Blog posts for the 2023 Challenge
Date
April Post
This year posted all posts as per schedule.
Sunday, April 30, 2023
Warehouse Robots Implementation Issues
Modeling Warehouse Picking Bots Implementation Costs
https://designed-analytics.com/2023/04/29/modeling-warehouse-picking-bots-implementation-costs/
Paint Company Processes
One of the world's largest DCS and MES projects for integrated paint manufacturing process
Integrated plant automation system for Asian Paints increases reliability, ultimately resulting in savings, better material usage and reduced losses
Khandala plant Asian Paints
https://new.abb.com/cpm/industry-specific-solutions/consumer-fine-chemicals/one-of-world-s-largest-dcs-and-mes-projects-for-integrated-paint-process
Lid Destacker
_________________
https://www.youtube.com/watch?v=VaiNMqiAg4w
_________________
ABB Paints, coatings and resins manufacturing solutions
Design, installation and commissioning of complete automated units for the formulation and manufacturing of coatings, paints, varnishes and resins.
https://new.abb.com/chemical/chemical/fine-speciality-consumer-chemicals/paints-inks-pigments
BERGER PAINTS FACTORY VIDEO
4 Sep 2014
https://www.youtube.com/watch?v=I7XyecrHTyo
Distemper, Paint, Adhesive, Chemical automatic filling and packing machines - iFill Technology
21 Sep 2016
https://www.youtube.com/watch?v=tmO9ZyO4lZ8
ASRS
https://www.cio.com/article/3450198/asian-paints-blends-it-right-with-robotics.html
Sep 2020
https://cio.economictimes.indiatimes.com/news/strategy-and-management/how-asian-paints-is-adapting-its-supply-chain-to-beat-covid-blues/77902850
https://www.sap-digital-business-services.com/reference/asian-paints-ltd/ Asian Paints Case Study
Material dispensing process
https://docs.oracle.com/cd/E26401_01/doc.122/e49057/T465565T465572.htm
EP0915401A2
European Patent Office
Computerized virtual paint manufacturing and application system
Abstract
A computer-implemented apparatus and method for coordinating paint-related process steps of at least one paint-related facility. The paint-related process steps exhibit paint-related characteristics. A data acquisition module is provided for acquiring paint characteristic data indicative of the paint-related characteristics. A paint process control data structure is provided for interrelating the acquired paint characteristic data with at least two of the paint-related process steps to produce interrelated paint process control data. A paint process control coordinator is connected to the data acquisition module for storing the acquired paint characteristic data in the paint process control data structure. A data display is connected to the paint process control data structure for remotely receiving and viewing the interrelated paint process control data.
1998-11-10
Application filed by BASF Corp
2018-11-10
Anticipated expiration
Status
Expired - Lifetime
https://patents.google.com/patent/EP0915401A2/en
Productivity and IE in Paint, Coating, and Adhesive Manufacturing
An Application of Lean Manufacturing Techniques in Paint Manufacturing Company -A Case Study
Integrated IT solution for the manufacturers of paints and coatings
Digital Twin in Paint Manufacturing
Productivity Through Innovation - Dacrylate Paints Ltd
https://www.ntu.ac.uk/business-and-employers/case-studies/dacrylate-paints-ltd-case-study
DACRYLATE USES HIGH PERFORMANCE SPRAY SOFTWARE.
Many high-performance coatings require higher pressures to atomise. In many cases equipment is pushed to the limit and may need re-configuring to achieve the higher atomising pressures. Spraytrain.com is an independent training provider for spray equipment operators and coating manufacturer’s technical and sales staff. The training covered all aspects of airless spray applications including: –
Controlling coating film thickness
Health and safety information
Optimisation of equipment settings
Introduction to the latest spray equipment software
The new software provided by Spraytrain.com enables computer simulation of spray applications. This enables Dacrylate to specify and design equipment formulation from their office. Dacrylate are the first paint company in the UK to employ this software.
The Most Optimum Filtration Machines for Accurate Gradation of your Paints & Coating
Before 26 January 2014
ABB paint industry solutions for optimization
Using its process expertise and experience in paint and coating production, ABB has
developed innovative and optimized solutions to each specific constraint encountered
in paint production phases: dispersing, grinding, tinting, filtration, cleaning, transfer,
pigging system, powder handling, pneumatic transfer, control system, scheduling.
http://www05.abb.com/global/scot/scot267.nsf/veritydisplay/46dd1794c10945c885256fdb0075d345/$file/paint_coatings_final.pdf
Energy Conservation for a Paint Company Using Lean Manufacturing Technique
Sobia Shahid1,*, Sibi Chacko1 , C M Shukla2
1 School of Engineering and Physical Sciences Faculty, Heriot Watt University Dubai Campus, 294345, Dubai, United Arab Emirates 2 Quality Control Manager, Jotun Paints, 3671, Dubai, United Arab Emirates
http://www.hrpub.org/download/201310/ujibm.2013.010302.pdf
Improving accurarcy of paint delivery
In the beginning of 2006, Nippon Paint started to make some simple changes by implementing an Intermec barcoding system to its operations in Singapore, with the support from Intermec’s partner MuRho. Nippon Paint’s goal was to improve the accuracy of paint delivery, while reducing administrative work.
Using Intermec’s MobileLAN WA22 wireless LAN access point, with Intermec 730 and Intermec 730 i-Safe handheld mobile computers, Nippon Paint redesigned the 5-stage work process with the use of technology; manufacturing, item movement from production to logistics, stock-taking, selection and loading.
The process is now barcoded and automatically integrated from where packing begins, and ending when the goods leave the factory premises.
The system has increased the worker’s efficiency and improved the productivity of the company. The system also reduces time required to train new staff, and ensures more consistent work processes regardless of staff experience. With the success of this system, Nippon Paint may propagate this to other facilities in the future.
http://www.intermec.dk/learning/content_library/case_studies/csNipponPaint.aspx
OPTIMUM MAINTENANCE STRATEGY FOR PAINT MANUFACTURING INDUSTRIES, A CASE STUDY
Godwin, Harold Chukwuemeka and Achara, Okechukwu Michael
http://www.technicaljournalsonline.com/ijeat/VOL%20IV/IJAET%20VOL%20IV%20ISSUE%20IV%20%20OCTBER%20DECEMBER%202013/Vol%20IV%20Issue%20IV%20Article%205.pdf
ABB paint industry solutions for optimization
Using its process expertise and experience in paint and coating production, ABB has
developed innovative and optimized solutions to each specific constraint encountered
in paint production phases: dispersing, grinding, tinting, filtration, cleaning, transfer,
pigging system, powder handling, pneumatic transfer, control system, scheduling.
http://www05.abb.com/global/scot/scot267.nsf/veritydisplay/46dd1794c10945c885256fdb0075d345/$file/paint_coatings_final.pdf
Energy Conservation for a Paint Company Using Lean Manufacturing Technique
Sobia Shahid1,*, Sibi Chacko1 , C M Shukla2
1 School of Engineering and Physical Sciences Faculty, Heriot Watt University Dubai Campus, 294345, Dubai, United Arab Emirates 2 Quality Control Manager, Jotun Paints, 3671, Dubai, United Arab Emirates
http://www.hrpub.org/download/201310/ujibm.2013.010302.pdf
Improving accurarcy of paint delivery
In the beginning of 2006, Nippon Paint started to make some simple changes by implementing an Intermec barcoding system to its operations in Singapore, with the support from Intermec’s partner MuRho. Nippon Paint’s goal was to improve the accuracy of paint delivery, while reducing administrative work.
Using Intermec’s MobileLAN WA22 wireless LAN access point, with Intermec 730 and Intermec 730 i-Safe handheld mobile computers, Nippon Paint redesigned the 5-stage work process with the use of technology; manufacturing, item movement from production to logistics, stock-taking, selection and loading.
The process is now barcoded and automatically integrated from where packing begins, and ending when the goods leave the factory premises.
The system has increased the worker’s efficiency and improved the productivity of the company. The system also reduces time required to train new staff, and ensures more consistent work processes regardless of staff experience. With the success of this system, Nippon Paint may propagate this to other facilities in the future.
http://www.intermec.dk/learning/content_library/case_studies/csNipponPaint.aspx
OPTIMUM MAINTENANCE STRATEGY FOR PAINT MANUFACTURING INDUSTRIES, A CASE STUDY
Godwin, Harold Chukwuemeka and Achara, Okechukwu Michael
http://www.technicaljournalsonline.com/ijeat/VOL%20IV/IJAET%20VOL%20IV%20ISSUE%20IV%20%20OCTBER%20DECEMBER%202013/Vol%20IV%20Issue%20IV%20Article%205.pdf
Updated on 30.4.2023, 15 October 2020
First published on 26 Jan 2014
Zenith of Industrial Engineering
Has industrial engineering reached its peak in the world economy?
IISE is celebrating 75 years of existence in this year. The topic is worth debating in IISE circles?
Are there IE departments in all Fortune 500 companies?
Industrial engineering departments are not reporting their achievements through the annual financial statements of their companies. They have to take courage and prepare annual reports of their department and ask their company management to make them public.
Part of
A to Z of Industrial Engineering - Principles, Methods, Techniques, Tools and Applications
https://nraoiekc.blogspot.com/2018/06/a-to-z-of-industrial-engineering.html
Saturday, April 29, 2023
ChatGPT for Industrial Engineering - LeanGPT™ - Kaizen Copilot - Your AI Partner for Industrial Engineering and Continuous Process Improvement
Happy. Now you have ChatGPT for Industrial Engineering. Your process improvement effort has now a machine assistant.
Visit https://retrocausal.ai/kaizen/ the machine assistant for industrial engineering.
You can ask for a Demo
Kaizen Copilot, the ChatGPT for Industrial Engineering leverages LeanGPT™ foundation models, shop-floor analytics, and secure knowledge base training to generate valuable documentation, analyses and ideas through a conversational interface.
Why Kaizen Copilot?
Do you have more Industrial Engineering (IE) projects than you have IE staff? Machine assistant is now available to reduce the load on current IEs and allow them to do more projects.
How well do you cross-pollinate knowledge gained at different facilities or different shifts? You can quickly make the new knowledge accessible for others.
After a Kaizen event, how quickly do you reanalyze the process and give feedback to the team?
Kaizen Copilot makes it easy. More IE projects, Quick Knowledge Transfer, Timely feedback,
What is Kaizen Copilot?
Industrial Engineers and Production Managers design, track, and optimize industrial processes by combining domain expertise, productivity science, productivity engineering and productivity management knowledge, organizational knowledge, and process improvement studies. The studies include tedious manual observations such as time studies, ergonomic assessments, and yield estimates from various resources.
Retrocausal AI trained a new kind of Generative AI foundation model called LeanGPT™, specialized for the manufacturing and industrial engineering domains.
Kaizen Copilot is a patent-pending assistive AI agent built on the LeanGPT model which gives it expert-level IE domain knowledge.
"We provide our customers the option to connect LeanGPT to their organizational knowledge bases in a secure and potentially even “on-premise” configuration. Further, Kaizen Copilot connects our computer vision and IoT-sensing platform to LeanGPT to minimize the need for manual measurements on the factory floor. We bake Lean Six Sigma workflows into Kaizen Copilot so that it can assist IEs in following widely accepted best practices."
What can Kaizen Copilot do?
1. Act as a virtual IE consultant for small sized manufacturers who cannot afford to hire one full-time.
2. Generate analyses such as FMEA, ISO-4501, Error-Proofing in seconds which typically take days and weeks to produce.
3. Simulate alternatives to your actual assembly line and calculate what may be achievable.
4. Identify commonalities in quality and line balancing problems amongst your factories which may appear unrelated at a first glance.
5. Assist your Industrial Engineers in the adoption of Lean Six Sigma and Toyota Production Systems best practices.
6. Maximize the value out of operator interactions on your Gemba walks.
7. Generate novel insights for productivity maximization by combining your organizational knowledge with all your digital factory data.
8. Run OEE and Pareto Analysis by combining data from ERP, MES, and manual reporting.
9. Facilitate compliance with regulatory standards by minimizing the time needed to generate relevant planning and audit documents.
How does it work?
You can think of Kaizen Copilot as “ChatGPT for Industrial Engineering”, with the following improvements:
Specialized for Manufacturing
Kaizen Copilot is built on our own Large Language Models called LeanGPT, much like ChatGPT is built on GPT-3. However, LeanGPT is specialized on manufacturing and industrial engineering texts as well as proprietary industrial Kaizen form datasets.
Talks to IoT Infrastructure
While ChatGPT is frozen in time, and unable to fetch data from external sources like the internet, LeanGPT is able to call external APIs specifically Pathfinder’s computer vision and IoT platform as well as an increasing number of third-party SCADA platforms to formulate its responses.
References Actual Documentation
In addition to (or in place of) training LeanGPT on your knowledge bases, you can also use it to search individual documents in these repositories. In this mode, you retrieve documents that correspond to specific queries, and then ask questions from these documents. As opposed to ChatGPT, this gives you specific documents that you can cite as sources of conclusions.
Built-in Lean Six Sigma Workflows
Kaizen Copilot gently nudges its users in the direction of Lean Six Sigma and Toyota Production Systems best practices by suggesting appropriate “Example Prompts”. Further, we have built in templates and tools that allow you to automatically fill out appropriate Lean Six Sigma and TPS-inspired worksheets e.g. Process Capability Sixpack Reports or OEE charts. You are able to refine these worksheets by conversing with LeanGPT and shuffling data around as needed.
Trains on Organizational Knowledge Bases
LeanGPT can be trained your knowledge bases including ERP, MES, QMS, and CI systems in a secure cloud or on-premise configuration. Training LeanGPT models allows it to simultaneously consider all your organizational knowledge (potentially including knowledge across factories) together with its own manufacturing domain expertise and shopfloor observations in formulating questions to your answers. This, by definition, is a super-human capability that allows it to discover new connections and arrive at novel insights and conclusions.
Excellence in Manufacturing - Survey Winners - American Machinist
Kennametal Inc. has again been named by American Machinist magazine as one of America's leading manufacturing technology companies in the 2000 Excellence in Manufacturing Technology Achievement Awards. Kennametal also received the award in 1998. The company's founder, Philip M. McKenna, also was posthumously inducted into the Hall of Innovators.
1998
Carr Lane Mfg. Co. — Workholding winner
Erwin Junker Machinery Inc. — Grinding Machines winner
Guhring Inc. — Cutting Tools, High Speed Steel winner
Haas Automation Inc. — Machining Centers winner
Hardinge Inc. — Turning Machines winner
HE&M Saw — Sawing & Cutoff
Komet of America Inc. — Cutting Tools, High Speed Steel winner
Manufacturing Data Systems Inc. (MDSI) — Manufacturing Software winner
Precision Twist Drill — Cutting Tools winner
http://americanmachinist.com/cutting-tools/1998-reader-selected-winners-excellence-manufacturing
Ud. 29.4.2023
Pub 15.11.2014
Best Machine Shop Surveys by American Machinist
Came across the survey of 2006
http://americanmachinist.com/beyond-cutting-zone/10-best-machine-shops
•Advance Turning & Manufacturing Inc.
•B&W Trailer Hitches
•Command Tooling Systems
•E.H. Wachs Company
•MKT Innovations
•Phinney Bay Machine Works
•PNM Company
•SPM Corp
•SOR Corp
•Turning Inc.
Turning Inc.
Number of employees 5
Sales $505,000
Quality is important. The key is in-process quality checking that does not add to a part's cycle time because it is done during cutting time. Even when the in-process checking does add to a part's cycle time, the amount is miniscule as compared with the time the customer would waste shipping back the part and operators reworking it.
Turning Inc. tries its best not to scrap even the first. For the first piece of a job, the machine offsets are adjusted out about 0.005 in. so the part won't come off undersize. Then the offsets are re-adjusted. This may add a little time to cutting the first part, but scrapping the part is eliminated in the set up job.
The shop also focuses on cycle time reduction and uses a lot of fixturing for holding multiple parts. Savings of even 5 percent make the shop competitive.
The owner says experience, skilled staff and latest manufacturing technology are essential to success and hence the shop is prepared to invest in latest technology. .
To add material
Ud. 29.4.2023
Pub. 6.11.2014
Productivity in Machine Shops - Industrial Engineering and Lean Thinking
332710 (US Industry Classification Number) - Productivity in Machine Shops
Productivity in Machine Shops - Articles
Productivity Science of Machining - Taylor to Current Times
Productivity Engineering of Machine Tools and Machining - F.W. Taylor - Part 1
https://nraoiekc.blogspot.com/2020/05/machine-work-study-machine-tool-metal.html
ChipChat: The Journey of a Part Through Manufacturing Excellence - Webinar
https://www.ellisontechnologies.com/news/chipchat-journey-part-through-manufacturing-excellence
RONSON GEARS – LEAN IN A MACHINE SHOP
https://txm.com/txm-lean-case-study-video-ronson-gears-lean-in-a-machine-shop/
Lean Manufacturing For Machine Shops With Collaborative Robots.
Lean Robotics Is The Evolution Of Lean Manufacturing For Machine Shops.
https://www.numaticengineering.com/lean-manufacturing-for-machine-shops-with-collaborative-robots/
5 Steps Toward A Lean CNC Shop
Posted on Fri, Sep 18, 2015
https://www.haasfactoryoutlet.com/about/local-news-and-events/5-steps-toward-a-lean-cnc-shop
Search machine shop lean
Sources for Information on Productivity Improvement News in Machine Shops
Adoptive feed control
An adaptive machining control system uses a sensor to measure the horsepower load on a spindle motor and adjusts the feed rate to achieve a continuous load.
Siemens - Adaptive Control & Monitoring (ACM) – for improved production results
Before 15 November 2014
2014
November 2014
The Liebherr LC 100 - 5 second cycle times
The Liebherr LC 100, introduced at AMB 2014 in September, is designed to machine small parts in mass production, including standard part for automatic gearbox applications, such as planetary and sun gears.
The machine enables achievement cycle times of approximately 5 seconds—just 20% of the time such a process usually takes.
http://americanmachinist.com/machining-cutting/every-second-counts-machining-small-precision-parts
Since its launch in 2013, Kennametal’ s NOVO advanced digital tool selector and process planner has been interfacing tool management, e-commerce, and other programs to capture accurate, timely tool knowledge for shops that need more and more actionable data. NOVO Version 1.3 is connecting via the cloud to tool management.
http://americanmachinist.com/imts-2014/turning-digital-tool-knowledge-real-productivity
2013
Controlling the Cost of Tooling
http://americanmachinist.com/shop-operations/controlling-cost-tooling
New HMCs for High-Productivity Medical Parts Production
Makino introduces two CNCs that achieve efficiency and accuracy, in a space-saving configuration
2013
http://americanmachinist.com/machining-cutting/new-hmcs-high-productivity-medical-parts-production
Precision, Productivity for Optical and Mechanical Parts
Multi-axis “ultra precision” machining for parts up to 1-m diameter
Nanoform® L 1000 was designed for “ultimate productivity and flexibility in diamond turning and deterministic microgrinding of optical lenses, mold inserts, mirrors, and precision mechanical components.”
http://americanmachinist.com/machining-cutting/precision-productivity-optical-and-mechanical-parts
Romi Expands Turning Series, Emphasizes Productivity
Romi GL 400 turning center, powered by a 30-hp motor and able to turn parts up to 400 mm diameter and 1,000 mm long. The GL turning center series was designed for medium- and high-volume production, with great efficiency and productivity.
Romi VTL 700MR vertical turning cente has a 46-hp motor, making it capable of plate turning parts up to 700 mm diameter. The VTL 700MR is capable of milling, drilling and tapping operations, too, improving its contribution to shop productivity.
http://americanmachinist.com/machining-cutting/romi-expands-turning-series-emphasizes-productivity
High-Efficiency, High-Productivity Multi-Sided Machining
Okuma introduces new five-axis vertical machining center
The MU-6300V was recognized by the Japanese business and technology daily Nikkan Kogyo Shimbun as one of 2012’s ten best new products.
http://americanmachinist.com/machining-cutting/high-efficiency-high-productivity-multi-sided-machining
5 Ways To Reduce The Cost Of Machining Unleaded Brass
If you are engaged in machining brass parts that will be used to deliver potable water, now you have to machine these parts from no-lead brass. It is expected that in the near future lead will no longer be used in any ferrous or non-ferrous alloys. CNC machine shops face new challenges in switching to unleaded material and have to plan for low cost machining of unleaded brass.
http://info.gosiger.com/news/bid/177891/5-Ways-to-Reduce-the-Cost-of-Machining-Unleaded-Brass
2012
Seco Tools boosts efficiency with tools providing faster cutting speeds and increased tool life.
http://americanmachinist.com/cutting-tools/imts-2012-increasing-productivity-innovative-metal-cutting
2010
Hydraulic Expansion Toolholders Need No Intermediate Sleeves
Redesigned Schunk series is even more universal, with torque transmission capacity increased up to 15%.
http://americanmachinist.com/cutting-tools/hydraulic-expansion-toolholders-need-no-intermediate-sleeves
10 Best Machine Shops - 2006
http://americanmachinist.com/beyond-cutting-zone/10-best-machine-shops
2004
Grinding wheel productivity
Vitrified bonds increase productivity
http://www.thefreelibrary.com/Vitrified+bonds+boost+CBN+wheel+productivity%3A+auto,+aero+quality...-a0119115025
ACM monitors the current cutting conditions in real-time and automatically adjusts the feed rate to the optimal level. When overload is detected, ACM reduces the feed and triggers an alarm to stop the machine. The real-time approach increases productivity, as well as the life of machines and tools and ensures a safer production process.
Heard above the adoptive feed control through a presentation by CNH team on 15 October 2020 in CII event on Digitalization, Robotics and Automation.
Machine Shop Cost Reduction News
2022 - 2021 - 2020 - 2019 - 2018 - 2017 - 2016 - 2015 - Up to 2014
2023
Sustainable manufacturing
The National Council for Advanced Manufacturing USA (NACFAM) defines sustainable manufacturing as creating products using non-polluting processes that also conserve energy and natural resources.
Here are five sustainable practices that increase productivity also in the manufacturing process.
NUMROTO is a comprehensive software package for producing and resharpening a wide range of tools.
It has never been so easy to manufacture and resharpen high-quality tools. If you...
machine a wide range of tools
are looking for the most economic and functional solution
and want the maximum performance thanks to professional user oriented support...
then talk to us. Be innovative and stay ahead of the competition to guarantee future success in tool grinding.
Case Study - Use of NUMROTO
Before 15 November 2014
2014
November 2014
The Liebherr LC 100 - 5 second cycle times
The Liebherr LC 100, introduced at AMB 2014 in September, is designed to machine small parts in mass production, including standard part for automatic gearbox applications, such as planetary and sun gears.
The machine enables achievement cycle times of approximately 5 seconds—just 20% of the time such a process usually takes.
http://americanmachinist.com/machining-cutting/every-second-counts-machining-small-precision-parts
Since its launch in 2013, Kennametal’ s NOVO advanced digital tool selector and process planner has been interfacing tool management, e-commerce, and other programs to capture accurate, timely tool knowledge for shops that need more and more actionable data. NOVO Version 1.3 is connecting via the cloud to tool management.
http://americanmachinist.com/imts-2014/turning-digital-tool-knowledge-real-productivity
2013
Controlling the Cost of Tooling
http://americanmachinist.com/shop-operations/controlling-cost-tooling
New HMCs for High-Productivity Medical Parts Production
Makino introduces two CNCs that achieve efficiency and accuracy, in a space-saving configuration
2013
http://americanmachinist.com/machining-cutting/new-hmcs-high-productivity-medical-parts-production
Precision, Productivity for Optical and Mechanical Parts
Multi-axis “ultra precision” machining for parts up to 1-m diameter
Nanoform® L 1000 was designed for “ultimate productivity and flexibility in diamond turning and deterministic microgrinding of optical lenses, mold inserts, mirrors, and precision mechanical components.”
http://americanmachinist.com/machining-cutting/precision-productivity-optical-and-mechanical-parts
Romi Expands Turning Series, Emphasizes Productivity
Romi GL 400 turning center, powered by a 30-hp motor and able to turn parts up to 400 mm diameter and 1,000 mm long. The GL turning center series was designed for medium- and high-volume production, with great efficiency and productivity.
Romi VTL 700MR vertical turning cente has a 46-hp motor, making it capable of plate turning parts up to 700 mm diameter. The VTL 700MR is capable of milling, drilling and tapping operations, too, improving its contribution to shop productivity.
http://americanmachinist.com/machining-cutting/romi-expands-turning-series-emphasizes-productivity
High-Efficiency, High-Productivity Multi-Sided Machining
Okuma introduces new five-axis vertical machining center
The MU-6300V was recognized by the Japanese business and technology daily Nikkan Kogyo Shimbun as one of 2012’s ten best new products.
http://americanmachinist.com/machining-cutting/high-efficiency-high-productivity-multi-sided-machining
5 Ways To Reduce The Cost Of Machining Unleaded Brass
If you are engaged in machining brass parts that will be used to deliver potable water, now you have to machine these parts from no-lead brass. It is expected that in the near future lead will no longer be used in any ferrous or non-ferrous alloys. CNC machine shops face new challenges in switching to unleaded material and have to plan for low cost machining of unleaded brass.
http://info.gosiger.com/news/bid/177891/5-Ways-to-Reduce-the-Cost-of-Machining-Unleaded-Brass
2012
Seco Tools boosts efficiency with tools providing faster cutting speeds and increased tool life.
http://americanmachinist.com/cutting-tools/imts-2012-increasing-productivity-innovative-metal-cutting
2010
Hydraulic Expansion Toolholders Need No Intermediate Sleeves
Redesigned Schunk series is even more universal, with torque transmission capacity increased up to 15%.
http://americanmachinist.com/cutting-tools/hydraulic-expansion-toolholders-need-no-intermediate-sleeves
10 Best Machine Shops - 2006
http://americanmachinist.com/beyond-cutting-zone/10-best-machine-shops
2004
Grinding wheel productivity
Vitrified bonds increase productivity
http://www.thefreelibrary.com/Vitrified+bonds+boost+CBN+wheel+productivity%3A+auto,+aero+quality...-a0119115025
Updated on 29.4.2023, 20.5.2022, 15 October 2020
First published 15 November 2014
Volkswagen - Industrial Engineering Activities and Jobs
New: Industrial Engineering ONLINE Course
Continuous Improvement Specialist (7006)
Productivity Science: Science developed for each element of machine operation and each element of human tasks in industry.
Productivity Science - Determinants of Productivity
Product Industrial Engineering: Redesign of products to reduce cost and increase value keeping the quality intact.
Product Industrial Engineering
Process Industrial Engineering: Redesign of processes to reduce cost and increase value keeping the quality intact.
Process Industrial Engineering
Industrial Engineering Statistics: Using statistical tools like data description, sampling and design of experiments in industrial engineering activity.
Statistics and Industrial Engineering
Industrial Engineering Economics: Economic analysis of industrial engineering projects.
Engineering Economics is an Efficiency Improvement Tool for Industrial Engineers
Human Effort Industrial Engineering: Redesign of products and processes to increase satisfaction and reduce discomfort and other negative consequence to operators.
Motion Study - Human Effort Industrial Engineering
Productivity Measurement: Various measurements done by industrial engineers in industrial setting to collect data, analyze data and use the insights in redesign: Product Industrial Engineering and Process Industrial Engineering.
Industrial Engineering Data and Measurements
Productivity Management: Management undertaken by industrial engineers to implement Product Industrial Engineering and Process Industrial Engineering. Management processes industrial engineering is also part of productivity management.
Productivity Management
New
Continuous Improvement Specialist (7006)
Date: Apr 6, 2023
Location: Chattanooga, TN, US, 37146
Company: Volkswagen Group of America, Inc.
Visit and Apply
The Volkswagen Group is one of the world's largest producers of passenger cars and Europe's largest automaker and is on the road to number one. Come join our team and you could be part of that ride. For our employees, Volkswagen stands for more than just efficient and sustainable products - it’s an expression of who they are and how they move through life. Become a part of the Volkswagen of America experience and work with people who are passionate, innovative, enthusiastic, and high performing team players. Everyone deserves a better car and everyone deserves a better company - it’s a Volkswagen thing.
VW. Two letters. Endless opportunities.
Summary
Key facilitator of change for complex, cross-functional initiatives. Set up and maintain innovative manufacturing processes, in close cooperation with manufacturing teams. Interface between production, planning, financial control and human resources. Supervise and support the activities in terms of standardization and optimization based on the principles of the VW-production system, in consultation with our production teams. Increase productivity and effectiveness, in order to reach the company goals and objectives. Ensure that all our operations follow the methods and processes of the Volkswagen Production System VPS.
Responsibilities
Identify and avoid waste within processes and operation to establish Lean Manufacturing.
Build and encourage continuous improvement culture.
Lead problem solving training and execution across the business units
Facilitate and lead 3P, Problem Solving, and CIP workshops.
Plan concepts and strategies for increasing efficiency and productivity.
Designing the relationship between people, product, machines and material flow in accordance with ergonomic principles and human factors
Analyze capital expenditures and project designs to identify means to cut cost
Integrate new technology and provide technical guidance to team members
Six Sigma problem-solving through continuous improvement projects, and events.
Major job duties will include leading, facilitating, and training teams with Lean Tools such as
Value Stream Mapping and Analysis
Kaizen Events
Lean 6σ Projects
Standard Work & Process Control
5S & Visual Work Place
Qualifications
Required
Bachelor’s Degree in Industrial Engineering, Operations Management, or equivalent work experience.
Certified in proven methodologies such as: LEAN/Six Sigma; Green Belt (or equivalent)
5 years minimum relevant work experience.
Automotive manufacturing experience and experience of innovative methods of working organization and production systems in an automotive manufacturing, lean thinking
Preferred
Master’s Degree in Industrial Engineering, Operations Management, or equivalent work experience.
Certified in LEAN/Six Sigma Black Belt (or equivalent)
7-10 years relevant work experience.
Visit and Apply
Industrial Engineering - Productivity Improvement - Process Improvement - Product Redesign - Continuous Improvement
Industrial engineering is improvement in various elements of engineering operations to increase productivity. Along with engineering elements, industrial engineers evaluate and improve many other elements also as they are responsible for productivity and cost of items produced in a process. Through assignments of improving productivity and efficiency of information technology and software engineering processes, industrial engineers specializing in IT were given responsibility for business processes also. Thus industrial engineers with focus on various branches of engineering provide their services to companies and society to improve various elements of the products and processes on a continuous basis over the product life cycle. They are active in engineering or production-maintenance-service-logistic processes and business processes.
Productivity improvement always focuses on quality and flexibility issues as productivity improvement should not lead to any deterioration in quality or flexibility. Delivery and cost are always at the core of industrial engineering. Thus when QFCD paradigm came, that is attention to quality, flexibility, cost and delivery became prominent, many industrial engineers were given the responsibility of managing this function of continuous improvement.
______________
______________
______________
Focus Areas of Industrial Engineering - Brief Explanation
Productivity Science: Science developed for each element of machine operation and each element of human tasks in industry.
Productivity Science - Determinants of Productivity
Product Industrial Engineering: Redesign of products to reduce cost and increase value keeping the quality intact.
Product Industrial Engineering
Process Industrial Engineering: Redesign of processes to reduce cost and increase value keeping the quality intact.
Process Industrial Engineering
Industrial Engineering Optimization: Optimizing industrial engineering solutions created in Product Industrial Engineering and Process Industrial Engineering.
Operations Research - An Efficiency Improvement Tool for Industrial Engineers
Operations Research - An Efficiency Improvement Tool for Industrial Engineers
Industrial Engineering Statistics: Using statistical tools like data description, sampling and design of experiments in industrial engineering activity.
Statistics and Industrial Engineering
Industrial Engineering Economics: Economic analysis of industrial engineering projects.
Engineering Economics is an Efficiency Improvement Tool for Industrial Engineers
Human Effort Industrial Engineering: Redesign of products and processes to increase satisfaction and reduce discomfort and other negative consequence to operators.
Motion Study - Human Effort Industrial Engineering
Productivity Measurement: Various measurements done by industrial engineers in industrial setting to collect data, analyze data and use the insights in redesign: Product Industrial Engineering and Process Industrial Engineering.
Industrial Engineering Data and Measurements
Productivity Management: Management undertaken by industrial engineers to implement Product Industrial Engineering and Process Industrial Engineering. Management processes industrial engineering is also part of productivity management.
Productivity Management
Applied Industrial Engineering: Application of industrial engineering in new technologies, existing technologies, engineering business and industrial processes and other areas.
Applied Industrial Engineering - Process Steps
How many Industrial Engineers can a Company Employ for Cost Reduction?
For $100 million cost, there can be one MS IE and 6 BSIEs.
https://nraoiekc.blogspot.com/2020/03/value-creation-model-for-industrial.html
Industrial Engineering - Lean Manufacturing - Parent - Child Relationship
Volkswagen is putting sweeping measures into place as it pursues greater productivity and efficiency in production. The goal: 30 percent higher productivity worldwide by 2025. The main plant in Wolfsburg and heart of the brand is to set a new benchmark.
https://www.volkswagenag.com/en/news/stories/2019/02/productivity-and-efficiency-at-volkswagen-production.html
Effective March 1, 2020, Dr. Arno Antlitz, becomes the Board member responsible for Finance at Audi.
Dr. Arno Antlitz (49) holds a doctorate in industrial engineering and has been the member of the Board of Management of Volkswagen Passenger Cars responsible for Controlling and Accounting since 2010. As a Board of Management member, he has also held responsibility for the North America Region since 2018. He began his career in 1999 at the management consulting firm McKinsey&Company. His main areas of expertise included strategy, organization and cost optimization in the automotive and component supplier industry. Having moved to Volkswagen in 2004, he was given responsibility for global product controlling at the Volkswagen brand in 2005.
https://www.volkswagen-newsroom.com/en/press-releases/personnel-changes-in-the-brand-board-of-management-5605
March 31st, 2020
Wolfgang Maluche came to Volkswagen's Chattanooga operations from Germany.
After serving as a technical project manager at the Volkswagen Engineering and Planning Center adjacent to the automaker's Chattanooga production plant, he was named vice president of engineering and heads the facility.
He studied industrial engineering at Texas A&M, where he obtained a master's degree.
https://www.timesfreepress.com/news/edge/story/2020/mar/31/vw-chattanoogpost-offers-international-experi/519371/
NOVEMBER 18, 2019
https://www.reuters.com/article/us-volkswagen-electric/vw-ceo-says-new-id-3-car-40-cheaper-to-build-than-electric-golf-idUSKBN1XS1BN
SEPTEMBER 13, 2019
“The product experience needs to be right. But you need to keep an eye on cost. You cannot run the business by focusing only on product,” CEO Herbert Diess told Reuters.
https://www.reuters.com/article/us-autoshow-frankfurt-volkswagen-electri/vw-ceo-shifts-strategy-from-empire-building-to-efficiency-idUSKCN1VY21G
Skoda wins award for dProduction - Digitalization project
https://www.volkswagenag.com/en/news/2019/07/Automotive_Lean_Production_Award.html
July 2nd, 2019
Hartmut Rickel becomes Spokesperson for the Management Board at Volkswagen Group Services GmbH.
Hartmut Rickel holds a degree in industrial engineering and has been with the Volkswagen Group for 28 years. Following several positions in Controlling at Volkswagen in Wolfsburg and in Controlling at Å KODA, he assumed responsibility for sales steering at the Volkswagen brand in 2009. Rickel joined the Management Board of Volkswagen Group Services GmbH in December 2017.
https://www.automotiveworld.com/news-releases/volkswagen-comprehensive-changes-at-human-resources/
This job is no longer accepting applications
Role Summary
The Value Engineering Associate is responsible for supporting the analysis of production parts and drawings, and provide a ‘bottom-up’, ‘clean sheet’, or ‘should be’ calculation of what the part and the related tooling & equipment cost is based on current and future market material, production, labor, profits and overhead to achieve the target project profitability for all NAR VW Brand vehicle models through the concept of “Design follows target.”
This position will report to the Director or Manager of Value Engineering and will be a member of Value Engineering NAR team which support the execution of and realizing the VW Brand’s mission of creating and selling exciting products suited and tailored for the NAR markets (USA, Mexico and Canada) profitably.
This will require effectively executing the Value Engineering Processes within the Region and build consensus to obtain buy-in from key stakeholders in Engineering, Purchasing, Quality, Production, Sales, Strategy, and Baureihen.
Role Responsibilities
Operational - 50%
Contribute to annual Business Plan for Analyzed Turnover for Piece Price and Tooling Investment Calculations.
Support the preparation of material piece price, Tooling Investment, and/or pre-logistics cost calculations for ‘Heavy Items’ in Forward Sourcing, on an ad-hoc basis, or per the Business Plan for various commodities.
Perform cost calculations based on best practices
Maintain updated cost analysis results in VW Group Systems.
Analyze drawings and other documentation to prepare time, cost, materials, and labor estimates for parts and assemblies
Consult with other Cost Calculators and internal departments to formulate estimates, resolve issues and changes or updates to cost calculation
Cost Reduction Management - 40%
Participate in the optimization of car lines to ensure appropriate content to maximize financial return.
Participate in the benchmarking of competitor products and specifications through teardown of complete vehicles, modules and systems or component parts for cost optimization for G3 & G4 products
Generate cost reductions ideas from competitor analysis, workshop participation, supplier discussions etc.
Systems & Process Optimization- 5%
Ensure that VW NAR performance requirements conform to the market
Analyze and monitor Global macro-economic, geo-political, and unforeseen events that influence material cost. Understand future safety, regulatory and Co2 requirements.
Analyze localization and deep localization rate of assigned parts. Support commodity purchasing strategies to increase localization and deep localization rate.
Innovation and Technology - 5%
Visit supplier production facilities and identify areas for supplier productivity enhancements to decrease material costs. Implement waste avoidance best practices Identify and provide purchasing with information to negotiate with suppliers.
Perform market intelligence, obtain consumer insights, and identify product innovation in order to influence and contribute to “Product Strategy” in the early stages of PEP. (Milestone PS-PM)
Primary Location
United States-Tennessee-Chattanooga
0 - 2 years of professional experience with an Automotive OEM or Tier 1 in the areas cost or value engineering, production or manufacturing engineering, component design and development or similar area of expertise.
BS Degree in Mechanical, Industrial, or Manufacturing Engineering.Or a BS in Business Finance, Accounting or Economics
Skills
Automotive manufacturing background and/or development engineering background
Strategic and conceptual thinking capabilities, with a view of the “big picture” and a vision of future products and mobility solutions
Analytical thinking using reasoning and logic
Interpersonal and communication skills
Persuasion, influencing and negotiation skills
Computer savvy – skilled in the use of (MS-Applications, TcPCM, Technical Drawings, CATIA, and SAP)
Problem solving – critical and complex
Skills Required
Fundamental knowledge of manufacturing processes of components and/or subsystems within the automotive industry
Understanding of manufacturing processes in at least one of the following production segments:
Interior/Exterior: injection molding, blow molding, extrusion, paint, chrome, etc.
Metals: stamping and welding, casting, forging, etc.
Electric: Injection Molding, Harnesses, PCB, Batteries, etc.
Working knowledge of and ability to read drawings, CAD data, blueprints, material data sheets
Ability to evaluate supplier quotations, cost breakdown worksheets, and tooling investment details
Interpersonal skills requiring the ability to work effectively in a team
Understanding of the automotive competitor landscape, evolving technologies and business models.
Understanding of materials and manufacturing processes of automotive parts.
Ability to make presentation using PowerPoint, Think Cell, Excel, Word, Visio, etc
https://www.linkedin.com/jobs/view/value-engineering-associate-at-volkswagen-of-america-inc-1780413332/
Next target is €325,000 in sa vings.
https://3dgbire.pro/case-studies/volkswagen/
Work. 2012;41 Suppl 1:4413-7. doi: 10.3233/WOR-2012-0739-4413.
Global ergonomics strategy in Volkswagen: from the product construction, over the planning until the serial process.
Toledo B1.
Author information
1
Industrial Engineering and Optimization of Indirect Areas, Volkswagen Group, Berliner Ring 2, Wolfsburg, Germany. begonia.toledo @ volkswagen.de
This topic is established in the industrial engineering of the production area of the group. We are working interdisciplinary with the medical services, human resources, work council and the protection of labor.
https://www.ncbi.nlm.nih.gov/pubmed/22317398
Work. 2012;41 Suppl 1:4418-21. doi: 10.3233/WOR-2012-1040-4418.
Ergonomics at Volkswagen Brasil. Multidisciplinary work to equalize health, productivity and quality.
Filus R (1), Wruca R, Charleaux V, Ortega A, Ferreira C, Jesus L, Stramari A, Neufel M, Maia U.
Author information 1 Corporate Ergonomics Sector coordinator - Volkswagen do Brasil. rodrigo.filus @ volkswagen.com.br
Abstract
Volkswagen Brazil ergonomists are concerned with the ergonomic efficiency of management applied to various levels of life of a product, since its creation to its final implementation on production lines.The preventive work of ergonomists during the processes leading to production of a vehicle is accomplished through assessments on a simulated system called the Digital Factory. Since the initial stages to final product delivery there is a need for a multidisciplinary aligning the concepts of ergonomics, productivity and quality of product. Industrial Engineering, Process Engineering, ergonomists and workers are involved in the analysis made through the Workshop's showing the importance of discussion between the various users of the systems. The processes of series are also equipped with a set of certifications flow of job and planned audits on items that describe processes and applied ergonomics.
https://www.ncbi.nlm.nih.gov/pubmed/22317399
2/1/2004
EM Fiberglas (EM, Hornsyld, Denmark) has given an exceptional ten-year price guarantee to Volkswagen AG (VW, Wolfsburg, Germany) on a new fiberglass composite roof assembly (The 300-mm/11.8-inch high roof) produced for VW's T5 transporter van.
https://www.compositesworld.com/articles/automated-rtm-process-optimizes-cost-reduction-in-vw-automotive-plant
Updated 29.4.2023, 17 May 2020
Published 25 April 2020
How many Industrial Engineers can a Company Employ for Cost Reduction?
For $100 million cost, there can be one MS IE and 6 BSIEs.
https://nraoiekc.blogspot.com/2020/03/value-creation-model-for-industrial.html
Industrial Engineering - Lean Manufacturing - Parent - Child Relationship
Volkswagen - Industrial Engineering
Increased productivity at the heart of Volkswagen
Volkswagen is putting sweeping measures into place as it pursues greater productivity and efficiency in production. The goal: 30 percent higher productivity worldwide by 2025. The main plant in Wolfsburg and heart of the brand is to set a new benchmark.
https://www.volkswagenag.com/en/news/stories/2019/02/productivity-and-efficiency-at-volkswagen-production.html
Effective March 1, 2020, Dr. Arno Antlitz, becomes the Board member responsible for Finance at Audi.
Dr. Arno Antlitz (49) holds a doctorate in industrial engineering and has been the member of the Board of Management of Volkswagen Passenger Cars responsible for Controlling and Accounting since 2010. As a Board of Management member, he has also held responsibility for the North America Region since 2018. He began his career in 1999 at the management consulting firm McKinsey&Company. His main areas of expertise included strategy, organization and cost optimization in the automotive and component supplier industry. Having moved to Volkswagen in 2004, he was given responsibility for global product controlling at the Volkswagen brand in 2005.
https://www.volkswagen-newsroom.com/en/press-releases/personnel-changes-in-the-brand-board-of-management-5605
March 31st, 2020
Wolfgang Maluche came to Volkswagen's Chattanooga operations from Germany.
After serving as a technical project manager at the Volkswagen Engineering and Planning Center adjacent to the automaker's Chattanooga production plant, he was named vice president of engineering and heads the facility.
He studied industrial engineering at Texas A&M, where he obtained a master's degree.
https://www.timesfreepress.com/news/edge/story/2020/mar/31/vw-chattanoogpost-offers-international-experi/519371/
NOVEMBER 18, 2019
Great Cost Reduction by Volkswagen - Product Industrial Engineering - Product Cost Reduction Engineering
New Model Electric Car at 40% Lower Cost Compared to Earlier Golfhttps://www.reuters.com/article/us-volkswagen-electric/vw-ceo-says-new-id-3-car-40-cheaper-to-build-than-electric-golf-idUSKBN1XS1BN
SEPTEMBER 13, 2019
VW CEO shifts strategy from empire building to efficiency
“The product experience needs to be right. But you need to keep an eye on cost. You cannot run the business by focusing only on product,” CEO Herbert Diess told Reuters.
https://www.reuters.com/article/us-autoshow-frankfurt-volkswagen-electri/vw-ceo-shifts-strategy-from-empire-building-to-efficiency-idUSKCN1VY21G
Skoda wins award for dProduction - Digitalization project
https://www.volkswagenag.com/en/news/2019/07/Automotive_Lean_Production_Award.html
July 2nd, 2019
Hartmut Rickel becomes Spokesperson for the Management Board at Volkswagen Group Services GmbH.
Hartmut Rickel holds a degree in industrial engineering and has been with the Volkswagen Group for 28 years. Following several positions in Controlling at Volkswagen in Wolfsburg and in Controlling at Å KODA, he assumed responsibility for sales steering at the Volkswagen brand in 2009. Rickel joined the Management Board of Volkswagen Group Services GmbH in December 2017.
https://www.automotiveworld.com/news-releases/volkswagen-comprehensive-changes-at-human-resources/
Value Engineering Associate
Volkswagen of America, Inc Company Location Chattanooga, TN, USThis job is no longer accepting applications
Role Summary
The Value Engineering Associate is responsible for supporting the analysis of production parts and drawings, and provide a ‘bottom-up’, ‘clean sheet’, or ‘should be’ calculation of what the part and the related tooling & equipment cost is based on current and future market material, production, labor, profits and overhead to achieve the target project profitability for all NAR VW Brand vehicle models through the concept of “Design follows target.”
This position will report to the Director or Manager of Value Engineering and will be a member of Value Engineering NAR team which support the execution of and realizing the VW Brand’s mission of creating and selling exciting products suited and tailored for the NAR markets (USA, Mexico and Canada) profitably.
This will require effectively executing the Value Engineering Processes within the Region and build consensus to obtain buy-in from key stakeholders in Engineering, Purchasing, Quality, Production, Sales, Strategy, and Baureihen.
Role Responsibilities
Operational - 50%
Contribute to annual Business Plan for Analyzed Turnover for Piece Price and Tooling Investment Calculations.
Support the preparation of material piece price, Tooling Investment, and/or pre-logistics cost calculations for ‘Heavy Items’ in Forward Sourcing, on an ad-hoc basis, or per the Business Plan for various commodities.
Perform cost calculations based on best practices
Maintain updated cost analysis results in VW Group Systems.
Analyze drawings and other documentation to prepare time, cost, materials, and labor estimates for parts and assemblies
Consult with other Cost Calculators and internal departments to formulate estimates, resolve issues and changes or updates to cost calculation
Cost Reduction Management - 40%
Participate in the optimization of car lines to ensure appropriate content to maximize financial return.
Participate in the benchmarking of competitor products and specifications through teardown of complete vehicles, modules and systems or component parts for cost optimization for G3 & G4 products
Generate cost reductions ideas from competitor analysis, workshop participation, supplier discussions etc.
Systems & Process Optimization- 5%
Ensure that VW NAR performance requirements conform to the market
Analyze and monitor Global macro-economic, geo-political, and unforeseen events that influence material cost. Understand future safety, regulatory and Co2 requirements.
Analyze localization and deep localization rate of assigned parts. Support commodity purchasing strategies to increase localization and deep localization rate.
Innovation and Technology - 5%
Visit supplier production facilities and identify areas for supplier productivity enhancements to decrease material costs. Implement waste avoidance best practices Identify and provide purchasing with information to negotiate with suppliers.
Perform market intelligence, obtain consumer insights, and identify product innovation in order to influence and contribute to “Product Strategy” in the early stages of PEP. (Milestone PS-PM)
Primary Location
United States-Tennessee-Chattanooga
0 - 2 years of professional experience with an Automotive OEM or Tier 1 in the areas cost or value engineering, production or manufacturing engineering, component design and development or similar area of expertise.
BS Degree in Mechanical, Industrial, or Manufacturing Engineering.Or a BS in Business Finance, Accounting or Economics
Skills
Automotive manufacturing background and/or development engineering background
Strategic and conceptual thinking capabilities, with a view of the “big picture” and a vision of future products and mobility solutions
Analytical thinking using reasoning and logic
Interpersonal and communication skills
Persuasion, influencing and negotiation skills
Computer savvy – skilled in the use of (MS-Applications, TcPCM, Technical Drawings, CATIA, and SAP)
Problem solving – critical and complex
Skills Required
Fundamental knowledge of manufacturing processes of components and/or subsystems within the automotive industry
Understanding of manufacturing processes in at least one of the following production segments:
Interior/Exterior: injection molding, blow molding, extrusion, paint, chrome, etc.
Metals: stamping and welding, casting, forging, etc.
Electric: Injection Molding, Harnesses, PCB, Batteries, etc.
Working knowledge of and ability to read drawings, CAD data, blueprints, material data sheets
Ability to evaluate supplier quotations, cost breakdown worksheets, and tooling investment details
Interpersonal skills requiring the ability to work effectively in a team
Understanding of the automotive competitor landscape, evolving technologies and business models.
Understanding of materials and manufacturing processes of automotive parts.
Ability to make presentation using PowerPoint, Think Cell, Excel, Word, Visio, etc
https://www.linkedin.com/jobs/view/value-engineering-associate-at-volkswagen-of-america-inc-1780413332/
Cost Reduction with 3D printed tools, jigs, and fixtures
By using 3D printed tools, jigs, and fixtures, Volkswagen Autoeuropa saved in 2017 €250,000.Next target is €325,000 in sa vings.
https://3dgbire.pro/case-studies/volkswagen/
Work. 2012;41 Suppl 1:4413-7. doi: 10.3233/WOR-2012-0739-4413.
Global ergonomics strategy in Volkswagen: from the product construction, over the planning until the serial process.
Toledo B1.
Author information
1
Industrial Engineering and Optimization of Indirect Areas, Volkswagen Group, Berliner Ring 2, Wolfsburg, Germany. begonia.toledo @ volkswagen.de
This topic is established in the industrial engineering of the production area of the group. We are working interdisciplinary with the medical services, human resources, work council and the protection of labor.
https://www.ncbi.nlm.nih.gov/pubmed/22317398
Work. 2012;41 Suppl 1:4418-21. doi: 10.3233/WOR-2012-1040-4418.
Ergonomics at Volkswagen Brasil. Multidisciplinary work to equalize health, productivity and quality.
Filus R (1), Wruca R, Charleaux V, Ortega A, Ferreira C, Jesus L, Stramari A, Neufel M, Maia U.
Author information 1 Corporate Ergonomics Sector coordinator - Volkswagen do Brasil. rodrigo.filus @ volkswagen.com.br
Abstract
Volkswagen Brazil ergonomists are concerned with the ergonomic efficiency of management applied to various levels of life of a product, since its creation to its final implementation on production lines.The preventive work of ergonomists during the processes leading to production of a vehicle is accomplished through assessments on a simulated system called the Digital Factory. Since the initial stages to final product delivery there is a need for a multidisciplinary aligning the concepts of ergonomics, productivity and quality of product. Industrial Engineering, Process Engineering, ergonomists and workers are involved in the analysis made through the Workshop's showing the importance of discussion between the various users of the systems. The processes of series are also equipped with a set of certifications flow of job and planned audits on items that describe processes and applied ergonomics.
https://www.ncbi.nlm.nih.gov/pubmed/22317399
2/1/2004
Automated RTM process optimizes cost reduction in VW automotive plant
EM Fiberglas (EM, Hornsyld, Denmark) has given an exceptional ten-year price guarantee to Volkswagen AG (VW, Wolfsburg, Germany) on a new fiberglass composite roof assembly (The 300-mm/11.8-inch high roof) produced for VW's T5 transporter van.
https://www.compositesworld.com/articles/automated-rtm-process-optimizes-cost-reduction-in-vw-automotive-plant
Industrial engineers are employed and productivity improvement and cost reduction are practiced in many companies using Industrial engineering philosophy, principles, methods, techniques and tools.
Volkswagen process improvement - Important Search Results
https://www.volkswagenag.com/en/news/stories/2019/02/productivity-and-efficiency-at-volkswagen-production.html
https://annualreport2020.volkswagenag.com/group-management-report/sustainable-value-enhancement/production.html
https://www.planettogether.com/blog/what-toyota-learned-from-vws-manufacturing-process-0
05/04/22 Wolfsburg Company Press Release
Volkswagen improves cost efficiency and economic efficiency in a tough environment
Continued focus on cost efficiency – outlook for 2023 confirmed
Volkswagen is continuing to work hard on improving its cost efficiency – for example on further reducing its fixed costs and overheads – in order to strengthen its competitiveness long term.
https://www.volkswagen-newsroom.com/en/press-releases/volkswagen-improves-cost-efficiency-and-economic-efficiency-in-a-tough-environment-7918
The Significance of MTM-HWD® for Digital Process Design
https://europe-aim.eu/wp-content/uploads/2020/09/1_MTM.pdf
Å KODA AUTO Volkswagen India Private LimitedÅ KODA AUTO Volkswagen India Private Limited
Full-time · 3 yrs 1 moFull-time · 3 yrs 1 mo
Industrial EngineerIndustrial Engineer
Feb 2022 - Mar 2023 · 1 yr 2 mosFeb 2022 - Mar 2023 · 1 yr 2 mos
Graduate Engineer Trainee (Industrial Engineering)Graduate Engineer Trainee (Industrial Engineering)
Mar 2020 - Mar 2023 · 3 yrs 1 moMar 2020 - Mar 2023 · 3 yrs 1 mo
Aurangabad, Maharashtra, IndiaAurangabad, Maharashtra, India
Currently functioning as Industrial engineer at the Skoda Volkswagen Luxury Vehicle Assembly Plant. I am responsible for following activities for each assembly shop
1.Manpower Calculation and Monitoring Changes.
2. Time and Motion Study.
3.Define Tact Time for different setups
4. Manpower Utilisation.
5. Line Balancing.
6. New Setup and Facility.
8. Improvements to reduce Non Value Added activities.
9.Space Optimization and Utilization for Equipment Installation and Area
10. Manpower Optimization proposal
https://www.linkedin.com/in/anirudha-suryawanshi-b89463201/?originalSubdomain=in
Vishal Lokhande 1st degree connection1st
Assistant Manager (Production systems & industrial Engineering) - Skoda Auto Volkswagen India Pvt Ltd || Industrial Engineer || MTM - UAS Practitioner || MTM - 1 Base || EAWS - Ergonomics
Å KODA AUTO Volkswagen India Private Limited
Institution of Engineers of India (IEI), Kolkata
Pune, Maharashtra, India
Å koda Auto Volkswagen India Private Limited logo
Assistant ManagerAssistant Manager
Å KODA AUTO Volkswagen India Private Limited · Full-timeÅ KODA AUTO Volkswagen India Private Limited · Full-time
Sep 2022 - Present · 8 mosSep 2022 - Present · 8 mos
Pune, Maharashtra, India · On-sitePune, Maharashtra, India · On-site
helped me get this jobLinkedIn helped me get this job
Production Systems and Industrial Engineering Expert
• MTM Analysis using MTM-UAS for F time calculations
•Ergonomic Evaluation and Improvement
•Standard work sheets (SWS) preparation, Line balancing of Assembly shop.
•Process Optimization using method building tools of VW Production system, KAIZEN, Lean Tools Implementation on shop floor.
•Time Study using lean tools like Ohno Circle, Time Evaluation for new Product Development, New Project management.
•People-Plan Chart Preparation, Manpower Calculation, Capacity Planning, NVA Reduction, Evaluation of Engineering change Notes (ECN).
•Manpower Layout, Value Stream Mapping for Assembly shop.
•Value addition doing waste reduction (NVA)
•Doing Continuous improvement (CI) workshops for process improvements.
Skills: Method study · Ergonomics assesment · Time Study
https://www.linkedin.com/in/vishal-lokhande-5a3544183/?originalSubdomain=in
Volkswagen Recruits Industrial Engineers
A look at our jobs portal will show you the opportunities that engineers and industrial engineers have with us across the many areas of work, roles and career levels we offer.
https://www.volkswagen-groupservices.com/en/career/professionals/engineers-jobs Accessed on 29.4.2023
Also See https://www.volkswagen-groupservices.com/en/services/technology
Specialist planning construction site (m/f/d) -
Job offer in Wolfsburg
Wolfsburg
experienced professionals
Manufacturing / Production
APPLY NOW
Our job offer
At Volkswagen Group Services GmbH, we plan systems for body-in-white construction in the Volkswagen Group worldwide. In order for these systems to go into operation and be handed over at all, we need colleagues in advance who can keep an overview and keep a cool head. Here we rely entirely on your structure and your organizational talent!
Supplement our team with your know-how as a construction site planning specialist (m/f/d).
Your tasks in detail
Planning and implementation of the detailed planning of shell construction systems with permanent stay at the site of the construction site in Germany and abroad
planning coordination in body construction in the project to secure the milestones
Creation of status reports and documentation according to the scope of services commissioned
Creation of measures for deficiencies, documentation, synchronization and harmonization of process steps, components, schedules and tests with engineering partners
Data procurement and tracking, logging of appointments and construction site rounds
your profile
Technical training in industrial mechanics, electrical engineering or comparable qualifications
first experience in car body construction
Willingness to travel and work weekends
Structured way of working, communication skills and team spirit
Initial knowledge of using the KVS system is desirable
This vacancy at Volkswagen Group Services GmbH will be filled in Wolfsburg with immediate effect .
https://www.volkswagen-groupservices.com/en/career/job-details/A-2023-6214 (In German translated by me)
Job Description - Industrial Engineer X2
We are looking to hire a driven Industrial Engineer X2 to join our stellar team at Volkswagen Group in Eastern Cape.
Growing your career as a Full Time Industrial Engineer X2 is a terrific opportunity to develop exceptional skills.
If you are strong in critical thinking, cooperation and have the right drive for the job, then apply for the position of Industrial Engineer X2 at Volkswagen Group today!
Location - Province
Eastern Cape (South Africa)
Location - Town / City Kariega
Type of Position: Applications are invited from suitably qualified & experienced employees to fill the above vacancy in Production - IE Department.
and Responsibilities
Conceptualizing & planning the optimal Work Process for both new projects & existing operations that is Robust & Sustainable to maximize Efficiency, Productivity & resultant SGK (Overhead) Costs.
Play a pivotal role in the design, measurement and improvement of projects & current operations on process cycle times, both manual & automatic.
Participating in design reviews to ensure that processes and facility layouts are designed to accommodate and provide the necessary disconnects and positioning that are efficiency orientated.
Compiling MAC’s, SAB’s and Ergonomic assessments for operations in Arbeitsplan & to test the validity of the determined or compiled.
Participating in new product planning requirements in order to meet future strategic needs of the Business unit and VW overall.
Supporting process efficiency and productivity improvement initiatives.
Developing more effective methods by design of layouts, material flow diagrams and man-assignment charts for improvement of quality and productivity.
Preparing monthly report on activities in areas which support cost savings and improved output.
Introduction of new and improved productivity and quality methods into production and non-production areas.
Monitoring and evaluating the activities of the Work Study Analyst with regard to time studies and other Industrial Engineering techniques.
Supporting management’s decision making with regards to financial analysis for the expenditure of budget on tooling, facilities and project work in order to facilitate Business Unit outputs cost, productivity and sustainability effectively.
Establishing standard work / process time by using direct work measurement or appropriate technique.
Creating and maintain a sound Labour Relations environment and climate in order to meet and satisfy the objectives of the business unit and corporate requirements.
Managing and approving engineering changes (ECR) originating from product improvements, running changes, quality improvements / cost reduction and model year changes in order to introduce changes timeously and successfully.
Education and Experience
National Diploma in Industrial Engineering or relevant IE qualification.
At least 1-2 years relevant experience in a production environment.
Skills, Attributes & Other requirements
ESSENTIAL:
Computer literate, Microsoft Office Package (Excel advanced & PowerPoint advanced)
Experience in MTM-UAS (motion time measurement-universal analysing system) simulations and EAWS (Ergonomic Assessment Work Sheet)
Be familiar with continuous improvement processes
Technical and mechanically minded
Enthusiastic and must be confident
Ability to communicate at all levels
PREFERRED:
AVON & Arbeitsplan system proficiency
SAP experience
The concept of Kaizen
German Language proficiency – Intermediate
Fundamentals of LEAN Manufacturing
https://grabjobs.co/southafrica/job/full-time/manufacturing/industrial-engineer-x2-urgent-hiring-19508515
Volkswagen: Industrial Engineer
Job Title: Industrial Engineer
Job Type: Strategic Talent Pool
Location - Town / City: Uitenhage
Type of Position: STRATEGIC TALENT POOL:
What is the Strategic Talent Pool?
Volkswagen Group South Africa is continuously looking for individuals with expertise in the Engineering field.
The aim of the strategic talent pool is to build a database of skilled individuals in the Engineering field.
Please note that there may not currently be positions available and screening will only commence once positions do become available. Individuals will be notified via email once positions become available.
Job Description and Responsibilities:
-Establishing and analysing all manpower needs for existing and new operations
-Providing Production with a quality Industrial Engineering service with regard to:
- Optimum operation and machine loading
- Maintaining an accurate standards base
- Assistance in reducing off-standard performances
-Performing Industrial Engineering-related activities i.e. work measurement and method studies
-Assisting Process Engineering in providing Production with optimum workplace layouts which conform to requirements
-Investigating process-related problems and recommending and implementing improvements to ensure smooth operation of all processes
-Conducting capacity studies for future planning strategies
-Evaluating facilities and services in order to upgrade where necessary
-Be flexible within Industrial Engineering to assist in problem areas, if required
Education and Experience:
-Must possess an Industrial Engineering or equivalent qualification
-A minimum of 2 years Production experience would be advantageous
-Must be computer literate, Microsoft Office Package (Excel advanced & PowerPoint advanced)
-Must have basic engineering design knowledge
-Must be familiar with continuous improvement processes
Skills, Attributes & Other requirements:
-Must be analytical
-Must be pro-active in terms of problem solving
-Must have the ability to communicate well at all levels
https://www.info-desk.co.za/vw-industrial-engineer/
Erstellt am 2. März 2023
Industrial Engineer (w/m/d)
Volkswagen AG
Hannover, Niedersachsen 30159, Germany Vollzeit
Reference: 237138130
The Industrial Engineering and Production Systems team is responsible for the efficient deployment of personnel in production and for productivity controlling to achieve the productivity goals of the Group components at the Hanover location.
The greatest challenge at the moment lies in the transformation of our plant. The expansion of the product portfolio from foundry and heat exchanger components to future-oriented products such as axles, charging stations and battery systems can only be a success with well-planned, digitized processes and a coordinated deployment of personnel.
If you can imagine designing sustainable, lean, excellent processes and holistically designed workplaces and you want to promote the implementation of innovative ideas and optimizations, then you have come to the right place. Become part of our team now and help shape the future.
your tasks
--Design of ergonomic workplaces and processes within production, maintenance and logistics by using MTM methods
--Professional processing of the topics of time management, performance accounting and productivity controlling
--Preparing and conducting workshops to ensure corporate goals, in particular value stream analysis, design and productivity workshops
--Methodical coaching of executives and employees regarding production methods and efficiency measures
her qualifications
You bring the following interdisciplinary skills with you:
--High structuring ability, as well as a strong understanding of process-related relationships and figures
--Very high level of initiative and self-assured demeanor
--Excellent communication and conflict management skills across all hierarchical levels
--Excellent teamwork
Your benefits:
--30 vacation days + 24.12. and 31.12. free
--35 hour week
--Company pension
--Flexible working hours and mobile working
--Educational and advisory services
--Special conditions for purchase and leasing
Volkswagen educational institute offers IE Courses
industrial engineering Offers (3)
IE - Basic License - Module 1 - Basics
IE - basic license - module 2 - production system
IE Basic License - Module 3 - Performance Control, Time Determination and Ergonomics
https://www.vw-bi.de/beratung/kursangebote/industrial-engineering-1305.html
Updated 29.4.2023, 17 May 2020
Published 25 April 2020
Yes - Say Yes for Industrial Engineering, Productivity Improvement and Cost Reduction
29 April
Do you have industrial engineering activities in your organization.
Say, Yes to start IE department and activities.
Part of
A to Z of Industrial Engineering - Principles, Methods, Techniques, Tools and Applications
https://nraoiekc.blogspot.com/2018/06/a-to-z-of-industrial-engineering.html
Friday, April 28, 2023
Productivity and IE in Automobile Manufacturing
336111 Automobile Manufacturing
Three Major Channels of Process Productivity Improvement.
1. Process Redesign by Process Planning Team.
2. Process Improvement Study by Industrial Engineering Team.
3. Continuous #Improvement by Involving Shop Floor Employees and All Employees.
Continuous Improvement - Employee Participation Principle of Industrial Engineering
BMW iFactory - New Debrecen plant in Hungary Based on Master plan for the production of the future.
Ford Motors - Industrial Engineering Activities and Jobs
Ford Motors - Industrial Engineering Activities and Jobs
2023
"2023 must be the year of productivity," VW finance chief Arno Antlitz.
https://europe.autonews.com/automakers/vw-will-focus-productivity-supply-chains-improve-and-car-production-rises
https://www.euronews.com/next/2022/12/16/volkswagen-agm-outlook
Mr. Antlitz is an industrial engineer by training. He joined Volkswagen in 2004. He was involved for years in overseeing the controlling and accounting departments for its Volkswagen brand. He has worked closely with Chief Executive Herbert Diess since 2015, when Mr. Diess served as head of the Volkswagen brand and Mr. Antlitz became his CFO. Mr. Diess was named group CEO in 2018.
Volkswagen Productivity News
https://www.volkswagenag.com/en/news/stories/2019/02/productivity-and-efficiency-at-volkswagen-production.html
https://www.volkswagen-newsroom.com/en/press-releases/productivity-in-plants-is-increasing-more-than-expected-5396
The Volkswagen Industrial Cloud aims to yield a 30 percent increase in productivity, 30 percent decrease in factory costs, and €1 billion in supply chain savings.
https://aws.amazon.com/blogs/industries/volkswagen-increases-productivity-decreases-costs-and-continues-to-innovate-using-aws-solutions/
Volkswagen's world-class procurement strategy produces breakthrough productivity gains.
https://public.dhe.ibm.com/software/fr/casestudies/db2/Volkswagen.pdf
VW to Automate 20 to 30 Percent of Production at New EV Assembly Plant - Trinity assembly plant.
Assembly is still 90 percent manual work according to the plant’s chief production officer. This will be changed in the new factory with automation increasing to 20 to 30 percent.
https://www.assemblymag.com/articles/97376-vw-to-automate-20-to-30-percent-of-production-at-new-ev-assembly-plant
https://www.3blmedia.com/news/volkswagen-group-makes-production-ergonomics-high-priority
https://www.automotivemanufacturingsolutions.com/volkswagen/volkswagen-enhances-plant-productivity/39225.article
https://www.telematicswire.net/computer-vision-to-make-production-within-the-volkswagen-group-even-more-efficient/
https://www.esgtoday.com/volkswagen-to-retrain-22000-employees-for-ev-production-as-part-of-e460-million-plant-transformation/
Improvement in Productivity in the Automotive Industry – a Success Story.
The company
This North American group has a turnover of $15 billion, is present in more than 20 countries, with 100 factories and 50,000 employees. It is a supplier to the automotive industry and manufactures parts and components for combustion, electric and hybrid engines,
Increase Productivity & Drive Innovation in the Automotive Industry with Additive Manufacturing
Robots in Automotive Industry: How to Use Them to Increase Efficiency
How the Benefits of IIoT Are Transforming the Automotive Industry
AUTOMOTIVE MANUFACTURING
Digitalize Parts Manufacturing
Connect with your machines using IoT technologies for higher visibility in production operations, compound preparations, effective machine operations, faster delivery with profitability
7 key Industry 4.0 Technologies - Application in Automotive Production
3 Uses of Augmented Reality in Automotive Manufacturing
Lowering Automotive Manufacturing Costs without Sacrificing Performance
Posted by Bead Electronics
TIG and MIG Welding for the Automotive Industry
Due to the high number of components required for vehicles, the welding processes vary in terms of complexity, volume and repeatability. For this reason, TIG welding and MIG welding are often used.
Leadership and Productivity: A Study of U.S. Automobile Assembly Plants
Soledad Giardili , Kamalini Ramdas , Jonathan W. Williams
Management Science, Vol. 69, No. 3.
March 2023
Pages 1323-1934, iii-iv
Abstract
We examine the effect of plant managers on productivity. Panel data on U.S. auto-assembly plants during 1993–2007. Variation in productivity due to managerial influence. We estimate the interquartile range of the effect of individual plant managers on average hours-per-vehicle to be about 30%. We also observe evidence that managers’ plant-specific tenure has a positive impact on productivity.
2022
Honda A – Organizational Change & Development Presentation
IvyPanda
Updated: Jul 20th, 2022
https://ivypanda.com/essays/honda-a-organizational-change-development/
Tesla - Diecast Bodies
31 July 2019
8 Sep 2020
Matthew Kenneth Kallas, who is credited as the inventor of a “Multi-Directional Unibody Casting Machine for a Vehicle Frame and Associated Methods,” for which Tesla has filed a patent claim. (Kallas, it has been reported, is no longer employed by Tesla, but holds a prominent position designing tooling for an automotive high-pressure diecasting business.)
4 June 2020
https://www.tesmanian.com/blogs/tesmanian-blog/tesla-model-y-production-rear-body-casting
It is a blog giving news of Tesla.
https://europe.autonews.com/automakers/tesla-bets-aluminum-casting-german-plant
April 26 2018
Ford Motor Co. is cutting an additional $11.5 billion from spending plans, curtailing further development and production of several sedans, including the Fusion and Taurus. The automaker is almost doubling a cost-cutting goal to $25.5 billion by 2022.
https://www.bloombergquint.com/business/ford-ceo-plans-11-5-billion-more-cuts-pulls-ahead-margin-goal#gs.1eD22lw
In October 2017, Ford had targeted USD4 billion in material cost reductions over five years. With the reporting of the company's first-quarter results, Hackett raised this target to savings of USD11.5 billion between 2019 and 2022, and said that one-third of that figure would be realised by 2020.
https://ihsmarkit.com/research-analysis/ford-announces-costreduction-targets-and-shift-from-sedans.html
2009
Honda to Suppliers: Flexibility Fundamental to Survival
60 Suppliers Receive Awards for Quality, Productivity and On-time Delivery
April 16, 2009
https://www.hondaalabama.com/article/honda-to-suppliers-flexibility-fundamental-to-survival
2007
CLOSING THE PRODUCTIVITY GAP
By David Brandt
In May 2007, Harbour Consulting released its annual report on the productivity status of North America’s six largest automobile industry competitors.
Honda Marysville Plant Tops Productivity List - Harbour Consulting annual report
https://www.streetdirectory.com/travel_guide/59656/car_parts/honda_marysville_plant_tops_productivity_list.html
Open Access Journal - ADVANCES-IN-AUTOMOBILE-ENGINEERING
http://www.omicsgroup.org/journals/advances-in-automobile-engineering.php
Updated on 28.4.2023, 19.5.2022, 19 Feb 2021
Open Access Journal - ADVANCES-IN-AUTOMOBILE-ENGINEERING
http://www.omicsgroup.org/journals/advances-in-automobile-engineering.php
Updated on 28.4.2023, 19.5.2022, 19 Feb 2021
5 December 2018
First published on 3 February 2014
First published on 3 February 2014
Subscribe to:
Posts (Atom)