped in the proper position. The form of any jig depends, to a great extent, on the shape of the work for which it is intended and also on the location of the holes to be drilled. As the number of differently shaped pieces which go to make up even a single machine is often very great, and as most parts require more or less drilling, jigs are made in an almost endless variety of sizes and forms. When all the holes to be drilled in a certain part are parallel, and especially if they are all in the same plane, a very simple form of jig can ordinarily be used.

Box Jigs. A great many machine parts must be drilled on different sides and frequently castings or forgings are very irregular in shape, so that a jig which is made somewhat in the form of a box, and encloses the work, is very essential, as it enables the guide bushings to be placed on all sides and also
makes it comparatively easy to locate and securely clamp the part in the proper position for drilling. This type of jig, which, because of its form, is known as a closed or "box jig," is used very extensively.

A box jig of simple design is shown in Fig. 2. This particular jig is used for drilling four small holes in a part (not shown) which is located with reference to the guide bushings B by a central pin A attached to the jig body. This pin enters a hole in the work, which is finished in another machine in connection
with a previous operation. After the work is inserted in the jig, it is clamped by closing the cover C, which is hinged at one end and has a cam-shaped clamping latch D at the other, that engages a pin E in the jig body. The four holes are drilled by passing the drill through the guide bushings B in the cover.

Another jig of the same kind, but designed for drilling a hole having two diameters through the center of a steel ball, is shown in Fig. 3. The work, which is shown enlarged at A, is inserted while the cover is thrown back as indicated by the dotted lines. The cover is then closed and tightened by the cam-latch Z), and the large part of the hole is drilled with the jig in the position shown. The jig is then turned over and
a smaller drill of the correct size is fed through guide bushing B on the opposite side. The depth of the large hole could be gaged for each ball drilled, by feeding the drill spindle down to a certain position as shown by graduation or other marks, but if the spindle has an adjustable stop, this should be used. The
work is located in line with the two guide bushings by spherical seats formed in the jig body and in the upper bushing, as shown. As the work can be inserted and removed quickly, a large number of balls, which, practically speaking, are duplicates, can be drilled in a comparatively short time by using a jig of this type.

A box jig that differs somewhat in construction from the design just referred to is illustrated at A in Fig. 4, which shows a side and top view. The work, in this case, is a small casting the form of which is indicated by the heavy dot-and-dash lines. This casting is drilled at a, b, and c, and the two larger holes a
and b are finished by reaming. The hinged cover of this jig is opened for inserting the work by unscrewing the T-shaped clamping screw s one-quarter of a turn, which brings the head in line with a slot in the cover. The casting is clamped by tightening this screw, which forces an adjustable screw bushing g down against the work. By having this bushing adjustable, it can be set to give the right pressure, and, if the height of the castings should vary, the position of the clamping bushing could
easily be changed.

The work is properly located by the inner ends of the three guide bushings ai, bi, and ci, and also by the locating screws I against which the casting is held by knurled thumb-screws m and n. When the holes a and b are being drilled, the jig is placed with the cover side down, as shown at A in Fig. 5, and the drill is guided by removable bushings, one of which is shown at r. When the drilling is completed, the drill bushings are replaced by reamer bushings and each hole is finished by reaming. The small hole c, Fig. 4, is drilled in the end of the casting by simply placing the jig on end as shown at B, Fig. 5. Box jigs which have to be placed in more than one position for drilling the different holes are usually provided with feet or extensions, as shown, which are accurately finished to align the guide bushings properly with the drill. These feet extend beyond any clamping screws, bolts, or bushings which may protrude from the sides of the jigs, and provide a solid support. When inserting work in a jig, care should be taken to remove all chips which might have fallen upon those surfaces against which the work is clamped and which determine its location.

Still another jig of the box type, which is quite similar to the one shown at A, Fig. 4, but is arranged differently, owing to the shape of the work and location of the holes, is shown at B in the same illustration. The work has three holes in the base h, and a hole at i which is at an angle of 5 degrees
with the base. The three holes are drilled with the jig standing on the opposite end y, and the angular hole is drilled while the jig rests on the four feet k, the ends of which are at such an angle with the jig body that the guide bushing for hole i is properly aligned with the drill. The casting is located in this jig
by the inner ends of the two guide bushings w and the bushing o and also by two locating screws p and a side locating screw q. Adjustable screws t and t\ in the cover hold the casting down, and it is held laterally by the two knurled thumb-screws u and v. If an attempt were made to drill this particular part
without a jig (as would be done if only a few castings were needed) it would have to be set with considerable care, provided the angle between hole i and those in the base had to be at all accurate, and it would be rather difficult to drill a number of these castings and have them all duplicates. By the use of
a jig, however, designed for drilling this particular casting, the relative positions of the holes in any number of parts are practically the same and the work can be done much more quickly than would be possible if it were held to the drill-press table by ordinary clamping appliances. Various designs of jigs
will be described in Chapter VII.

Details of Jig Design. The general principles of the design and use of jigs have been explained. The details of jig design will now be considered. Generally speaking, the most important parts of a jig are the guide bushings for the drills and other tools, the clamping devices, and the locating points, against which the work is placed to insure an accurate position in the jig. The guides for the cutting tools in a drill jig
take the form of concentric steel bushings, which are placed in the jig body in proper positions.

The drill bushings are generally made of tool steel, hardened and lapped, and, where convenient, should be ground inside and out. They should also be long enough to support the drill on each side regardless of the fluting, and they should be  so located that the lower end of the bushings will stop about the same distance above the work as the diameter of the drill, so that chips will clear the bushings readily. Where holes are drilled on the side of a convex or a concave surface, the end of the bushing must be cut on a bevel and come closer to the part being drilled, to insure the drill having adequate support while starting into the work. The bushings should have heads of sufficient diameter. Long bushings should be relieved by in-creasing the hole diameter at the upper end. The lower end of the bushing should have its edges rounded, in order to permit some of the chips being shed from the drill easily, instead of all of them being forced up through the bushing. It is also good practice to cut a groove under the head for clearance for the wheel when grinding the bushing on the outside. A complete treatise covering dimensions and design is given in the chapter on "Jig Bushings."

In order to hold the work rigidly in the jig, so that it may be held against the locating points while the cutting tools operate upon the work, jigs and fixtures are provided with clamping devices. Sometimes a clamping device serves the purpose of holding the jig to the work, in a case where the work is a very large piece and the jig is attached to the work in some suitable way. The purpose of the clamping device,
however, remains the same, namely, that of preventing any shifting of the guiding bushings while the operation on the work is performed. The clamping device should always be an integral part of the jig body in order to prevent its getting lost. Different types of clamping devices are shown and described
in the chapter on "Jig Clamping Devices. "

The locating points may consist of screws, pins, finished pads, bosses, ends of bushings, seats, or lugs cast solid with the jig body, etc. The various types used are described in detail in the chapter on "Locating Points and Adjustable Stops."

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More resources
http://nptel.iitk.ac.in/courses/Webcourse-contents/IIT%20Kharagpur/Manuf%20Proc%20II/pdf/LM-33.pdf

http://www.brighthubengineering.com/machine-design/47195-the-3-2-1-principle-of-jig-fixture-design/

Ud. 26.3.2022,  30.1.2022
Pub 17.11.2013

Friday, March 25, 2022

Seven Wastes Model of Taiichi Ohno and Flow Process Chart - Industrial Engineering

Waste Elimination is part of industrial engineering since the discipline began. Waste elimination is part of productivity improvement. Productivity of inputs will increase when their waste is eliminated.

Taiichi Ohno in Toyota Industrial Engineering practice, has identified certain types of waste for particular attention and doubled the productivity of Toyota in comparison to US companies of that day. Thus best practices of tackling these 7 wastes were developed in the Toyota Motors. Shigeo Shingo of JMA was a teacher and consultant to Toyota in this endeavor.

In strategic management text of Thompson and Strickland, best practices implementation in value chain activities is an important step in strategy execution process. Companies world over are trying implement waste elimination practices developed in Toyota in their companies.

Seven Wastes - Taiichi Ohno - page 19 - Toyota Production System


   Waste                          -                   Methods to prevent it.

Waste of overproduction - One cannot produce without a production Kanban. Managing demand 
                                           variability. Reducing time between order receipt and starting of production.

Waste of time on hand (waiting)  - Multiple machines to an operator, all producing as per tact time.

Waste in transportation - Machines in line or flow placed close together

Waste of processing itself - Standardized Methods (plan the process well - process planning)

Waste of stock on hand (inventories) - JIT system - low inventory - SMED - Poka-Yoke

Waste of movement (of workers) - Machine layout changes so that an operator handling multiple machines does not waste movement. Can there be control unit for all the machines at one place only?

Waste of making defective products - Problem solving approach to produce zero defects. 5 Why approach to find where the problem or defect occurred in the earliest stage. Educating and training operators by other team members and management.



Seven Waste Model is also expressed as TIMWOOD

T – Transport – Movement of material, people
I – Inventory – Stock of materials, parts, and finished items
M – Motion – movement of hands and other body parts in operating machines of hand tools
W – Waiting – Men and machines waiting for parts or instructions
O – Over production – Making more than is IMMEDIATELY required
O – Over processing – Tighter tolerances or higher grade materials than are necessary
D – Defects – Items scrapped and rework


Compare the seven waste model with flow process chart


Flow process chart recommends recording and examining 5 items.

Process -   will examine  1.Waste of processing itself,  2. Waste of overproduction

Inspection -  3. Waste of making defective products  - The inspection is only shown as a stage in flow process chart, It needs to be augmented with a record of defects or defectives found during inspection.

Transport - 4. Waste in transportation, 5. Waste of movement (of workers)

Temporary delay - 6. Waste of time on hand (waiting)

Permanent storage - 7. Waste of stock on hand (inventories)

Thus we can see, flow process charts has provided the foundation for analyzing the seven wastes proposed by Taiichi Ohno.

But subsequent persons have indicated Eighth Waste.

Wastage of physical and mental skills of people.

Alan Mogensen identfied this gap in industrial engineering theory and introduced work simplication workshops to involve operators and supervisors in productivity improvement. Subsequently, suggestions scheme became popular. Japanese managers brought more improvements and made operators given large number of suggestions and provided forums for participation.

Please think over this statement of Taylor.

Respect for People - F.W.Taylor -  The Principles of Scientific Management.
Under scientific management the "initiative" of the workmen (their ingenuity) is obtained ...  to a greater extent than is possible under the old system; and in addition to this improvement on the part of the men, the managers assume ... new duties. 



Narayana Rao proposed Ninth waste.

9th Waste - Wastage of Machine Potential, Capability and Power - Wasting Machine's Potential Productivity

Industrial engineering has ignored wastage of potential of machines and equipment even though Taylor has advocated right from his piece rate system paper that for productivity improvement both machine and man are to be analyzed and improved.

Wastage of potential of the machine is recognized in the OEE calculation. Still IEs are yet to develop the area.

9th Waste - Wasting Machine's Potential Productivity -- Elimination - Essential Industrial Engineering Activity


Bibliography

Seven Wastes
http://accountability.wa.gov/leadership/lean/documents/2012_Lean_Conference/Thinking_Tools_Techniques/24/The%207%20Wastes.pdf

Seven Wastes Tool
http://www.gcu.ac.uk/media/gcalwebv2/theuniversity/supportservices/pace/documents/Seven%20Wastes.pdf

Lean for Government: Eliminating the seven wastes
http://ntrs.nasa.gov/search.jsp?R=20120016881

Lean in Government
http://www.epa.gov/lean/government/

Seven Wastes in Preventive Maintenanee Programs
http://www.techcorr.com/news/Articles/Article.cfm?ID=2450


Updated 25.3.2022, 18.10.2021, 23 August 2017, 15 November 2013