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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.
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).
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.
Uzwil (Switzerland), November 3, 2021 – With the Carat 840 and the Carat 920, Bühler has further extended its portfolio as the automotive industry’s demand for larger and more complex parts continues to increase.
Bühler's vision for the future of the die casting industry is: 0% scrap, 40% less cycle time, and 24/7 uptime.
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
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
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
Waste and inefficiency in outdated government IT systems.
A recent BBC article has drawn attention to the extraordinary amount of wasted expenditure on outdated IT systems in government. The article, drawn from a Cabinet Office report entitled ‘Organising for Digital Delivery’, notes that the government’s use of outdated technology – with some systems being over thirty years old.
The price tag for keeping many outdated systems alive is an astonishing £2.3 billion per year – almost half of the government’s £4.7 billion annual IT expenditure.
Data-Driven 3D Printers: The Real Game-Changers for Manufacturing? Artificial intelligence and machine learning take additive to the next level.
Connected 3D printers can use collected data for artificial intelligence-powered automation. During each print job, 3D printers produce large quantities of data that are sent to and stored in the cloud. This data can help businesses make decisions about which parts to print and how best to print them, while improving the quality of print jobs.
Machine learning can optimize hardware, automatically enhancing 3D printers through software updates to increase printing speeds and improve resolution. AI can help businesses determine which parts, when produced in-house through additive manufacturing, will have the biggest impact on their bottom line. It can use digital catalogs of parts and detect which specific parts are the best candidates to be printed through various additive manufacturing techniques.
3D printers can use machine learning to automatically generate tooling jigs or fixtures to hold the parts they print. AI-based optimizations are used during the design stage of new parts — simulating how the digital design for a part, once printed, will perform under specific loads. AI is also employed in additive manufacturing to detect print failures (proactively pausing prints when needed), and to inspect parts as they’re being printed to ensure quality and conformance.
A Closed Loop
The same hardware out in the field is consistently learning, improving and getting smarter with every over-the-air update. As providers advance the quality of information collected during fabrication and build modes of collecting data about how each 3D printed part does its job on the field, manufacturing technology approaches a fully automated “closed-loop” printing process: One that can simply be presented with a real-world manufacturing problem to solve, and then design and build the part using the specific digital fabrication technology that makes the most sense given the defined time, cost, and performance constraints.
This smart, closed-loop automation of fabrication can substantially increase outputs and production speeds. And while additive manufacturing inherently streamlines the process of building parts, each savvy application of data collected by the printers can streamline distinct points within the additive manufacturing process.
Productivity of 3D Printing - Additive Manufacturing - High-speed 3D printing and the expanding material choice
3D Printer manufacturers are focusing on developing technologies that support higher production volumes, and materials that enable advanced AM applications. As a result, on the hardware side, the rise of binder jetting and multi-laser powder bed fusion for metals and vat photopolymerisation processes for plastics is occurring. Materials manufacturers are increasingly focusing on high-performance materials, including advanced alloys and composites.
The introduction of high-speed polymer AM technologies has significantly boosted the growth of 3D printing in dental. As estimated by the market research firm SmarTech, the AM dental and medical industry has topped $3 billion. Over 70% of dental labs in the US are predicted to own 3D printing technology by the end of 2021, with dental 3D printing becoming a $9.2 billion industry in the next five to seven years.
Metal powder bed fusion: Metal 3D printing encompasses many technologies, but one of the most matured among them remains metal Powder Bed Fusion (PBF). Key market players are launching solutions for automated and integrated production. They offer a high level of automation in a bid to maximise efficiency and reduce the amount of manual labour required. Thanks to these developments, laser PBF has found its way into many industries and applications. One industry that has been adopting metal PBF is aerospace. Today, metal PBF 3D-printed parts are powering crucial aircraft and spacecraft systems like engines. This is where the technology’s key capabilities — the production of complex parts with simplified assembly and less material waste — truly shine.
New launches of Additive Manufacturing systems with enhanced productivity (e.g. SLM Solutions, ExOne, Nexa3D, Voxeljet, EOS Systems), and a growing number of software companies in the field of AM boost the hope for applying AM technologies for a larger share of components. We at VTT & Aalto University are supporting productivity improvement of AM and have been developing and testing promising bio-based engineering materials produced from sustainable sources within the ValueBioMat project. We are focusing on advances in material science and innovation that are needed to get prepared for the future of AM, with productivity in line with sustainability.
BOFA International (Poole, UK) has developed an innovation that makes the exchange of filters in metal additive manufacturing processes safer, faster, and better for productivity. The laser powder-bed fusion process used in metal additive manufacturing needs filters. When new filters are needed for these systems, equipment has to be shut down and moved to a safe area for the saturated filters to be removed and replaced by operatives wearing full PPE—up until now. The new standalone AM 400 system’s technology enables the filters to be exchanged on site without risking a thermal event. The BOFA’s AM 400 filters are contained within a separate housing with a robust seal, enabling filter exchange to be completed quickly and safely without isolating the additive manufacturing equipment. This will reduce downtime of the equipment and increase productivity.
Application of Industrial Engineering Focus Areas in Additive Manufacturing
Productivity Science - Additive Manufacturing
Productivity science has to indicate process parameters that contribute to productivity improvement.
INFLUENCE OF PROCESS PARAMETERS ON THE MECHANICAL BEHAVIOUR AND PROCESSING TIME OF 3D PRINTING
Ramu Murugan, Mitilesh R.N, Sarat Singamneni
International Journal of Modern Manufacturing Technologies,
Vol. X, No. 1 / 2018 http://www.ijmmt.ro/vol10no12018/10_Murugan_Ramu.pdf
Ingrassia T., Nigrelli V., Ricotta V., Tartamella C. (2017) Process parameters influence in additive manufacturing. In: Eynard B., Nigrelli V., Oliveri S., Peris-Fajarnes G., Rizzuti S. (eds) Advances on Mechanics, Design Engineering and Manufacturing. Lecture Notes in Mechanical Engineering. Springer, Cham https://link.springer.com/chapter/10.1007/978-3-319-45781-9_27
Antonio Lanzotti, Marzio Grasso, Gabriele Staiano, Massimo Martorelli, (2015) "The impact of process parameters on mechanical properties of parts fabricated in PLA with an open-source 3-D printer", Rapid Prototyping Journal, Vol. 21 Issue: 5, pp.604-617, https://doi.org/10.1108/RPJ-09-2014-0135 https://www.emeraldinsight.com/doi/full/10.1108/RPJ-09-2014-0135
A Process Modelling and Parameters Optimization and Recommendation System for Binder Jetting Additive Manufacturing Process
Product Design Improvement for Productivity - Design for Additive Manufacturing
A design framework for additive manufacturing based on the integration of axiomatic design approach, inverse problem-solving and an additive manufacturing database
by
Sarath Renjith
MASTER OF SCIENCE
Major: Industrial Engineering
Program of Study Committee:
Gül Erdem Okudan Kremer, Major Professor
Michael Scott Helwig, Committee Member
Mark Mba-Wright, Committee Member
Iowa State University
Ames, Iowa
2018 http://www.imse.iastate.edu/files/2018/11/Chennamkulam-RenjithSarath-thesis.pdf
Process Improvement for Increasing Productivity of Additive Manufacturing
30 January 2018
To improve additive manufacturing productivity and lower cost per part, Renishaw has launched its latest system, the RenAM 500Q. Featuring four 500 W lasers, the compact machine will greatly improve productivity in the most commonly used platform size https://www.renishaw.com/en/pioneering-productivity-in-additive-manufacturing--43150
VERY HIGH POWER ULTRASONIC ADDITIVE MANUFACTURING (VHP UAM)
FOR ADVANCED MATERIALS
K. F. Graff, M. Short and M. Norfolk
Edison Welding Institute, Columbus, OH 43221
2010
To extend current ultrasonic additive manufacturing (UAM) to advanced materials, higher speeds and larger parts, it was essential to greatly increase the process ultrasonic power. EWI,
with Solidica™, several industry, agency and academic partners, and support of Ohio’s Wright
Program, have developed a “Very High Power Ultrasonic Additive Manufacturing System” that
greatly extends current technology. A key part was the design of a 9.0 kW “push-pull”
ultrasonic system able to produce sound welds in materials such as Ti 6-4, 316SS, 1100 Cu and
Al7075. The VHP system can fabricate parts of up to 1.5m x 1.5m x 0.6m. http://sffsymposium.engr.utexas.edu/Manuscripts/2010/2010-06-Graff.pdf
Industrial Engineering Economic Analysis of Additive Manufacturing
Optimal process parameters for 3D printing of dental porcelain structures
Hadi Miyanajia, Shanshan Zhanga, Austin Lassella, Amir Ali Zandinejadb, Li Yanga
Department of Industrial Engineering, J.B. Speed School of Engineering
Department of Oral Health and Rehabilitation, School of Dentistry
University of Louisville, KY, 40292
2015 http://sffsymposium.engr.utexas.edu/sites/default/files/2015/2015-132-Miyanaji.pdf
Human Effort Industrial Engineering of Additive Manufacturing
Industrial Engineering Measurements - Cost, Productivity and Time Measurement of Additive Manufacturing
Resource Consumption of Additive Manufacturing Technology
Nanond Nopparat, Babak Kianian
School of Engineering, Blekinge Institute of Technology Karlskrona, Sweden
2012
Thesis submitted for completion of Master of Sustainable Product-Service System Innovation (MSPI)
Blekinge Institute of Technology, Karlskrona, Sweden. https://www.diva-portal.org/smash/get/diva2:831234/FULLTEXT01.pdf
Technology Adoption
Partnering in Technology Development for Productivity Improvement
Volkswagen adopts the latest 3D printing technology, the "HP Metal Jet" process, which simplifies and speeds up metallic 3D printing. The process improves productivity by a simply staggering 50 times compared to other 3D printing methods for some components.
This process produces production-ready components for mass production applications in the automotive industry for the very first time. Volkswagen has closely partnered with printer manufacturer HP and component manufacturer GKN Powder Metallurgy in development for mass production use. The new process was demonstrated at the International Manufacturing Technology Show (IMTS) in Chicago this week.
85% Cost Reduction Due to Additive Manufacturing - $50,000 to $7,000.
10 sets of inlet booster rake for measuring air flow turbine engine test cells were made for $50,000 using a combination of welding, brazing, EDM, and other conventional medicines. The additive machining technology center made it for $7,000.
Huge Savings at Company Level - Honeywell Federal Manufacturing & Technologies
Honeywell Federal Manufacturing & Technologies has achieved huge cost reduction. As of FY 2018, they have printed more than 60,000 tooling fixtures for product testing and calculated $125 million in cost avoidance.
Design for Additive Manufacturing - Additive Manufacturing Industrial Engineering are Necessary for Effectiveness and Productivity
Huge Hybrid Manufacturing Machine is Ready to Start 3D Printing Construction Parts and Structures and Give Higher Productivity
31 JAN 2019
The machine will be tested to manufacture demonstrator parts, such as large cantilever beam structures, airplane panels and wind turbine parts. The machine and the process technologies are expected provide a more productive solution for the hybrid manufacturing of large engineering parts and deliver a projected 20% reduction in time and cost expenditure, as well as a target 15% increase in productivity for high-volume additive manufacturing production. https://adsknews.autodesk.com/news/huge-hybrid-manufacturing-machine-ready-to-start-3d-printing-construction-parts
Rather than building up plastic filaments layer by layer, a new approach to 3D printing lifts complex shapes from a vat of liquid at up to 100 times faster than conventional 3D printing processes, University of Michigan researchers have shown.
Michigan Engineering
January 11, 2019 https://news.engin.umich.edu/2019/01/3d-printing-100-times-faster/
SLA 3D Printing 100 Times Faster
________________
________________
MIT Researchers Developed FDM 3D Printing Head that makes Build Speed 10X
A. John Hart, an associate professor of mechanical engineering and director of the Laboratory for Manufacturing and Productivity and the Mechanosynthesis Group at MIT.
Screw mechanism for feeding the wire and a laser in the printhead to melt the wire more thoroughly were incorporated into the print head.
–Size of extrusion nozzle opening: ; The bigger the opening the more the material flow.
–Size of part to be printed. More volume, more time
–Part orientation on the build bed. X-Y orientations can usually be built faster than parts set up to build in the Z orientation.
–Complexity of part to be printed. Parts with many angles, curves and other geometric features will take longer to build than a straightforward box type shape.
–Material choice. In extrusion systems, every material flows at a different rate.
–Type of laser used in powder-bed systems.
–Type of material used in powder-bed systems. Plastics and metals will build at different rates.
–Required print resolution; Fine resolutions mean slower build rates.
–Part density. Fully dense parts can take longer to build than those with filler support.
The Ultimaker desktop 3D printer, gives its depositio rates as: With a 0.25 size nozzle, it is up to 8 mm3/s, a 0.40 nozzle it is up to 16 mm3/s, a 0.60 nozzle up to 23 mm3/s, and a 0.80 nozzle can deposit up to 24 mm3/s.
Professional 3D printer, the SLM Solutions 500HL gives deposition rates for its two-laser version as 55 cubic centimeters/hour, and its four-laser version as 105 cubic centimeters/hour.
Comparison of FDM, SLA and SLM
Fused Deposition Modeling (FDM)
Fused Deposition Modeling is the most widely used form of 3D printing at the consumer level. , FDM 3D printers build parts by melting and extruding thermoplastic filament, which a print nozzle deposits layer by layer in the build area. FDM works with a range of standard thermoplastics, such as ABS, PLA, and their various blends. The technique is well-suited for basic proof-of-concept models, as well as quick and low-cost prototyping of simple parts. .
Stereolithography (SLA)
Stereolithography was the world’s first 3D printing technology, invented in the 1980s, and is one of the most popular technologies for professionals. SLA uses a laser to cure liquid resin into hardened plastic in a process called photopolymerization. SLA parts have the highest resolution and accuracy, the clearest details, and the smoothest surface finish of all plastic 3D printing technologies. Material manufacturers have created innovative SLA resin formulations with a wide range of optical, mechanical, and thermal properties to match those of standard, engineering, and industrial thermoplastics.
Selective Laser Sintering (SLS)
Selective laser sintering is the most common additive manufacturing technology for industrial applications. SLS 3D printers use a high-powered laser to fuse small particles of polymer powder. The unfused powder supports the part during printing and eliminates the need for dedicated support structures. SLS is ideal for complex geometries, including interior features, undercuts, thin walls, and negative features. Parts produced with SLS printing have excellent mechanical characteristics, with strength resembling that of injection-molded parts.
Igor Yadroitsev, Ina Yadroitsava, Philippe Bertrand, Igor Smurov, (2012) "Factor analysis of selective laser melting process parameters and geometrical characteristics of synthesized single tracks", Rapid Prototyping Journal, Vol. 18 Issue: 3, pp.201-208, https://doi.org/10.1108/13552541211218117
A successful Process Engineer will use process improvement experience to quantitatively assess current production/business system performance and execute change to reduce cost and optimize capacity.
This role demands excellent communication and interpersonal skills as well as a holistic understanding of manufacturing operations.
This role will focus on creative problem solving and working cross functionally (production, design, quality, finance, supply chain, demand and production planning) to improve capacity, workstation design, and reduce downtime. A successful team member will have excellent critical and creative problem-solving skills with a focus on issue resolution and inter-department engagement.
· Oversees and assesses existing processes and workflows in place and develops SOPs
· Evaluates data to implement improvements in production processes.
· Identify, quantify, compare, and execute production process improvements to drive safety and ergonomics, quality (first pass yield), availability (uptime), performance (cycle time variability), capital utilization, and demand attainment.
· Work cross-functionally to develop and implement best practices for assembly and standard work instructions.
· Identify, propose, manage, and monitor manufacturing improvements.
· Use predetermined time standard methods to analyze and optimize current and future planned manufacturing processes.
· Create and implement tools to audit efficiency and identify cost-reduction opportunities.
· Utilizes process simulation software to test and find the most appropriate production strategies.
· Manage and communicate improvement opportunities and implementation plans to all relevant levels and functions in the factory
· Oversees and assesses existing processes and workflows in place.
· Evaluates data to implement improvements in production processes.
· Creation of reporting documentation for processing status and changes.
· Tracks metrics to discover areas for improvement and monitor upgrades.
· Provides thorough instructions for successful implementation of process changes.
· Conducts risk assessments and develops process flows, PFMEAs, and Control Plans.
· Designs facility layout and personnel requirements in relation to production operations.
· May perform other assignments as required and may travel 15 to 20 % as required.
Skills & Qualifications:
Functional understanding of Statistical Process Control (SPC).
Functional understanding of Value Stream Mapping (VSM), experience is preferred.
Functional understanding of Just-in-Time (JIT) supply chain strategy.
Knowledge of process engineering simulation software (E.g., FlexSim).
Robust knowledge of computer-based tools such as MS Office, Visio, Lucid chart, etc.
Strong Excel skills associated with data analysis.
Experience in MySQL is an added advantage.
Strong attention to detail with a proven ability to identify gaps in operational systems.
Ability to read and interpret assembly/component drawings and engineering specifications.
Demonstrated ability to assess and solve problems.
Familiarity with Environmental Health & Safety regulations.
Demonstrable communication skills:
Written
Verbal
Presentations
Education, Experience, and Licensing Requirements:
BS in industrial engineering or a related field such as manufacturing or mechanical engineering.
2-3 years of relevant work experience in a production environment.
2-3 years experience in continuous improvement activities and knowledge of Lean Manufacturing principles
Experience with industry-standard problem-solving methodologies (A3, 8D, ATS), preventive and autonomous maintenance concepts, time/motion study analysis (MODAPTS preferred), continuous improvement (6 sigma techniques, lean manufacturing), and change management
Master’s degree in engineering is a plus.
About Cox Automotive
At Cox Automotive, people of every background are driven by their passion for mobility, innovation and community. We transform the way the world buys, sells, owns and uses cars, accelerating the industry with global powerhouse brands like Autotrader, Kelley Blue Book, Manheim and more. What’s more, we do it all with an emphasis on employee growth and happiness. Drive your future forward and join Cox Automotive today!
BlueOval SK, LLC · Glendale, KY 7 months ago · 29 applicants
Hybrid Full-timeMatches your job preferences, job type is Full-time. Entry level
5,001-10,000 employees · Motor Vehicle Manufacturing
1 connection works here · 1 school alum works here
Skills: Industrial Engineering, Root Cause Analysis, +8 more
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About the job
Introduction to BlueOval SK
At BlueOval SK, we will lead the transformation of the electric vehicle (EV) battery business through partnership (Joint Venture formed by Ford and SK On) to provide products and processes to increase our customers’ experience. As the future of BlueOval SK, you will help lead the battery revolution by working alongside our teams as we build the batteries required for electric vehicle business excellence.
Ford and SK On are investing billions in Kentucky and Tennessee including building three state-of-the-art battery manufacturing facilities between the two campuses at BlueOval City in Tennessee and BlueOval SK Battery Park in Kentucky. These brand-new advanced manufacturing facilities will use Ford’s 100-years of automobile manufacturing expertise and SK On’s 30+ years of electric vehicle battery expertise to become the world’s best battery manufacturer.
The Industrial Engineer at BlueOval SK Battery Park in Glendale, Kentucky will have a unique, once-in-a-lifetime opportunity to be a key member of the start-up team, launching the facility from the ground up.
Key Areas of Responsibility:
Drive development and/or installation of direct and indirect labor standards and methods.
Track labor, efficient manpower utilization and line balancing
Conduct Job Ergonomics evaluations
Analyze problem process constraints and conduct equipment cycle time analysis
Recommend most efficient distribution of manpower and review daily employee manpower, analyze plant methods and standards
Prepare or direct the preparation of cost estimates of new or revised methods and standards
Review proposed changes in plant layout, processes, material handling, routing, etc.
Analyze production and non-production operations to determine those requiring study and develop new or improved methods and standards
Conduct time and motion/MODAPTS studies and review employee proposals and suggestions
Develop cycle line layouts for current and future models using ACAD. Lead job methodization and process allocations
Coordinate engineering changes and planning. Conduct value stream mapping and process audits
Develop cost saving project proposals and write projects as required
Assist production in planning labor allocations for mix and line speed changes
Minimum Requirements:
Experience:
Must possess the ability to analyze and resolve issues quickly through route cause analysis and drive change back to the production departments. Must have the necessary skill set to have job placement flexibility and the expectation to rotate to various positions within the plant such as Production or Quality
Must display strong customer orientation with a commitment to upholding plant processes through strict adherence to the Quality Operating System.
Must demonstrate the ability to execute to achieve results, while organizing and managing multiple priorities
Must have the ability to serve as a strong and confident technical mentor to the production organization (both hourly and salary)
Must have strong written and verbal communications skills
Ability to support any shift in a 7-day work pattern
Candidate must be flexible to significant travel during initial plant start-up phase
Candidate must be willing to work remotely and in-person at temporary facilities as needed during initial plant start-up phase
Successful candidate must be able to demonstrate leadership behaviors consisting of outstanding interpersonal, teambuilding, and communication skills
Preferred Requirements:
Education: Bachelor’s Degree in Industrial Engineering
Experience: 3-5 years’ experience
MODAPTS Certification
GSPAS knowledge
About BlueOval SK
At BlueOval SK, we will lead the transformation of the electric vehicle (EV) battery business through partnership (Joint Venture formed by Ford and SK On) to provide products and processes to increase our customers’ experience. As the future of BlueOval SK, you will help lead the battery revolution by working alongside our teams as we build the batteries required for electric vehicle business excellence. We have a wide variety of opportunities for you to accelerate your career.
Tesla - Notes taken from the Fireside Chat with Drew Baglino (SVP, Tesla Motors)
Shirley Meng, Professor at The University of Chicago, Chief Scientist of Argonne Collaborative Center for Energy Storage Science
March 28, 2023
The importance of dry electrode
DB’s insights
a. Manufacturing at SCALE requires reducing site footprint, labor cost and CAPEX cost – dry processing can enable reduction of these things by a factor of 3.
b. Dry processing can overcome the speed limit set by wet processing. A factor of 2 to 3 enhancement in manufacturing speed is possible, for example, 200-300m/min production speed is possible.
c. Single percentage yield improvement matters now because the metal prices (Li, Ni, Co) are going up. This is important that the yield of dry process continues to improve.
The production of electric cars is growing day by day. Therefore the need for batteries is also growing. Efforts are on by various entrepreneurs to create capacity for battery manufacturing. Industry associations have come up and are doing their bit to put in place in environoment, systems and procedures so that profitable industry emerges.
Industrial engineering profession has to set up its own organization to study and introduce industrial engineering principles, methods and tools into the upcoming advanced battery industry right from the design stage of products and production systems.
McKinsey on Battery Prices and Costs - 2012 Analysis
Our analysis indicates that the price of a complete automotive lithium-ion battery pack could fall from $500 to $600 per kilowatt hour (kWh) today to about $200 per kWh by 2020 and to about $160 per kWh by 2025. In the United States, with gasoline prices at or above $3.50 a gallon, automakers with batteries at prices below $250 per kWh could offer electrified vehicles competitively, on a total-cost-of-ownership basis, with vehicles powered by advanced internal-combustion engines. Any further decrease in battery prices and increase in gasoline prices could tilt the balance in favor of electric vehicles. http://www.mckinsey.com/insights/energy_resources_materials/battery_technology_charges_ahead http://naatbatt.org/naatbatt-blog/engineering-vs-materials-science-in-advanced-batteries/
April 2012
An all-electric vehicle needs the battery size of around 23 kilowatt hours.
That size batter is priced around $12,000 to $15,000 a battery. The price of a gasoline-powered Focus (Ford) is about $22,000. Ford is currently promoting its $39,200 Focus Electric car.
Based on the indicated price range for the battery we estimate that Ford is paying between $522 and $650 a kilowatt-hour for its electric-vehicle batteries.
