Monday, April 29, 2024

Yamaha - Industry 4.0 - Industrial Engineering 4.0

 


2024


High-speed Surface Mount Assembly


Yamaha Robotics SMT Section will team with its distributor ANS Elektronik to showcase innovations for high-speed surface mount assembly at SMTconnect 2024.

At the event in Nuremberg, Germany, June 11-13, experts from both companies will show visitors how advanced equipment from Yamaha’s 1 STOP SMART SOLUTION can raise productivity and quality control with automated features. These include the YRP10 printer, YRM20 mounter, YRi-V 3D AOI system, and new software including tools for inspection and troubleshooting.


The YRP10 printer is built on Yamaha’s ultra-rigid YR chassis for superior accuracy and repeatability. The printer’s cutting-edge features automate laborious procedures and ensure high speed, achieving cycle time of just six seconds and boosting accuracy by 20% to handle extremely small component sizes, spacing, and interconnect pitch.

https://goldlandsmt.com/product-item/yamaha-yg100rb-chip-mounter-high-precision-smt-equipment-for-advanced-assembly/


The YRM20 mounter is designed for efficient motion with fast and flexible component handling. Extensive automation of parts feeding, product changeovers, and nozzle management permits mounting up to 120,000 cph to meet customer demands for productivity and flexibility.


The YRi-V 3D AOI system appears with the latest upgrades including stopperless transfer for fast cycle time and sharp images, also leveraging the extra rigidity of the YR chassis. Camera options with up to 25Mpixel sensor and 5”m lens ensure high resolution and the 8-way projector provides shadow-free illumination. Also, new AI tools that help create component libraries simplify and accelerate programming.


The software area will showcase powerful capabilities including the latest YSUP software intelligent-factory tools that help operators schedule activities, handle exceptions, and keep production on target. In addition, YSUP Dashboard with award-winning automatic pickup-error diagnostics takes the guesswork out of troubleshooting. The advanced AOI software features, including new multi-component alignment checking that eases programming to inspect arrayed components such as LED light sources and position sensors.

https://www.industryemea.com/news/79776-yamaha-to-showcase-latest-generation-assembly-equipment-and-software-tools-at-smtconnect


https://global.yamaha-motor.com/business/smt/


https://global.yamaha-motor.com/business/smt/software/ifactory/


https://www.smtfactory.com/YSM40R-Yamaha-SMT-PCB-Automatic-Pick-And-Place-Machine-pd43840264.html

















Saturday, April 27, 2024

Xiaomi Corporation (MI) - Smart Factory - Industry 4.0 - Industrial Engineering 4.0

 



June 4, 2021


On May 20, 2021, the founder of Xiaomi Corporation Lei Jun announced: “Xiaomi is building the second phase of the smart factory, which is expected to be completed by the end of 2023. When it is completed, the factory will have an annual production capacity of 10 million high-end smartphones


On August 11, 2020, at the Xiaomi cooperation 10th anniversary, Lei Jun showed the Xiaomi smart factory to the public for the first time. With a total construction area of 18,600 square meters and an investment of 600 million yuan, applying the large-scale of automated production lines, 5G networks, robots, big data, cloud service platforms, and other technologies, the Xiaomi smart factory is a "black light factory" that can realize the entire factory production management process, mechanical processing process, packaging, storage, and transportation process, It can produce more than million smartphones per year.


Most of the equipment in the factory is independently developed by Xiaomi and Xiaomi Investment Company, and the degree of localization is extremely high.

Xiaomi is using Huiling Technology’s Z-Arm series robots arm assembling the mobile phones. The Z-arm series robot arm adopts an integrated drive and control design without an external control box, which greatly saves the equipment space, and its lightweight structure, flat and foldable arm can flexibly back and forth in some narrow spaces. It is very suitable for the light industry.

Over the years, Lei Jun and the subsidiary company of Xiaomi Group: Shunwei Capital, and Xiaomi Ventures have continued to work on the smart manufacturing industry chain, and it also set up an industry fund to support the growth and development of intelligent manufacturing.

Four years ago, Xiaomi began to conceive of the realization of completely unmanned production in the field of consumer electronics production.

 Lei Jun also told  the public that in the future, Xiaomi will make efforts to provide smart factory solutions to the entire manufacturing industry to improve production efficiency.


 https://www.linkedin.com/pulse/xiaomis-second-phase-smart-factory-completed-2023-hitbot-robotics/




Introducing Xiaomi Smart Factory | MWC 2023

Xiaomi

 2 Mar 2023   #ConnectedFuture

We're proud to introduce Xiaomi Smart Factory! A fully-automated assembly line that is capable of manufacturing over 1 million flagship smartphones in a lights-out plant.


https://www.youtube.com/watch?v=v6jb6PP4APc



Mi Mobile Factory Tour - How SmartPhone are Made in India? 


Time To UnBox


22 Dec 2022  #phone #Xiaomi #tamil

Mi Mobile Manufacturing Factory Tour - How Mobiles are Made in India?


#Tech #tamil #MI #Mobile #phone #manufacturing #Xiaomi


Recently we were invited to visit The Xiaomi mobile Manufacturing unit in Sri City, In this video we showed and explained the each steps that includes in MI mobile manufacturing process, also we had a chance to talk to Mr.Murali(President of Xiaomi India) ,so we asked him few interesting questions that generally on peoples mind about Xiaomi. 


How SmartPhone are Made in India,Mi Mobile Factory Tour,mi manufacturing plant in india address,xiaomi manufacturing plant in india,xiaomi factory location,xiaomi first manufacturing plant in india,mi manufacturing company in india,mi store,xiaomi manufacturing plant in chennai,xiaomi manufacturing plant.



How Smart Phones Manufactured đŸ”„, Xiaomi SmartPhone Factory Tour -  In Telugu 

VaasuTechVlogs
7 Dec 2022 




Xiaomi unveils its most advanced factory -  10 million flagship smartphone production capacity
Feb 18, 2024

The official opening of its smart factory in Changping, Beijing. It  has  a self-developed production line capable of churning out over 10 million flagship smartphones per year. 

 











Friday, April 26, 2024

Western Digital - Prachinburi Plant - Industrial Engineering 4.0 - WEF - McKinsey Light House Plant

Industrial Engineering 4.0 - Computer Aided Industrial Engineering: Work Systems Analysis in Industry 4.0

Rao, Kambhampati Venkata Satya Surya Narayana; Rathod, Aniket.  IIE Annual Conference. Proceedings; Norcross (2021): 49-54.

https://www.proquest.com/openview/d32ef32bbaa911d170e046479790c035/1  



8650+ Downloads/Reads so far. 
INTRODUCTION TO MODERN INDUSTRIAL ENGINEERING. 
Free Download EBook (122 pages).  Download from:

https://academia.edu/103626052/INTRODUCTION_TO_MODERN_INDUSTRIAL_ENGINEERING_Version_3_0   



Western Digital - Prachinburi Plant - Thailand


Press Releases

Western Digital Enables Industry 4.0 Transition With High-Endurance Storage Solutions for Industrial-Grade AI, ML And IOT Applications

Smart Factories and IoT Devices Benefit from Reliable, Low-Power Storage Solutions Built to Thrive in Varied Environments


SAN JOSE, CA - September 19, 2019

https://www.westerndigital.com/en-in/company/newsroom/press-releases/2019/2019-09-19-western-digital-enables-industry-40-transition-with-high-endurance-storage-solutions


Western Digital Turned a Million Machines into Connected Data and Improved Its Utilization of Testing Slots and Reduced Maintenance Time and Cost

September 29, 2021


Western Digital started its Fourth Industrial Revolution (4IR) efforts seven years ago. 

The company decided to start by tackling testing processes, an operation that takes place only after manufacturing and assembly are complete.  


Testing times

Storage devices undergo exhaustive testing and stringent validation processes. Hard drives may undergo several weeks of testing.  Jackie Jung, Western Digital’s global operations VP of strategy and chief of staff leading the company’s 4IR efforts, came out with a question, “can we predict more so that we can test more efficiently?”

“Testing processes needed a rethinking”

Together with a group of domain experts, Jung began investigating different variables that could help predict hard drive health.  A few months later, the team had advanced algorithms crunching through more than 2,000 parameters that could reliably point to a hard drive’s health condition in real time. This allowed testing and optimization processes to be tailored for each drive produced. 

The team carefully integratde the algorithm-based testing into high volume manufacturing. Once in production, testing efficiency improved by a remarkable 15%.  

It was a data science home run and the beginning of a prodigious transformation of Western Digital’s manufacturing, supply chain, and operations. 


Hard data

Enterprise hard drives are where the ginormous data of the digital economy lives (think search engines, social apps, and the massive data of cloud-based services).  Cloud giants maintain so much data that they buy hard drives in the thousands, tens of thousands, and some even hundreds of thousands. “The world’s largest cloud companies can deploy a million drives”

Any quality issue for these titans is both a potential disaster to their services and a gargantuan headache. Imagine having to service 30,000 data center components. It’s not outlandish; it’s the brave world of hyperscale.  To ensure utmost reliability, the testing and qualification of enterprise hard drives is rigorous, exhaustive, and extraordinarily long. 


The sea of testers

Qualifying an enterprise-grade hard drive can take up to four weeks. With Western Digital’s manufacturing site in Prachinburi, Thailand, producing more than 100,000 enterprise hard drives every day, the factory depends on a huge amount of testing slots to keep operations from bottlenecking. 

Altogether, there are more than 1 million slots today and the number will be rapidly increasing. These slots are sprawled across automated machines the size of a bus. Some with more than 12,000 slots. If the slots were stacked on top of each other, they’d reach more than 40 miles high, far into the Earth’s mesosphere (where meteors burn up). 

Keeping this army of sophisticated machines as productive as possible is no small challenge. Even if only 0.5% of tester slots report an error, that’s still over 6,000 slots that need attention every day. 

A web of connected assets

Peter Pang knows every crevice in the belly of the HDD test slot beast. As the director of automation and test systems engineering at Western Digital, his team of engineers is responsible for everything from developing the test routines to working with hundreds of technicians to keep systems running. 

He also knew that the daily maintenance of these testers was labor-intensive and slowing things down. Whenever a slot would shut down due to a failure, a technician would frequently need to grab a 12-foot ladder, climb up, remove the slot, and take it to a lab to investigate the issue. 

So, Pang teamed up with manufacturing engineers, analytics teams and IT. Together, the cross-functional team turned the ocean of standalone testers into a web of connected assets. 

“We had to link standalone testers from different vendors and generations spanning 15 years”

Testers can now provide real-time data about hardware health and operational conditions. Slots can be addressed from a remote station without technicians having to leave their desk.

And, machine learning algorithms have learned how to pinpoint root cause issues and automatically perform self-healing operations. 

The amount of data collected every second by this bustling operation is staggering; the outcome impressive — a 6% improvement in hardware utilization or 78,000 slots.

“Being a smart factory is not about how much data is collected,” said Pang, “it’s about the quality of data and understanding what to do with it.”

Data science cavaliers

Since their first success, Jung and Western Digital’s senior director of data science, George Ng, have been at the heart of Western Digital’s Herculean transformation. The company has upskilled thousands of its factory workforce, multiplied productivity, and reduced emissions through data-driven logistics. 

https://blog.westerndigital.com/smart-manufacturing-million-machines-into-connected-data/



Western Digital - 2022 Story - pdf file - 31 pages

https://documents.westerndigital.com/content/dam/doc-library/en_us/assets/public/western-digital/collateral/company/western-digital-FY2022-ourstory-summary.pdf


https://www.linkedin.com/posts/western-digital_how-western-digital-turned-a-million-machines-activity-6849010597279924226-I5US/


https://www.linkedin.com/posts/western-digital_western-digitals-manufacturing-site-in-prachinburi-activity-6987547776167424001-OuOR/









Thursday, April 25, 2024

Volkswagen - Industry 4.0 - Industrial Engineering 4.0

Industrial Engineering 4.0 - Computer Aided Industrial Engineering: Work Systems Analysis in Industry 4.0

Rao, Kambhampati Venkata Satya Surya Narayana; Rathod, Aniket.  IIE Annual Conference. Proceedings; Norcross (2021): 49-54.

https://www.proquest.com/openview/d32ef32bbaa911d170e046479790c035/1  



8625+ Downloads/Reads so far. 
INTRODUCTION TO MODERN INDUSTRIAL ENGINEERING. 
Free Download EBook (122 pages).  Download from:

https://academia.edu/103626052/INTRODUCTION_TO_MODERN_INDUSTRIAL_ENGINEERING_Version_3_0   


2016


May 26, 2016 

VW offers its vision of Industry 4.0.

Fabian Fischer, head of internal processing in VW's Group Research unit for Materials and Manufacturing.

Serious 4.0 work for VW only began in 2013, Fischer said, but it's progressing quickly. The company has finished a prototype car where each part has RFID chips or similar technology for traceability.


2019

Volkswagen 4.0 – the production systems of tomorrow are being developed in the GlĂ€serne Manufaktur in Dresden

World first: The headliner for the e-Golf is now being fitted by a robot as standard.

03/14/19Company Press Release


The GlĂ€serne Manufaktur in Dresden is continuing to develop into the Volkswagen Group’s primary test location for trialling innovative technologies. In conjunction with the Wolfsburg and Emden factories, the GlĂ€serne Manufaktur is part of a “technical centre” project. The primary idea is to achieve automation of complex work steps within assembly. The first project at the Dresden site is a world first – the headliner for the e-Golf is now being fitted by a robot as standard. This manufacturing step will also be used in production of the ID from the end of 2019 at Volkswagen’s Zwickau plant.


Dr Andreas Tostmann, member of the Board of Management for Production and Logistics of the Volkswagen brand: “We want to achieve a 30% improvement in productivity in the Volkswagen brand factories by 2025 compared to 2018 to ensure our competitiveness in the long term and to make a decisive contribution to improving the profitability of the Volkswagen brand. To achieve this, the factories must become faster, leaner and more efficient. The various technical centre projects in Wolfsburg, Emden and Dresden make an important contribution to this by testing innovative technologies.”

The innovations in Dresden are supported by Volkswagen Brand Planning and Wolfsburg plant engineering. Other projects at the Dresden site include the automated assembly and removal of the car doors and the human/robot collaboration.

Note: A clip for automated installation of the e-Golf headliner is available at https://www.youtube.com/watch?v=PIg9wfjx81E 


Volkswagen boosts line efficiency in car manufacturing with Siemens Industrial Edge

Siemens Knowledge Hub YT video

 5 Dec 2023

Juergen Jaskolla, Manager Digital Production Management at VW and Tobias Siegel, Head of Product Portfolio Management of Startup Apps at Siemens AG talk about the challenges of efficiency losses in discrete manufacturing lines and how Siemens Industrial Edge and Industrial Apps (in this case especially OT Connectors and Performance Insight and its cycle time analysis feature) can create transparency in an easy and scalable way, so that optimization potentials can be pointed out clearly to derive the right actions.

https://www.youtube.com/watch?v=5Wuwj-FyXEk









Sunday, April 21, 2024

Die Casting Productivity - Science and Engineering - Bibliography



Lesson 252 of Industrial Engineering ONLINE Course Notes. 

North American Die Casting Association: NADCA
https://www.diecasting.org/

Die Casting Handbook - Gaton Brass
https://www.gatonbrass.com/die-casting/



Interesting on Project on Quality Science - Useful to Develop Productivity Science Also

MUSIC Project Guide to Die Casting Quality Parameters


Conference Paper PDF Available
Correlation between process parameters and quality characteristics in aluminum high pressure die casting
January 2015
Conference: NADCA
Authors: Martina Winkler,  Lothar Kallien,  T Feyertag



2024

Die Casting Industrial Engineering 4.0 - Intelligent Die Casting

 

Dr Mark Cross, Global Business Development Director - Die Casting at Quaker Houghton


“More intelligent die casting is necessary to improve productivity, efficiency, and quality, reduce costs and enhance sustainability.


“Operations can be further optimized with modern monitoring technology to maintain parameters, helping to improve process stability, reduce cycle times and manufacture consistent high-quality products.


Quaker Houghton provides the complete solution to improving die casting performance throughout the die casting manufacturing value chain.

https://www.foundry-planet.com/d/quaker-houghton-to-showcase-intelligent-die-casting-solutions-at-euroguss-mexico-2023/


Intelligent Die Casting Cell


YIZUMI Intelligent Die Casting Island focuses on providing a complete set of turnkey solutions for industrial production processes like robotic automated intelligent manufacturing systems, peripheral equipment, and related technical support and services. It meets the fully automated production needs of the die-casting industry and completes the full set of automated production processes such as robot take-out, inlaying, spraying, product cooling, de-slagging, trimming, engraving, conveying, etc. in the die-casting and post-processing related industries, and is suitable for different die-casting production lines.


Easy central integrated control

Adopting well-known brand PLC and high-definition touch screen, with the human-machine dialogue interface which is constantly optimized according to the needs of customers' front-line operators, it can conveniently carry out quick view of information and set and read alarms detection for various parameters, etc.


Removal and insertion robot system

Experienced in designing claw hands for various types of inlay pieces, the precise material handle arms and product robot arms ensure stable and reliable gripping.


Robotic grinding and deburring can guarantee the accuracy and reliability of product cleaning while lowering the rate of human scrap. Meanwhile, it could prevent the spread of dust and reduces the dangers of environmental pollution and occupational diseases.


LEAP Series Die Casting Machine

YIZUMI fully benchmarks against the performance and functions of world-class die-casting machines . Through the joint efforts of the international and domestic R&D teams with years of experience in the die-casting industry, we developed this series from concept to product, and have independent intellectual property rights in its technology. Yi-Cast real-time closed-loop injection system makes every injection with quality assurance. ORCA control system adopts the world's most advanced control technology and algorithm. The easy-to-use HMI enables the full digitalization of the die-casting machine. Supported by highly innovative servo + feedimng energy-efficient pump units, the machine has achieved higher Overall Equipment Effectiveness (OEE).


https://www.yizumi.com/en/ras/intelligent-die-casting-cell



https://www.foundry-planet.com/d/lk-technology-and-guangdong-hongtu-launched-the-worlds-first-12000t-intelligent-die-casting-unit/


https://diecastiq.quakerhoughton.com/


https://www.mdpi.com/2227-9717/11/10/2947


https://www.youtube.com/watch?v=B1lQi1laoB4


https://medium.com/@taohaiying6688/application-and-advantages-of-artificial-intelligence-and-robotics-in-the-die-casting-industry-5aef872cfd12


https://www.researchgate.net/publication/285385686_Modeling_of_Pressure_Die_Casting_Process_An_Artificial_Intelligence_Approach


https://www.visi-trak.com/smart-die-casting-and-foundry-4-0/


https://www.linkedin.com/pulse/larger-intelligent-solutions-transforming-die-casting-sajal-sen



https://www.youtube.com/watch?v=qHCQS3W7S5E


https://www.facebook.com/lkmachineryint/photos/a.725205084279174/2302088436590823/?type=3


https://www.toyota-industries.com/news/2021/04/12/005049/index.html


https://www.sciencedirect.com/science/article/abs/pii/S0924013620303939


https://castingssa.com/lk-group-introduces-the-worlds-first-9-000t-giant-die-casting-machine/


https://themachinemaker.com/news/godrej-boyces-smart-die-casting-die-enters-the-market


https://www.magmasoft.de/en/magmaacademy/training-sessions/training/Economical-and-High-Quality-Die-Casting-Through-Intelligent-Efficient-Temperature-Control


https://tvarit.com/principles-for-ai-based-die-casting-process-optimization/


https://easyengineering.eu/the-road-to-leap-a-story-of-yizumi-leap-series-die-casting-machine/


https://www.empcasting.com/development-trend-of-aluminum-alloy-die-casting-pr.html


https://www.advantech.com/en/resources/case-study/low-cost-automation-and-monitoring-in-the-die-cast-manufacturing-process


https://www.zetwerk.com/resources/knowledge-base/die-casting/future-of-gravity-die-casting-advancements-and-opportunities/


https://journals.sagepub.com/doi/10.1177/1550147719879378


https://hitachi.co.in/adstefan/featured-casting-processes.html


https://www.toolsforsmartminds.com/en/case-studies/46-foundires-similar/309-how-the-first-predictive-maintenance-platform-for-the-die-casting-industry-was-developed


https://www.computer.org/csdl/proceedings-article/icitbs/2021/485400a300/1wB6T2pPK3m


https://link.springer.com/article/10.1007/s12541-017-0161-x


https://www.youtube.com/watch?v=BwDolZlzNBY



2023

Study of Process Parameters in High Pressure Die Casting

Low pressure die casting's productivity is limited by solidification time, leading to cycle times of typically several minutes.


17 April 2023
Implementing Robots into Your Die Casting Process

Solutions to Automate Die Casting
Save Time & Improve Safety.

2022



Gravity die casting - automation packages

With the proven automation packages for modern and cost-effective gravity die casting, KUKA supplies the ideal basis for high casting quality.

Gravity die casting: the technology
Gravity die casting is a casting process in which the melt is poured from above into a permanent metal mold through a sprue. The mold is filled through the effect of gravity alone. The high thermal conductivity of the mold provides for accelerated cooling of the solidifying melt. This in turn results in a dense and fine-grained structure with improved mechanical properties.

Automated gravity die casting

There are extensive product range of robots, software tools, deburring systems, casting carousels, casting machines, systems for pre-machining and the required peripheral equipment.

The tilting gravity die casting machines with their innovative drive, operating and control concept provide you with the basis you need for high casting quality. The software function in the KRC ROBOTstar synchronizes the pouring motion of the robot with the tilting motion of the casting machine providing for a precise filling process.


Automated Gravity die casting: the advantages

  • Robust, low-torsion mechanical construction with a low-backlash drive concept characterizes the series of single and double tilt casting machines.
  • Positionally accurate due to the servo drive, the machines are suitable for linear casting cells as well as for gravity die casting in combination with casting carousels.
  • The app-based KUKA casting machine controller can be intuitively operated and offers maximum ease of use.
  • Additional positive effects of automating gravity die casting include increased productivity, improved casting quality and high profitability of your production system.
  • In contrast to sand casting, gravity die casting has low space requirements.
  • Full mechanization using robots is possible for gravity die casting.
  • The robots ensure a high pouring rate meeting the requirements of each casting.




2021
Lesson 252 of Industrial Engineering ONLINE Course Notes. 


BĂŒhler introduces strongest die-casting machines worldwide
Uzwil (Switzerland), November 3, 2021 – With the Carat 840 and the Carat 920, BĂŒhler has further extended its portfolio as the automotive industry’s demand for larger and more complex parts continues to increase.

BĂŒhler's vision for the future of the die casting industry is: 0% scrap, 40% less cycle time, and 24/7 uptime.
https://www.buhlergroup.com/content/buhlergroup/global/en/media/media-releases/buehler_introducesstrongestdie-castingmachinesworldwide.html

How Much Does a Die Casting Tool Cost?
Published on June 30, 2021

2019
Productivity Improvement High Pressure Die Casting - IIM - Delhi
Productivity Improvement in. High Pressure Die Casting. Presentation By: SENDIL KUMAR K. Kaushiks International, Bangalore.  https://www.linkedin.com/in/sendil-kumar-k-38972013/
Good presentation giving technical alternatives that will improve productivity.
http://www.iim-delhi.com/upload_events/Presentation_KaushiksInternational.pdf

Machines covered in the presentation

U20 Die Casting Machine
Product of 25 ton class can cast at parting injection
U Series Features
Less air trapped in the metal flow during die fill, it makes the casting parts excellent.
With parting injection system, it makes less re-melting material and can reduce a lot of re-melting cost.
Sprueless system it makes die opening stroke shorter.
https://hishinuma.jp/english/menu/2013/11/u20english.html

https://www.kaushiksinternational.com/

Kaushiks International is the exclusive manufacturers' representatives in India for numerous world class products catering to core engineering industries, foundry and other applications.

These include CFD simulation software, machineries and ancillary equipments for productivity improvement.


Dr. Ravindran B
Owner, Kaushiks International
Bengaluru Area, India
https://www.linkedin.com/in/dr-ravindran-b-74a5bb17

Kaushik Balasubramanian
CEO at Kaushiks International
Bengaluru, Karnataka, India
https://www.linkedin.com/in/kaushik-balasubramanian-bb84ba15


Productivity for the diecasting industry | Foundry Trade Journal
At EUROGUSS, BĂŒhler presented products and services focused on increasing the productivity of customers today and tomorrow.
https://www.foundrytradejournal.com/features/productivity-for-the-diecasting-industry



BĂŒhler Die Casting says “Welcome to PRODUCTIVITY”
BĂŒhler supplied its first the casting machine exactly 80 years ago. Today, BĂŒhler is at the cutting edge of die casting technology.
https://former.buhlergroup.com/europe/ru/604-4723.htm?title=#.XrfveURLiM8


[PDF]overall productivity improvement in casting and fastening industry - IRAJ
http://iraj.in/journal/journal_file/journal_pdf/2-12-139383136143-48.pdf

Abstract: The purpose of this research is to improve productivity for small and medium scale casting industry.
Productivity Improvement in Automated Manufacturing Cell for Die Casting
The parts are produced in an automated cell with Gravity die casting technique. Currently the company has one Automated line.
https://www.researchgate.net/publication/321145060_Productivity_Improvement_in_Automated_Manufacturing_Cell_for_Die_Casting_Project

2019
[PDF]Innovative Trends in Die Casting - Chem-Trend
Innovative Die Lubricant Trends for Evolving Productivity
https://chemtrend.com/wp-content/uploads/2019/02/chemtrend_die_cast_innovative_trends_web.pdf

2018
https://www.bruschitech.com/blog/production-process-improvement-die-casting-industry


Odyssey helps die casters monitor tooling cycles down to the cavity level.  Dyersville Die Cast boosts productivity with Cloud-based Odyssey ERP.
https://www.blinfo.com/about/customer-success/case-studies/dyersville-die-cast-story/


Increasing Productivity and Reducing Emissions through ... - NREL
For the entire domestic die casting industry (6,000 die casting units):. • Energy savings of 24.6 trillion. Btu and 24 million kWh per year. • Savings of 18 million ...
https://www.nrel.gov/docs/fy01osti/27622.pdf

High Productivity Diecasting Cell Delivers Results - MRT Castings
MRT's greatest asset is their skilled team of production, engineering and ... will gain experience in tooling and process design, aluminium die casting, trimming, ...
https://www.mrt-castings.co.uk/latestnews/High_Productivity_Diecasting_Cell_Delivers_Results.html

Gravity die casting | KUKA AG - KUKA Robotics
Additional positive effects of automating gravity die casting include increased productivity, improved casting quality and high profitability of your production ...
https://www.kuka.com/en-in/products/process-technologies/2016/07/gravity-die-casting

Die Casting Machines | Product Lineup | Ube Machinery Corporation ...
Ube machinery corporation utilizes die-casting machine manufacturing ... and advanced technology: Improvements in energy efficiency, productivity and ...
https://www.ubemachinery.co.jp/english/product/diecast.html


[PDF]Die Casting - ABB
power and productivity to all foundry processes. □ Home .... The robot-based automation of die casting processes is rapidly becoming a key factor for success .
https://library.e.abb.com/public/0e84d872d6edcc96c1257ad40043fbfa/FO10003_EN_R2.pdf

Case Study: Component to be machined shifted to die casting for 50% cost benefit
https://www.dynacast.com/en/knowledge-center/case-studies/machining-conversion-to-die-casting


Ud. 21.4.2024, 21.4.2023, 13.5.2022,  11.4.2022,  4.12.2021
Pub 11.5.2020


Saturday, April 20, 2024

Renault - Industrial Engineering 4.0

 


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

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.



Renault - Industry 4.0


Renault Industry 4.0 -  Production Plants

Our production system is future-focused, undergoing a major transformation in response to the changing challenges of the automotive industry and the expectations of our customers. The 4.0 revolution is ushering in new business functions, new skills and new tools. It is the driving force behind a connected, agile and competitive production base.
 

An illustration of this digital shift is our recent partnership with Google Cloud.

With an ambitious objective: a sharing of industrial and technological experience between two leaders to encourage the creation of new industrial solutions. This ambition illustrates the continuation of our digital transformation, initiated in 2016: connecting our production sites, managing industrial data, transforming our logistics processes around the world, with the aim of continuously improving our standards of excellence. At the heart of this plan, our teams will have the opportunity to strengthen their data culture, with coworking sessions and high-level training with Google teams.

4 Key initiatives to drive digital transformation

Real-time supply management
As soon as a customer orders a vehicle, suppliers are informed, raw materials are prepared and logistics flows are established.

Simpler processes with connected tools
In our production plants, digital technology helps employees to be more mobile and proactive and to share information. It also contributes to easier decision-making on the production line.

Continuous traceability
Vehicle parts, assembly and packaging are tracked in real time, so customers can follow the progress of their order.

Data for planning
Data are sent and analyzed continuously to conduct remote operations and simulations as well as to optimize maintenance.

#01
People and robots, hand in hand
In the production plant of the future, the production line resembles a futuristic ballet.

Robots and machines of all sorts work alongside human operators. Automatic trolleys zip around continuously, carrying the required kits, articulated arms help operators in their work, a cobot or collaborative robot fits parts with a high degree of precision, alongside an operator...

In industry 4.0, people and robots work together.

8000
robots in our plants

Our perspective:
With the continuous increase in product customization to satisfy customer expectations and the presence of connected project managers, the 4.0 plant allocates the heaviest and most repetitive tasks to robots: handling unwieldy parts or part picking. This takes the strain off the operators who are thereby able to concentrate on tasks of greater added value, such as the quality of engine or vehicle assembly. The 4.0 plant has an essential component at its core: people!

It’s a real revolution. The energy of the cobot needs to be controlled since there is always somebody next to it. The movements mustn’t be too fast. A shared pace of work needs to be established, based on task-sharing.
JAIME
Cobot Manager, Séville plant (SPAIN)

#02
Virtual reality, real progress!
With VR, we train operators, anticipate maintenance issues and conduct production line simulations that resemble reality as closely as possible. For example, we can study how best to integrate a new part on the line and optimize configuration. As a result, we can carry out all sorts of tests and adjustments without interrupting the flow.

4364
people followed VR training in Brazil

Our perspective:
VR can be used to model the production line and make sure in advance that space is used efficiently. We can also study the best way to build several versions of a vehicle without stopping the lines for reconfiguration. The virtual and real worlds are synchronized. This improves on-site productivity. With respect to learning, VR ensures that trainees learn the right techniques and movements safely. VR is an essential tool in industry 4.0, delivering benefits that are both economic and operational.

Here we deploy all digital themes. For training, Virtual Reality (VR), used as a complement to practical cases, allows us to learn by example. At the forefront of this approach, we worked with a local VR/3D startup to develop immersive and fun virtual tours with them.
ISABELLE
Lean and Digital Manager, Cléon plant (FRANCE)

#03
Total traceability, nothing is wasted!
Total traceability is one of the pillars of digital transformation, one of the main driving forces in the 4.0. plant.

As part of an approach to maximize quality, the Full Track and Trace project provides the history of the vehicle as it is put together, rather like an ID card! We can see the context in which it was built, who by, and we can track it through to delivery. The customer has access to all the stages preceding vehicle reception.

The Packaging Managing System tracks every parcel. As packaging can be expensive – sometimes costing more than the part inside – real-time tracking is a major objective. In this way, the plant is able to keep a tight rein on inventory and procurement. All efforts are made to avoid disrupting production.

2200
LoRa Sensors

Our perspective:
Full traceability is at the core of our approach to quality. It also contributes to cost efficiency. By improving part identification, standardizing traceability, associating a part with a production process and implementing geolocation data, we are able to track logistics in real time. We save time in managing inventory, which is sized to the minimum necessary. In the plants, various technologies such as RFID chips and the LoRa protocol (Long Range) are used.

New technologies create value for our business. We have made real savings in packaging. We are proud to have developed the first Alliance logistics flow featuring geolocated packaging, using LoRa technology. This protocol allows small amounts of data to be collected in real time, with great accuracy and customization.
DANIEL
Senior Manager Logistics, Pitesti plant (ROMANIA)



















Renault - Industrial Engineering Activities 



NOVEMBER 29, 2019 All news
RENAULT-NISSAN-MITSUBISHI ACCELERATE OPERATIONAL EFFICIENCY OF THE ALLIANCE

PRESS RELEASE – November 29, 2019

Renault-Nissan-Mitsubishi, the world’s leading automotive alliance, held its monthly Alliance Operating Board Meeting in Boulogne-Billancourt, France, attended by Jean-Dominique Senard, Chairman of the Alliance Operating Board and Renault, Makoto Uchida, nominated CEO Nissan Motor Co, Osamu Masuko, Chairman Mitsubishi Motors, Clotilde Delbos, acting CEO Renault, Takao Kato CEO Mitsubishi Motors, Ashwani Gupta, nominated COO Nissan Motor Co, Jose-Vicente de Los Mozos, acting Deputy CEO Renault and Olivier Murguet, acting Deputy CEO Renault.

The meeting concentrated on improving the efficiency of the Alliance with a deep, common understanding of the work to be achieved by the Alliance in the future.

The Board members all agreed on programs to significantly enhance and accelerate the operational efficiency of the Alliance for the benefit of the three companies, including action plans to maximize the contribution of the Alliance to support each company’s strategic plan and operating profit.

Synergy based operational efficiency target is more than €10 billion cost reduction by the end of 2022
https://www.alliance-2022.com/news/renault-nissan-mitsubishi-accelerate-operational-efficiency-of-the-alliance-and-will-appoint-alliance-general-secretary/

RENAULT-NISSAN-MITSUBISHI INCREASE ANNUAL SYNERGIES TO €5.7 BILLION
PRESS RELEASE – Paris/Yokohama/Tokyo, June 13, 2018

• Annual synergies rise 14%, from €5 billion in 2016 to €5.7 billion in 2017
• Mitsubishi Motors reports first full year of synergies as Alliance member
• Further convergence underway in Aftersales, Quality & Total Customer Satisfaction and Business Development
• The Alliance reaffirms synergy target of more than €10 billion by the end of 2022
https://www.alliance-2022.com/news/renault-nissan-mitsubishi-increase-annual-synergies-to-e5-7-billion/


Lean Leadership
March 24, 2014

Renault-Nissan Consulting’s Managing Consultant Dean Simpson shares his view on Lean Leadership principles.

Lean principles

What are the key concepts of Lean thinking?


A clear focus on everyone meeting the external customer’s requirement
A clear definition of internal/supplier relationships

All value-adding activities in the organisation should be improved
All non-value adding activities should be removed
A faster process is a better process
Effective measurement and analysis of processes
https://renaultnissanconsulting.wordpress.com/2014/03/24/lean-leadership/

Where is industrial engineering in Renault's lean?

All value-adding activities in the organisation should be improved
All non-value adding activities should be removed
A faster process is a better process
Effective measurement and analysis of processes

All the above four are achieved by IE methods and techniques

An interview with lean thinking pioneer Freddy Ballé (Renault)
July 30, 2019
http://leaninpublicsector.org/an-interview-with-lean-thinking-pioneer-freddy-balle/

https://www.scality.com/solved/lean-management-with-michael-balle/

https://www.koganpage.com/article/why-should-leaders-switch-from-lean-to-hyper-manufacturing (The idea of hyper-frugality has attracted many companies (industrial or not), such as Renault, which developed its Dacia Logan following the principles of hyper-frugality).


January 20, 2013

Akira Sakurai who successfully steered Renault-Nissan Automotive India, operations in the initial phase of production  as Chief Executive Officer & Managing Director of RNAIPL,  has now been appointed as SVP, Manufacturing & Industrial Engineering division at the Corporate Headquarters in Japan.
https://www.business-standard.com/article/companies/renault-nissan-appoints-kou-kimura-as-ceo-md-111042000225_1.html


Renault - Industrial engineers


Adnane BOULAHFA
Industrial Engineer
Paris Area, France
Renault-Nissan-Mitsubishi
Dec 2017 – Dec 2019

https://www.linkedin.com/in/adnane-boulahfa-048b1595/

İrem Nizamoğlu
Industrial Engineer at Groupe Renault
Bursa, Turkey
https://www.linkedin.com/in/irem-nizamo%C4%9Flu-106875183/


Mesut GURCAN
Industrial Engineer chez Renault-Nissan-Mitsubishi
France

Aftersales Logistics Industrial Engineer
Renault-Nissan-Mitsubishi
Jul 2017 – Present

• In charge of Aftersales APW (Alliance Production Way) activities for European Division
• APW and Lean Coach
• DMD Auditor through European Spareparts Warehouses (7 countries)
• Realisation of “Lean Improvement Chantier” at Suppliers and internally
• Monitorisation of Standard Operation definition for the new WMS project
• Support for training and monitoring of the QRQC Problem Solving method
• Carry out Quick win Kaizen actions
• Definition of shared standard methods and tools with NISSAN
https://www.linkedin.com/in/mesut-gurcan-55aa9171/

kamar ait lemqeddem
Industrial Engineer chez Renault-Nissan-Mitsubishi
Paris Area, France
https://www.linkedin.com/in/kamar-ait-lemqeddem-641073a0/

RENAULT CHOOSES DASSAULT SYSTÈMES FULL V6 PLM TO IMPROVE THE COMPANY’S PRODUCTIVITY

Renault and Dassault SystĂšmes pioneer ground-breaking approach: Global online Collaboration to boost Innovation. Renault has selected Dassault SystĂšmes’ V6 PLM (Product Lifecycle Management) as its new global product development solution, in order to improve productivity.

Renault has already started to implement the ENOVIA V6 based collaborative platform and CATIA V6, and will rapidly move to the full DS V6 portfolio to enable the company and its suppliers to collaborate on the creation of new product designs in real time.

Renault will deploy V6 PLM in all geographies and throughout all brands. The online access to the digital mock-up (DMU) will lead to a simplification of the collaboration between engineering sites. This use of a unique, collaborative interface for all developers worldwide supports simultaneous product/process engineering to get it ‘right the first time’.
https://www.cadcam-group.eu/blog/renault--press-release

Renault Samsung ranks high in productivity in Harbour Report
By Shim Woo-hyunPublished : Nov 28, 2017
http://www.koreaherald.com/view.php?ud=20171128000911

https://www.fleetnews.co.uk/news/2002/7/16/renault-has-biggest-number-of-productive-plants/11877/


Nissan

BBC Video on Lean in Nissan - for Students

https://www.bbc.co.uk/teach/class-clips-video/business-ks4-gcse-steph-mcgovern/zdp6gwx


Ryan McDaniel
Director, Manufacturing Strategy & Planning Office at Nissan North America
United States
https://www.linkedin.com/in/ryan-mcdaniel-74b77012/


Industrial engineers are employed and productivity improvement and cost reduction are practiced in many companies using Industrial engineering philosophy, principles, methods, techniques and tools.

Index to Industrial Engineering Practice in Top Global Manufacturing Companies - Top 100

Online Handbook of Industrial Engineering

Wednesday, April 17, 2024

Otis - Industry 4.0 - Industrial Engineering 4.0 - Productivity and Quality Engineering and Improvement

 Industrial Engineering 4.0 - Computer Aided Industrial Engineering: Work Systems Analysis in Industry 4.0

Rao, Kambhampati Venkata Satya Surya Narayana; Rathod, Aniket.  IIE Annual Conference. Proceedings; Norcross (2021): 49-54.

https://www.proquest.com/openview/d32ef32bbaa911d170e046479790c035/1   


8550+ Downloads/Reads so far. 

INTRODUCTION TO MODERN INDUSTRIAL ENGINEERING. 
Free Download EBook (122 pages).  Download from:

https://academia.edu/103626052/INTRODUCTION_TO_MODERN_INDUSTRIAL_ENGINEERING_Version_3_0 


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

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.


How many Industrial Engineers can a Company Employ for Cost Reduction?
For $100 million cost, there can be one MS IE and 6 BSIEs.



Otis

We move 2.3 billion people a day and we maintain ~2.3 million customer units worldwide - the world’s largest portfolio. We can be found in many of the world’s most recognizable buildings as well as the busiest transportation hubs and retail centers. We are everywhere people are on the move.

Otis President Judy Marks  - How to meet the expectations of the digitized world promised by Industry 4.0?

Given the availability of technology to acquire and capital to invest in facilities,   “I think how Industry 4.0 gets applied and the pace at which it gets applied, is  based on  how it can be adopted, reduced to practice, and then put into operation.” 

We are into service transformation using industry 4.0.

We have to push ourselves into what is possible now. We should not get stuck with what we have done till now.

2018


2024



Otis China Opens Industry 4.0 Escalator Factory in East China
2020 SHANGHAI, CHINA





Otis  Company - Industrial Engineering Activities and Jobs

https://www.otis.com/en/us/about/meet-the-team/





Emory Head, III
Industrial Engineer at Otis Elevator Company
Florence, South Carolina

Mechanical Engineer with 3+ years experience in research and analysis of various materials. Skilled in investigating previous works and developing novel techniques and/or materials for overall improvement and effiiency. Also experiened in proctoring classes (Freshman Engineering) as well as providing detailed AutoCAD (NX 5.0, NX7.5) tutorials and lesson plans.
https://www.linkedin.com/in/emory-head-iii-2a8a2430/

Kevin Hwang
Industrial Engineer at Otis Elevator Company
Greater Atlanta Area

Since Mar 2012
LocationFlorence, South Carolina Area

Develop and maintain Manufacturing Tracking System.
Comprehensive database management and migration from concept to JDE.
Generate and maintain BOM and ECN.
Root cause analysis, quality control, Perform Process Mapping & Value Stream mapping
Review and evaluate STD processes and procedures for various MFG lines
https://www.linkedin.com/in/kevin-hwang-a465079/



Omkar Kiran Inamdar
Industrial Engineer at Otis Elevator Co.
Florence, South Carolina

Industrial Engineer with an academic and professional experience in process improvement and cost optimization solutions, highly focused on Lean Manufacturing and Material Flow Management.

Achievements:
1. Manufacturing operations cost savings of over $480k
2. Generated future state scenarios for process improvement
3. Updated Standard Work sheets for 6 assembly lines

Education
Western Michigan University
Western Michigan University
Degree NameMaster of Science - MSField Of StudyIndustrial Engineering
Dates attended or expected graduation2016 – 2018
https://www.linkedin.com/in/omkar-kiran-inamdar/


Meltrin Segars
Industrial Engineer at Otis Elevator Company
Goose Creek, South Carolina

About
Experienced Industrial Engineer with a demonstrated history of working in the consumer services industry. Skilled in Manufacturing Operations, Electrical Wiring, Manufacturing, Root Cause Analysis, and Lean Manufacturing. Strong operations professional with a Master's degree focused in Management and Leadership from Webster University.

Since Aug 2013

• Time studies / Standard times
• Improvement Techniques
• Kanban
https://www.linkedin.com/in/meltrin-segars-958b1470/







Industrial engineers are employed and productivity improvement and cost reduction are practiced in many companies using Industrial engineering philosophy, principles, methods, techniques and tools.

Index to Industrial Engineering Practice in Top Global Manufacturing Companies - Top 100

Online Handbook of Industrial Engineering






Friday, April 12, 2024

K-Water - Hwaseong - REPUBLIC OF KOREA - Industrial Engineering 4.0 - WEF - McKinsey Light House Plant

Industrial Engineering 4.0 - Computer Aided Industrial Engineering: Work Systems Analysis in Industry 4.0

Rao, Kambhampati Venkata Satya Surya Narayana; Rathod, Aniket.  IIE Annual Conference. Proceedings; Norcross (2021): 49-54.

https://www.proquest.com/openview/d32ef32bbaa911d170e046479790c035/1   


8900+ Downloads/Reads so far.  (9.5.2025)

INTRODUCTION TO MODERN INDUSTRIAL ENGINEERING. 
Free Download EBook (122 pages).  Download from:

https://academia.edu/103626052/INTRODUCTION_TO_MODERN_INDUSTRIAL_ENGINEERING_Version_3_0 


K-Water - Hwaseong

ENERGY & UTILITIES

The climate crisis has caused significant water supply concerns, as heatwaves and heavy rains create more volatile and turbid supplies. To address this, K-water launched a next-generation AI water treatment plant to reduce production costs, improve responsiveness and reduce human error. It is being scaled across 40+ other sites.

It has helped K-water to reduce its chemical usage by 19%, improve labour efficiency by 42% and reduce power consumption by 10%.


https://www.kwater.or.kr/eng/busi/sewaPage.do?s_mid=1289


https://en.wikipedia.org/wiki/Hwaseong,_Gyeonggi



http://newsworld.co.kr/detail.htm?no=9676


https://www.rcrwireless.com/20240103/industry-4-0/industry-4-0-lighthouses-commended-for-ai-based-productivity-sustainability-gains


http://49.247.192.66:8080/pages/story/MH/cont?rawid=510633



https://archives.kdischool.ac.kr/bitstream/11125/42656/1/A%20Study%20on%20the%20establishment%20of%20autonomous%20operation%20system%20for%20data-based%20water%20purification%20facilities.PDF


https://www.linkedin.com/posts/daehyun-bae-8b95b0bb_kwater-smart-water-activity-6912820629905825792-1E3J







Video

AI-based Smart Opeation for Water Treatment Plant (K-water)


 9 Jun 2023


K-water Research Institute


https://www.youtube.com/watch?v=0YSsnveCID8


water utilities need Innovation in the fourth industry Revolution bid data AI Technologies are accelerating Industries are opening a new chapter converging with digital Technologies K Water realized the digital transformation of its water treatment plants by introducing big data and AI into its water operations K-water the world's first Smart Water Treatment Plant Smart Water Treatment Plant Technologies consist of four functions autonomous operation Energy Management predictive maintenance and intelligent video surveillance after learning from data like water quantity slash quality the AI operates the water treatment process on its own reducing energy usage and achieving carbon neutrality through operation optimization and power Peak management monitoring facility conditions and self-diagnose AI detects incidents in water utilities with CCTV and enables workers to respond quickly the autonomous operation consists of eight water treatment processes intake chemical dosing sedimentation Etc AI predicts and controls the valve opening of the intake well the chemical dosing process categorizes raw water qualities into clusters and predicts coagulant dosing rates AI predicts and controls the speed of the flocculator AI predicts the amount of sediment and operates sludge collectors AI operates  by predicting the operating number of filter basins and scheduling the backwash filtration process the disinfection process is operated by deriving the chlorine injection rate from the residual chlorine evaporation predicted by the AI energy management system reduces energy use by optimizing the operation of energy-intensive facilities and managing power Peaks AI predicts the minimum required pie pressure in the distribution area and controls the water pump manage power Peak with AI predicted power demand values the predictive maintenance system uses AI to monitor the status of key facilities in real-time and autonomously diagnose any abnormalities Monitor and analyze facility operations data in real time the AI recognizes the abnormal data and identifies the failure mode in the equipment and suggests the cause of the failure the intelligent video surveillance system uses AI to detect eight items fire pipe leakage falling electric shock Etc through CCTV and enforces Safety Management and Water Treatment Plant works with these Technologies Smart Water Filtration has the real-world impact of planting 4 million pine trees through annually reduced power chemicals maintenance and carbon reduction from worker-centered operations to Ai and workers convergence shift paradigm in addition K water will complete a fully autonomous operation system by 2030 through the application of advancing AI Technologies to all 42 water treatment plants by collaborating with Global Partners we hope K water's Smart Water Treatment Plant technology would become a global model in response to the climate crisis K water is taking a step forward with Smart Water Technologies



Ud. 9.5.2024

Pub. 12.4.2024





Thursday, April 11, 2024

Johnson & Johnson - Industrial Engineering - Productivity Improvement Activities - Industry 4.0 Lighthouse Plant

Industrial Engineering 4.0 - Computer Aided Industrial Engineering: Work Systems Analysis in Industry 4.0

Rao, Kambhampati Venkata Satya Surya Narayana; Rathod, Aniket.  IIE Annual Conference. Proceedings; Norcross (2021): 49-54.

https://www.proquest.com/openview/d32ef32bbaa911d170e046479790c035/1  





Industry 4.0 Lighthouse Plant

Johnson & Johnson - Xi’an

60% decrease in non-conformance, while improving productivity by 40%, operating costs by 24% and GHG emissions by 26%.


To improve agility and responsiveness, raise quality standards and enhance competitiveness, Johnson & Johnson Xi’an replaced its manual facility with a Fourth Industrial Revolution-enabled new factory in 2019. This facility includes digital twins for technology transfer and material handling, intelligent automation of continued process verification (CPV) and batch execution processes. This has shortened the product transfer time by 64% during site relocation and has enabled a 60% decrease in non-conformance, while improving productivity by 40%, operating costs by 24% and GHG emissions by 26%.

PEOPLE'S REPUBLIC OF CHINA

Johnson & Johnson - Xi’an



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.

___________


_________________






Johnson & Johnson


Commendable Cost Reduction in Number of Years. Every Industrial Engineer must achieve and claim such cost reductions.


Tara Ramsey
Head of Consumer NA Supply Chain Sourcing
Skillman, New Jersey

Johnson & Johnson
Head of Consumer NA Supply Chain Sourcing
since May 2018

Director, Transportation Sourcing and Supplier Performance
Nov 2014 – May 2018

Group Manager, Direct Materials and Supplier Engineering
Jun 2010 – Feb 2011

• Responsible for $100MM in raw material and packaging spend annually; manage year on year cost reduction goal of $10MM.

Commodity Manager
Johnson & Johnson Vision Care, Inc.
Jan 2007 – Jun 2010

• Manage $50MM in raw material and packaging spend annually with global suppliers between Jacksonville, FL and Limerick, Ireland manufacturing plants.
• Consistently exceeded savings targets of 10%, to achieve +$5MM in cost reduction and improvement projects annually.

Senior Strategic Buyer
Company NameJohnson & Johnson Vision Care, United Kingdom
Aug 2004 – Dec 2006

London, England
• Created and led the Non Stock Purchasing Department for Vision Care EMA, including all indirect purchases and the supervision of the requisition to pay process within the SAP environment
• Manage $72MM in spend annually across 16+ major markets using 2000+ suppliers, collaborating with 3 Regional Managing Directors and their EMA-wide staff
• Achieved $3.8MM in cost savings across Marketing & Sales, Transportation, Media and other disciplines which is 5% savings of total spend (exceeded 2006 goal of $2MM)

• Led the first Vision Care EMA Advertising negotiation in EMA history, achieving a $400M cost savings (40% of total annual spend)

• Analyzed, then strategically bid both the inbound and outbound transportation of finished goods, achieving $1.2MM in cost savings, which was directly removed from SG&A by Finance business partners


Johnson & Johnson Consumer Products Company
Jan 2004 – Aug 2006

Manage $5.9MM in Marketing & Sales spend achieving annual savings of $400M (6% of total spend).
Established business partnership with Marketing, Sales, Trade Promotions, Trade Marketing, and Supply Chain to successfully launch new products and promotions while identifying on-going cost savings opportunities. Increased Purchasing penetration by 65%.

Reengineered Marketing Print process for Johnson & Johnson Consumer Products and incorporated the use of eSourcing tools. Completed over 65 projects contributing $210M in savings.

Led Neutrogena’s deployment of new Marketing Print process to include qualifying preferred suppliers, end-user training, process adoption, and metrics. Savings generated in 4 months were $240M.

Team lead for Non Stock collaboration (with Vistakon) to further leverage CPC knowledge and expertise of Print Buying. Generated $200M savings (incremental to business plan) by standardizing certain printed pieces

Achieved green belt certification by reducing Ariba mismatches by 72% for 13 core users yielding an annual financial savings of $30M; process then yielded less than 5% mismatches of total invoices, exceeding Corporate goal

https://www.linkedin.com/in/tara-ramsey-6869494/



Energy Efficiency Improvement at Johnson & Johnson


Johnson & Johnson Strives to Implement
Best Practices by Year 2000
Harry A. Kauffman, Johnson & Johnson

In 1995, after a year and a half of development, J&J rolled out Best Practices for energy efficiency. There are 150 in all and every one of them has been completed by at least one of the  facilities around the world and therefore they are validated ideas. They are state of the art technologies and practices, they are not projects with extremely high paybacks. J&J used as a cost effectiveness test an internal rate of return of 20%, which is about a 5 year simple payback. The facilities are not forced to implement each of  them. They need prepare project feasibility reports and  implement all that pass the cost effectiveness test. They are actually encouraged to go beyond these practices and develop new practices. In addition, an on-going process to identify new technologies that are developed and proved to be cost effective will be added to the Best Practices.

Examples of the Best Practices include:

Stage 1: Upgrade lighting with T-8 or T...5 fluorescents, occupancy sensors, metal halide or high pressure sodium, Light Emitting Diode (LED) exit signs and implement group relamping.

Stage 2: Perform preventive maintenance and calibrations, challenge and fine tune operating schedules, survey leaks including steam traps and compressed air, track, graph, analyze, and publicize energy usage and cost, develop pie chart of functional usages of energy, and optimize energy purchasing.

Stage 3 Upgrade office equipment. Upgrade building envelope with double-paned windows, and appropriate insulation, seal any openings, and complete a thennographic scan of the entire building.

Stages 4 & 4+: Evaluate all motor systems throughout the facilities and upgrade including technologies such as premium efficient motors, variable speed drives, and Direct Digital Control.

Upgrade Chillers, Boilers, Compressed Air and Electrical Distribution to include: non-CFC, central-chiller water system with 0.56 KW/Ton water-cooled chillers with variable speed drives, primary/secondary chilled water pumping system, low excess air burner for the boiler with stack economizer and blow-down heat recovery, automated compressed air systems with proper storage,
looped piping system, and minimum pressures, and k rated energy efficient transfonners with capacitors for power factor correction.

To validate the bundle of Best Practices, two facilities were selected as pilots.  Ethicon Endo-Surgery manufacturing facility in Albuquerque, NM completed all 150 of the Best Practices by 1997 and reduced their overall energy usage by 23% and energy costs by $156,403. They were recognized for this effort by "Energy User News" magazine with an Efficient Building Award in 1998 in the Industrial category, as well as by the EPA as its Outstanding Building Upgrade for 1998.

The other pilot was a multi-company (two companies), multi-facility (four buildings -- one administration and three manufacturing) operation in Manati, PRe. They have completed 97% of the Best Practices (inability to shutdown equipment has delayed some motor upgrades) and reduced their overall energy by 28% and energy costs by $604,630. In addition to the typical upgrades, they consolidated their individual steam, chilled water and compressed air systems. They shared the EPA's Outstanding Building Upgrade with the Albuquerque facility.

The cost, savings and paybacks vary by grouping of Best Practices. The average simple paybacks for completed project by Stage have been: Stage 1 OM 2.15 years, Stage 2 ... 2.48 years, Stage 3 - 3.46 years, Stages 4/4+ - 2.79 years, Stage 5 - 10.. 15 years.


Design to Value

https://www.sec.gov/Archives/edgar/data/200406/000020040619000009/form10-k20181230.htm



Process Excellence in the Manufacturing Value Chain
Learn how J&J is using Six Sigma, Lean and other techniques to achieve process excellence in its manufacturing operations.
Sep 14, 2004
https://www.pharmamanufacturing.com/articles/2004/91/


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

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.


Industrial engineers are employed and productivity improvement and cost reduction are practiced in many companies using Industrial engineering philosophy, principles, methods, techniques and tools.

Index to Industrial Engineering Practice in Top Global Manufacturing Companies - Top 100

Online Handbook of Industrial Engineering



ud. 26.1.2024
Pub. 11.4.2020