Showing posts with label IE in different sectors of industry. Show all posts
Showing posts with label IE in different sectors of industry. Show all posts

Monday, December 8, 2025

DFMA - Design for Sand Casting - Some Important Points

2023 BEST E-Book on #IndustrialEngineering. 

INTRODUCTION TO MODERN INDUSTRIAL ENGINEERING.PRODUCT INDUSTRIAL ENGINEERING - FACILITIES INDUSTRIAL ENGINEERING - PROCESS INDUSTRIAL ENGINEERING.  Free Download.

https://academia.edu/103626052/INTRODUCTION_TO_MODERN_INDUSTRIAL_ENGINEERING_Version_3_0 



Lesson 254 of IEKC Industrial Engineering ONLINE Course Notes.

Product Design for Manufacture and Assembly, Third Edition

Geoffrey Boothroyd, Peter Dewhurst, Winston A. Knight

CRC Press, 08-Dec-2010 - Technology & Engineering - 712 pages

https://books.google.co.in/books/about/Product_Design_for_Manufacture_and_Assem.html?id=W2FDCcVPBcAC 

Note: It is important to read the books by Boothroyd to understand the full method of DFMA. The DFMA method is to be combined with Value Analysis and Engineering to do product industrial engineering. In the note only attempt is made to make readers aware of issues raised and solutions proposed by DFMA method. 


12.   Design for Sand Casting 517
12.1 Introduction 
12.2 Sand Casting Alloys 
12.3 Basic Characteristics and Mold Preparation 
12.4 Sand Cores 
12.5 Melting and Pouring of Metal 
12.6 Cleaning of Castings 
12.7 Cost Estimating 
12.8 Design Rules for Sand Castings 
12.9 Example Calculations 
References 
_________________



https://www.youtube.com/watch?v=CSQahYClJ1k


_________________


DESIGN RULES FOR SAND CASTINGS 

A study states that the cost of a casting can easily be doubled due to designs that do not take cost drivers into consideration. 

The following design rules are to be followed to avoid the expense of increased scrap and possibly large increases in production cost.

Avoid Sharp Angles and Multiple-Section Joints

Metal structure is affected by the shape of the casting section. Solidification of the molten metal begins at the mold face, from which crystals grow into the casting at right angles. A straight section of constant thickness  results in uniform cooling, which will in turn produce uniform material properties. On the other hand, sharp angles can cause large temperature variations in the casting, which often lead to casting defects. Hot spots result where the free cooling of the casting is interrupted as parts of the sand are loaded with more energy than other areas. Also, chilled areas arise on external corners from being exposed to two cooling planes. The resulting grain structure is not homogeneous and, in particular, weak areas in the casting are created in the areas where the cooling rate is excessive. A well-designed casting brings the minimum number of sections together at intersections and avoids acute angles. Wherever a number of sections converge, the appropriate solution is to create a large hole like the center of a web.

Examples of good and bad section configurations are shown in a figure in the book.  

Design Sections of Uniform Thickness

Design the casting so that all of the section thicknesses are as consistent as possible. This promotes even cooling of the casting, reducing the likelihood of defects. If larger masses of metal are unavoidable, the designer should make them accessible for feeding either directly or with a riser.

Designing for uniform thickness also reduces the amount of material in a casting, saving weight and reducing machining, and results in a stronger casting.

However, if section thicknesses are too small, then feeding problems may occur.

The increased cost of scrap caused by incomplete feeding (caused by metal freezing and blocking the section from being completely filled) will normally be higher than the material savings in a lighter casting. The economical minimum section thicknesses of different metals to be sand cast are available.

Proportion Inner Wall Thickness

Inner sections in a casting cool more slowly than a section exposed to the mold face. If a complex geometry is necessary, the designer should reduce the inner section thickness to 80% of the outer wall thickness. Also, core section thicknesses should always be greater than the section thickness of the surrounding metal. If the core is too small, it will become overheated and slow down the solidification rate of the surrounding metal, leading to the possibility of defects.

Consider Metal Shrinkage in the Design

Almost all alloys shrink as they solidify. While the patternmaker is the one affected by the shrinkage, the designer must still compensate for it in the design. In a good design, the section thicknesses decrease as the distance from the feed system or riser increases. In order to accomplish this, the designer must be familiar enough with the casting process to be able to visualize how the casting will be fed and adjust the casting's dimensions to assist the metal flow. The greater the shrinkage of the metal, the more the designer must consider it when designing the casting. Tables are available in handbooks regarding the shrinkage of several of the commonly cast alloy groups. The amount of shrinkage depends upon the precise carbon content for irons and steels and varies over the ranges shown.

Use a Simple Parting Line A flat plane, known as a straight parting line, separating the two mold halves, results in more economical casting than a tiered or contoured separating surface.

More complex parting lines often result in fewer parts per mold, more costly patterns, less accuracy, and increased scrap. Also, the parting line should be positioned so that it has minimal effect on the functional characteristics of the part.

Locating the parting line in less critical parts of the casting is desirable for two main reasons. First, dimensions around the parting line are the hardest to control.

Additionally, flash occurs at the parting line. If the surface around the parting line is not critical, then flash removal costs will be lower.

Define Appropriate Machining Allowances

The machining allowance is material added to the casting to compensate for dimensional and surface variations in the as-cast part. The amount of stock added is a function of the size of the surface to be machined and to a lesser degree the machining method and the final accuracy required. Minimal additional material is needed if only flatness, possibly with some unmachined surface areas, is desired. A larger allowance is required if the full surface is to be machined without any imperfections. Normal machining allowances vary from 0.25cm for small castings (< 15 cm) to as much as 2.5 cm for large castings (>250 cm).

Use Economical Tolerances

The tolerances achievable by a foundry vary depending on the types of processes employed at the facility. For example, automated molding machines are capable of producing molds with tighter tolerances than might be produced by hand.

Conservative tolerances, which are readily achievable by most foundries and are therefore the most economical, are used in the following discussion.

Tighter tolerances may be obtained by machining, which significantly increases the cost of the casting.

The most basic tolerance is the linear tolerance. It refers to how precisely the distance between two points can be produced. Linear tolerances of ±1.0 mm are readily achievable for small castings. An additional factor of ±0.03 mm should be added for every centimeter over 15 cm for larger parts. An additional tolerance must be added to the linear tolerance of a dimension that passes through or originates from the parting surface. These additional tolerances reflect variations caused by expansion and contraction of the mold, the metal during solidification, patternmaking tolerances, and vibration of the pattern during removal from the mold. The size of the additional tolerance depends upon the projected area of the casting at the parting surface. The typical tolerance assignment is ±0.25 mm for each 10cm2  of projected area.

Cores create tolerance variation because of the clearance that is necessary for their placement into the mold. The features produced by the core surface can be held to a tighter tolerance than the features produced by the mold surface, because cores are stronger and able to be produced to tighter tolerances than the mold.

However, the surface produced by the core may be displaced from the surface created by the mold because of core shift. The additional tolerance for core shift varies with the protected area of the core normal to the dimension being considered. The recommended value is the same as for the additional parting line tolerance given above.


https://dawangcasting.com/sand-casting-design-considerations/



REFERENCES 

1. Brown, J.R., Foseco Foundryman's Handbook, 10th ed. Butterworth-Ffeinemann, 1996. 

2. Wukovich, N., Evaluating Side Risers and Necks, Part 1, Modern Casting, December 1988, p. 42. Design for Sand Casting 547 

3. Wukovich, N., Evaluating Side Risers and Necks, Part 2, Modern Casting, January 1988, p. 49.

 4. Wukovich, N, Evaluating Side Risers and Necks, Part 3, Modern Casting, February 1988, p. 56. 

5. American Society of Metals Casting, Vol. 15, Metals Handbook, 9th ed. ASM International, Metals Park, OH, 1988, pp. 577-597. 

6. Suschil, T., Designing Gates and Risers in an Artful Compromise, Modern Casting, March 1989, pp. 27-29. 

7. Wieser, PR, Steel Castings Handbook, 5th ed., Steel Founders Society of America, 1980. 

8. Bralower, P.M., Sand Molding: From Hand Ramming to Near Net Shape Castings, Modern Casting, May 1989, pp. 53-58. 

9. Burditt, M.F., Designs and Operation of Melting Furnaces Differ Markedly, Modern Casting, August 1989, pp. 51-55.

10. Burditt M.F. and P.M. Bralower, Good Pouring Practice Contributes to Quality Castings, Modern Casting, 1989, pp. 59-63.

11. Mrdjenovich, R., Shakeout: Separating the Casting from Its Mold, Modern Casting, October 1989, pp. 45-47.

12. Luther, N., Cleaning and Finishing: Getting the Casting Ready for Shipping, Modern Casting, November 1989, pp. 53-58.

13. Kobrak, G., Design and Early Cost Estimation of Sand Castings, M.S. Thesis, University of Rhode Island, Kingston, 1993.

14. Mietrach, D., AGARD Handbook on Advanced Casting, AGARD-AG-299. North Atlantic Treaty Organization Advisory Group for Aerospace Research and Development, Bremen, Germany, p. 9.

15. Casting Engineering and Foundry World, Continental Communications, Inc., Bridgeport, CT.

16. Customers Foundry Orientation Manual, Robinson Foundry, Alexander City, AL.

17. Bralla, G.B., Handbook of Product Design for Manufacturing, McGraw-Hill, New York, 1986.


Cut Sand Casting Costs: Cores, Alloys & DFM Techniques – Practical Playbook

https://aluminium-foundry.com/cut-sand-casting-costs-cores-alloys-dfm-techniques-practical-playbook/



Casting Design Issues and Practices
H.W. Stoll

https://books.google.co.in/books?id=vQAj5iB4KY4C&pg=PA1#v=onepage&q&f=false


DFM Guidelines for Specific Manufacturing Processes

https://eng.libretexts.org/Courses/Northeast_Wisconsin_Technical_College/Design_for_Various_Manufacturing_Methods/02%3A_DFM_Guidelines_for_Specific_Manufacturing_Processes













Friday, February 7, 2025

Industrial Engineering in Apparel Industry

Online Education/Training Session on "Effective Industrial Engineering and Productivity Management."

I developed an online education/training session on "Effective Industrial Engineering and Productivity Management." I can present the session in one hour, one and half hour or two-hour long sessions. The sessions will be valuable when company industrial engineers and other engineers and managers attend as a group. Industrial engineers require active cooperation and participation of other engineers and managers in their studies and projects. Hence a common presentation and discussion on effectiveness will be very useful.


Supporting Information.

Effective Industrial Engineering - Some Thoughts by Narayana Rao K.V.S.S.

Effective industrial engineering has to satisfy management about the contribution it made to the organization year after year.

The prime contribution of IE has to be cost reduction through productivity improvement.

https://nraoiekc.blogspot.com/2025/07/effective-industrial-engineering-some.html

https://www.linkedin.com/in/narayana-rao-kvss-b608007/

Levels at which Industrial engineering needs to be done.


System IE.


Product IE.


Facilities IE.


Process IE.


Operation IE.


Machine Effort IE.

Machine Work Study in Garment Manufacturing Factories


Human Effort IE.


Elemental Operation IE.


The primary focus of IEs has to be improvement of engineering. In addition to it, they have to improve many other areas. In all areas including engineering, they have to involve specialists from those areas to do detailed designs, production and installation. Industrial engineers have to evaluate all new developments in engineering for use within the systems, facilities and processes in their organization for productivity improvement.

Modern Industrial Engineering - A Book of Online Readings.

365+ Lessons and articles and 100+ Case Studies on Industrial Engineering. 

https://www.academia.edu/126612353/Modern_Industrial_Engineering_A_Book_of_Online_Readings


2024 Popular E-Book on IE.

Introduction to Modern Industrial Engineering.  #FREE #Download.

10250+ Downloads so far.

https://academia.edu/103626052/INTRODUCTION_TO_MODERN_INDUSTRIAL_ENGINEERING_Version_3_0


Online Free Access Handbook of Industrial Engineering includes all modules of IE Online Course Notes.

https://www.timessd.com/endless-re-engineering-in-apparel-manufacturing/

Industrial Engineering in Garment Manufacturing
100+ posts by Prasanta Sarkar
http://www.onlineclothingstudy.com/2011/03/industrial-engineering.html
You can download all the articles as E-book also.

IE in Apparel Manufacturing-6: Making of Operational Bulletin  - Interesting - Machine selection.
by Prabir Jana 16-February-2015
https://apparelresources.com/business-news/manufacturing/industrial-engineering-apparel-manufacturing-vi-making-operational-bulletin/
1.
IE in Apparel Manufacturing-1 - Method Study
https://apparelresources.com/business-news/manufacturing/ie-apparel-manufacturing-method-improvement-method-study/
2
https://apparelresources.com/business-news/manufacturing/ie-apparel-manufacturing-ii-operator-rating/

3.
https://apparelresources.com/business-news/manufacturing/ie-apparel-manufacturing-iii-work-measurement-using-time-study/

4.
https://apparelresources.com/business-news/manufacturing/ie-apparel-manufacturing-iv-work-measurement-using-pmts/

5
https://apparelresources.com/business-news/manufacturing/ie-apparel-manufacturing-v-determining-allowances/

6
IE in Apparel Manufacturing-6: Making of Operational Bulletin  - Interesting - Machine selection.
by Prabir Jana 16-February-2015
https://apparelresources.com/business-news/manufacturing/industrial-engineering-apparel-manufacturing-vi-making-operational-bulletin/

7
https://apparelresources.com/business-news/manufacturing/industrial-engineering-in-apparel-manufacturing-vii/

8
https://apparelresources.com/business-news/sourcing/industrial-engineering-in-apparel-manufacturing-viii/


9
https://apparelresources.com/business-news/manufacturing/industrial-engineering-in-apparel-manufacturing-ix/

10.
https://apparelresources.com/business-news/manufacturing/ie-in-apparel-manufacturing-x/

11
https://apparelresources.com/business-news/manufacturing/ie-in-apparel-manufacturing-xi/

12. Value Engineering
https://apparelresources.com/business-news/manufacturing/ie-in-apparel-manufacturing-xii/


Industrial Engineering in Apparel Manufacturing
Dr. Prabir Jana, Dr. Manoj Tiwari
Apparel Resources Pvt. Ltd., 11 Mar 2020 - Business & Economics - 305 pages

Advanced Level of Technologies and It’s ROI in Apparel Manufacturing
Front Cover
Dr. Prabir Jana
Apparel Resources Publication, 23 Jun 2020
https://books.google.co.in/books/about/Advanced_Level_of_Technologies_and_It_s.html?id=LqnsDwAAQBAJ&redir_esc=y


https://www.linkedin.com/posts/prabir-jana-4097306_apparel-manufacturing-is-science-how-pmts-activity-7263432673681956864-icp6/



McKinsey Papers

The State of Fashion 2025: Challenges at every turn
November 11, 2024 | Report

Reimagining the apparel value chain amid volatility
May 24, 2024 | Article

Redesigning apparel manufacturing in Asia: A pattern for resilience
May 31, 2023 | Article


An Approach To Style Change Management in Apparel Manufacturing

-------------------------------------




2024
The Future of Apparel Manufacturing: Why Industrial Engineering and Operational Excellence Matter
https://consulting.groyyo.com/the-future-of-apparel-manufacturing-why-industrial-engineering-and-operational-excellence-matter/

Diploma in Apparel Industrial Engineering
A Comprehensive Training Program for Future Industrial Engineering Leaders
8 sections • 12 lectures • 1h 9m total length
https://www.udemy.com/course/trainee-industrial-engineering-officer/







IMPLEMENTATION OF MODULAR MANUFACTURING IN THE CLOTHING INDUSTRY IN
KWAZULU-NATAL: A CASE STUDY
2011 paper, South African Journal of IE.
http://www.up.ac.za/dspace/bitstream/2263/16580/1/Ramdass_Implementation%282011%29.pdf

Application of Work Study in Apparel Industry
http://www.slideshare.net/bejayrocks/application-of-workstudy
Good project presentation

Supply Chain of an Apparel Retailer
http://industrialeducation.blogspot.com/2009/08/study-of-supply-chain-zara-fast-fashion.html

IE in Apparel Industry - An Explanation of IE
http://www.icmim.ir/Files/Article/2009-02-25_11.45.24_Apparel%20engineering.pdf

Cambodia Garment Industry Workforce assessment 2006 report
http://www.betterfactories.org/content/documents/Cambodian%20Garment%20Industry%20Workforce%20Assessment%20June06%20%28en%29.pdf


The U.S. Apparel Industry - Supply Chain Review
http://www.bilkent.edu.tr/~alpersen/Papers/ApparelReview_Sen_November_2003.pdf

Report on use of IE in Apparel Companies by KSA Technopak - Good Report
http://www.genprom.org.pk/pdf/58624.pdf


Updated on 6.8.2024, 13.10.2023,  25 May 2020
1 December 2013


Wednesday, December 25, 2024

Mining - Productivity, Industrial Engineering and Lean Production



2023
The Mining Industry Productivity Problem
Forbes
6 Jul 2023 — A productive mining operation minimizes waste, maximizes output and makes optimal use of known resources in the ground, all within a set budget.
https://www.forbes.com/councils/forbesbusinesscouncil/2023/07/06/the-mining-industry-has-a-productivity-problem-the-need-for-operational-excellence/

2020

https://www.cummins.com/news/2020/10/06/digging-deeper-two-aspects-improving-productivity-mining-operations

2015

Productivity in mining operations: Reversing the downward trends. 

McKinsey & Company
PDF
by A Lala · Cited by 54 — Worldwide mining operations are as much as 28 percent less productive today than a decade ago, according to new McKinsey research.
https://www.mckinsey.com/~/media/McKinsey/Industries/Metals%20and%20Mining/Our%20Insights/Productivity%20in%20mining%20operations%20Reversing%20the%20downward%20trend/Productivity%20in%20mining%20operations%20Reversing%20the%20downward%20trend.pdf


https://www.mckinsey.com/industries/metals-and-mining/our-insights/productivity-in-mining-operations-reversing-the-downward-trend

https://www.bcg.com/publications/2015/metals-mining-productivity-minings-productivity-imperactive-burning-fat-building-muscle-and-thinking-straight

2013
https://www.sciencedirect.com/science/article/pii/S2300396015300148

2008 - pdf - 176 pages
https://www.pc.gov.au/research/supporting/mining-productivity/mining-productivity.pdf



19.2.2014

Increase your mining productivity by up to 20% - 2014 Information - Schneider Electric

Challenges
Mining companies must have a global plan to achieve the best results across the entire supply chain.

Mining operations can no longer afford to focus on local maximization
Each work centre needs to perform and achieve individual KPIs, as well as deliver to the overall plan
Problems in one area propogate through the chain
Trains could be delayed, product could remain undelivered, ships could queue for lack of product, demurrage would increase and target shipments could be missed

Until now, miners have been held back by the lack of stadard solutions and realizable architectures.

Solutions

Integrated Planning and Optimization Solution makes the most of your resources by:

Planning and scheduling to optimize the resource-to-market chain (local plans are driven by the global plan, not vice versa)
Making production, asset and process performance more reliable and more capable
Making better decisions through reliable and timely information
Reducing cost and improving environmental performance by reducing excess energy and water usage

The Integrated Planning and Optimization Solution is a powerful solution that utilizes StruxureWare software for Mining, Minerals and Metals to reach operational excellence.


Value Proposition
Mine planning: optimize mine planning considering both mining and processing constraints
Mine operations: ensure operations plans are coordinated with shipping and mining plans. Identify and correct performance issues before they have impact
Plant operations: optimize throughout quality and recovery, whilst minimizing energy consumption
Stockpile blending: optimize blending opportunities to maximize profit and customer service through real-time, reliable inventory data
Rail logistic: eliminate rail penalties and optimize throughput through the rail network
Port stockpile: ensure materials handling is as efficient as possible, maximizing opportunities for direct train-to-ship loading
Port logistics: minimize demurrage penalties and maximize port throughput
Customers: opportunity to extend the supply chain to unloading ports and end customers to truly optimize from mine to blast furnace
http://www.schneider-electric.com/solutions/ww/en/sol/341380276-increase-your-mining-productivity-by-up-to-20



USA Coal Mine Productivity - 1949 - 2011

Short tons per employee hour
                                                            1949             2011

Underground                                          0.68             2.76

Surface                                                   1.92             8.86

http://www.eia.gov/totalenergy/data/annual/showtext.cfm?t=ptb0707







Productivity Trends in the Coal Mining Industry in Canada
CSLS Research Report 2004-07
October, 2004
http://www.csls.ca/reports/csls2004-07.pdf


Productivity Change in U.S.Coal Mining
Joel Darmstadter with the assistance of Brian Kropp
Discussion Paper 97-40, July 1997
http://www.rff.org/Documents/RFF-DP-97-40.pdf





Ud. 25.12.2024
pub. 19.2.2014

Sunday, July 28, 2024

Saint-Gobain - Industrial Engineering Activities and Jobs


Case 58 - Information for IE - Industrial Engineering ONLINE Course





World class manufacturing model by Yamashina gives industrial engineering its due and primary place in improvement methods. Industrial engineering is concerned with work place facilities, work resources and work place methods with focus on productivity improvement, waste elimination and cost reduction. subsequently TQM, JIT, and TPM appeared with focus on specific areas.

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.
Applied Industrial Engineering - Process Steps

How many Industrial Engineers can a Company Employ for Cost Reduction?

For $100 million cost, there can be one MS IE and 6 BSIEs.
https://nraoiekc.blogspot.com/2020/03/value-creation-model-for-industrial.html

Industrial Engineering - Lean Manufacturing - Parent - Child Relationship



Saint-Gobain - Industrial Engineering Activities and Jobs


Reference : 575911

Continuous Improvement (WCM) Coordinator


UNITED STATES, WORCESTER
Regular

POSITION DESCRIPTION
The Continuous Improvement (WCM) Coordinator provides plant leadership and oversight for the implementation of the Saint-Gobain continuous improvement program, World Class Manufacturing (WCM).  WCM is a global initiative that is key to the future of PCR.  This position will actively ensure that the business and its employees have the appropriate skills, tools, and implementation plans to deliver world-class results.

The main functions of the role include:

Continuous Improvement Supervision:  Functions as the leader for the WCM Steering Committee and one or more of the WCM pillars.  Oversee that the WCM operating standards and tools are implemented in the most effective and sustainable way with all individuals at site.  The Coordinator streamlines communication about the WCM program.  The Coordinator answers questions/points of clarification in a timely manner to deliver the required understanding and commitment to WCM toolset.  Works with Management, Engineering, Technical and Operational functions to define, establish, fully deploy and continuously improve "best practices" for processes, engineering, and working procedures across the site, sharing successes with peers.

Loss Identification and Data Analysis:  Collect and stratify the loss data for the plant and distribute this data to the pillar owners monthly.  Conduct bi-annual loss assessment sessions with the Steering Committee and helps lead analysis and discussion.  Challenges the team appropriately to drive maximum improvement and cost savings.  Enter loss data into the cost deployment models and ensure the priorities of the site are in agreement with the cost deployment.  Collect, collate, and analyze data to chart progress of the site against the WCM plan and recommend countermeasures to overcome adverse variances.

Coaching:  Coach and support teams to meet the deadlines of the WCM program milestone plan which includes regular auditing that is critical for pace and standard.  Support the management team in the review of progress and the identification and implementation of countermeasures to ensure the WCM program is achieved.

Change Management:  Helps to oversee, advise on, and implement change management to help ensure improvements are executed succinctly and timely.  Effectively handle resistance to change situations by utilizing strong team building, motivating and coaching skills.
Performs other related duties and responsibilities as needed and / or requested by management.

REQUIRED QUALIFICATIONS
Bachelor’s degree in Engineering, Logistics, Operations, Management, Lean Manufacturing or related field required. Master’s degree preferred
Good experience (5 years) in manufacturing, process engineering or technical project development with a good understanding of the plant organization and manufacturing processes
Knowledge or understanding WCM methods and techniques (Lean Manufacturing or Six Sigma)
Technical skills to include root cause analysis
Knowledge of Operational strategy and organization
Team work and coaching skills
Communication skills
Persuasion skills

The job requires actively influencing and motivating a variety of people in changing situations. Strong influencing skills are needed as selling WCM is accomplished by gaining acceptance.
WHO ARE WE ?
Saint-Gobain Industrial Ceramics is a worldwide manufacturer of high temperature specialised refractory materials. Our products are manufactured for the Ceramics, Metallurgy, Foundry, Chemical, Petrochemical, Power Generation, Waste Processing and Glass Making Industries. We specialise in products ranging from refractory bricks, tiles and blocks to mortar, cements, ramming and gunnable monolithics  and trowelling mixes to low mass kiln furniture systems.

https://joinus.saint-gobain.com/en/usa/tpr/p/60768/575911/continuous-improvement-wcm-coordinator


Process Improvement Manager (Manufacturing)

Hawton, Newark (NG24), NG24 3BZ

St-Gobain Building Distribution Ltd
Permanent, Expired

Innovative? Customer Focused? Agile? Open and Engaging? Entrepreneurial? – Our key attitudes and way we like to work at Saint-Gobain. If this sounds like you, please read on to find out more about the Process Improvement Manager opportunity.

How you will utilise your skills?

This role is working with Saint-Gobain Formula in Newark – we are a very diversified business focused on providing and manufacturing plaster and gypsum for industrial applications. Our customers are industrial companies which use our formulations either as part of their manufacturing process or as a raw material to manufacture finished products. You may have heard of our other Gypsum businesses which include British Gypsum and Artex.

The purpose of this opportunity is to develop plant process capability and improve plant performance. You will be key in facilitating this through day to day and ongoing projects by working closely with our onsite teams, identifying new opportunity to improve production or reduce cost and standardising our processes.

Innovation and continuous improvement are at the forefront of our business, we strive to push and progress ourselfs using World Class Manufacturing techniques to be the best we can be.

Ensure plant process capability is maintained and where necessary improved upon to allow plant OEE to improve continuously
Coach and train of team members and other functions (quality, production, etc) on the different processes and create process handbooks
Actively ensure continuous improvement in all areas of the plant through the adoption and implementation of WCM philosophies tools and techniques associated with FI and AM practices
Development of departmental data analysis tools
Undertaking of improvement activity that reduces energy consumption per tonne
Carry out Process and Engineering investigations and rectify specification / product issues
Collect data and set up measures to analyse losses and report back to the business
Ensure safety (SMAT) audits and risk assessments are completed
Provide training and develop skills of operators where required
Carry out ISO Audits including preparation and manage post audit actions.
Use WCM tools and six Sigma to support solving process and quality problems
What kind of person are we looking for?

First and foremost, we always want to recruit talented people that align well with our values and way of working. In addition to the five Saint-Gobain attitudes we shared at the start, suitability for the role is always key; does the following criteria sound like you?

Previous industrial/manufacturing experience driving and implementing continuous improvement (CI)/ Process Improvement
Experience improving energy consumption
Exposure to leading and developing project teams (Formal Project Management training will be advantageous)
Experience of working using WCM or similar CI methodology (Lean Six Sigma)
Data driven and highly numerate and analytical
Experience of change management (MOC)
Personal attributes will include drive, determination, energy and enthusiasm.
Excellent Excel (macro, Formulas, Graphs), Access and PowerPoint skillset
Who are Saint-Gobain?

Saint-Gobain was founded in 1665 to deliver a world first – the production of glass on an industrial scale. We have continued to adapt and grow through providing innovative ideas, services and products to our customers. 350 years later we have a presence in 67 countries and employ 170,000 people worldwide. The UK & Ireland is home to over 30 of the most well-known and respected businesses within the construction sector including: British Gypsum, Jewson, Weber, Graham and Glassolutions.

You are applying to work with Saint-Gobain Formula, this is one of more than 30 fascinating Saint-Gobain businesses that operate within UK and Ireland.
GDPR - You will find information on our privacy notice here: http://www.saint-gobain.co.uk/applicantdataprivacy/

Contact: Oliver Allcock
Reference: Totaljobs/568485
Job ID: 86561893
https://www.totaljobs.com/job/manager-of-manufacturing/st-gobain-building-distribution-ltd-job86561893?v=1585366947889

Summer Intern - Continuous Improvement Engineer

Saint-Gobain, Faribault, MN
2020
Description
SunIRef:Manu:title

Summer Intern - Continuous Improvement Engineer - SAINT-GOBAIN
Faribault, MN 55021


SAINT-GOBAIN

SageGlass is the pioneer of the world's smartest electrochromic glass and is transforming the indoor experience for people by connecting the built and natural environments. Electronically tintable SageGlass controls sunlight to optimize daylight, outdoor views and comfort while preventing glare, fading and overheating without the need for blinds or shades. SageGlass dramatically reduces energy demand and the need for HVAC by blocking up to 91 percent of solar heat. As a wholly owned subsidiary of Saint-Gobain, SageGlass is backed by more than 350 years of building science expertise that only the world leader in sustainable environments can provide.

SAGE is all about its people, its products and its company culture. The vision of the company is to deliver a durable, reliable and high-performance energy-saving electrochromic product for buildings and to provide a healthier indoor environment for their occupants. Its award winning electronically tintable glass solution is second-to-none and recognized by Green Building, Inc. as one of the top ten green building products available on the market place.

SageGlass is looking for a Continuous Improvement Intern!

Internship placement at SageGlass is designed to provide successful candidates with hands on experience in a specialist area of the industry. Under the supervision of the placement manager and through interaction with other department team members, he/she will have the opportunity to engage in a full spectrum of tasks and an overall understanding of how the department works.

The Continuous Improvement Intern will be responsible for process development activities in a manufacturing environment with a focus on improving production flow and product quality. The position will interact with multiple departments, bridging the gaps between them.

Essential duties may include:

Learn the SageGlass process with a focus on workflows
Clearly communicate business processes
Document processes for future reference
Create and maintain digital forms
Analyze operations data and maintain KPI reports
Resolve production issues and help improve the process
Time studies and cycle time analysis

Currently enrolled in a Science, Technology, Engineering or Mathematics degree program with a strong academic record
Experience in a manufacturing environment
Competent with Excel and PowerPoint
Knowledge of Lean principles
Experience and coursework in Supply Chain, Logistics, or Industrial Engineering preferred
Experience with SQL databases, Point, and Python scripting preferred

Saint-Gobain provides equal employment opportunities (EEO) to all employees and applicants for employment without regard to race, color, religion, gender, sexual orientation, gender identity or expression, national origin, age, disability, genetic information, marital status, amnesty, or status as a covered veteran in accordance with applicable federal, state and local laws. Saint-Gobain is an equal opportunity employer of individuals with disabilities and supports the hiring of veterans.

Saint-Gobain - Just posted
https://www.internships.com/posting/sam_3526647699

Lean Manufacturing Global Champion H/F

Saint-Gobain
La Défense - 92

The mission

Reporting to the Gypsum, Ceilings & Roofing WCM Director within the Saint-Gobain Group Industrial Excellence Programs team, you are leading the progress of our Saint-Gobain World Class Manufacturing program over some part of our industrial activities, interacting directly with Regional or Country Industrial Directors, WCM Coordinators, as well as Plant Managers, across the world, in order to serve effectively the businesses' objectives.

Main responsibilities are :
Develop the WCM standards and frameworks to ensure an effective implementation in the business (Policy Deployment ; link between WCM, budget process & 3-Yr plan, Cost Deployment (Zero Losses definition, Best Business Standards, etc.), Contribute to WCM Central Standards development and validationMain tasks are :
To coach, train the Plant Managers, WCM Plant Coordinators, WCM Regional Champions To measure and assess adherence to the business roadmap and identify high level constraints for each site in your perimeter. In case of deviation, together with the Plant Manager and Regional/International Champion, identify the barriers. Define / Validate the appropriate countermeasures
To identify, share and promote best practices relevant to your Activity As WCM Senior Auditor, perform audits outside your perimeter, and, within your perimeter, support the plants self-assessments, perform audits and coachings
Develop and update your own WCM knowledge

Key indicators are :
Customer Satisfaction
WCM Net Manufacturing Savings
Sustainable Operational KPI improvement

You will work in a highly international environment, in a position allowing significant further career development. While most of your team will BE Paris-based, you will work on a global scale with extensive travel, up to 70% of your time. Therefore, localization within a Saint-Gobain site in Europe convenient for travel, though not preferred, can BE considered.

You get a high Degree in Engineering
You have a minimum of 5 years' experience in a manufacturing environment
You have demonstrated experience in continuous improvement approach and/or operations
You are Fully fluent in English and another tong, some French preferred

Technical Skills
Production planning
Solid track record of WCM projects delivering significant gains
Performance management
Continuous improvement methodologies
IATF preferable
DATE 31/03/2020
https://www.cadreo.com/emplois/lean-manufacturing-global-champion-h-f-3775472-8.html



Saint-Gobain - Industrial Engineering, Productivity Improvement, Cost Reduction Activities




SAINT-GOBAIN - ENERGY SAVINGS PLAN
10/06/2022


The plan  is based on two pillars:

Continuous optimization of its production processes and the use of its buildings, to limit energy consumption and CO2 emissions,
Designing and commercializing solutions that combine both performance and sustainability for energy-efficient building renovation and light construction.


Doubling our actions for continuous improvement of our production processes  by:

improvements to production tools (e.g. work on furnace insulation; installation of more energy-efficient and/or variable-speed motors; improved metering and visualization of energy consumption, energy management system; reduction of equipment idling) and production processes (e.g. recovery of waste energy for heating or energy production),

solutions to reduce the use of natural resources, through the reuse or recycling of raw materials: the use of recycled glass - cullet - for the production of flat glass or glass wool also has the advantage of emitting less energy during melting than sand,

the development of lighter materials and products, which require less energy and fewer raw materials to manufacture.

Additional energy savings thanks to the investment of €100 million per year to reduce CO2 emissions

Saint-Gobain is earmarking a targeted investment and research and development budget of around €100 million per year until 2030 to reduce CO2 emissions and save energy, especially in the European plants.

Shifting the energy mix towards low-carbon and renewable sources
Throughout the world, the Group is accelerating the switch to green energy sources, with very concrete results in Mexico, Brazil, Poland, Spain and the United-States. In the latter, for example, the Group doubled in 2021 its share of renewable electricity in its global electricity consumption to nearly 40%.

Mobilizing all Group employees
In addition to these initiatives, the Group is mobilizing all its employees worldwide to save energy, with numerous initiatives in offices, sales outlets, logistics centers, research centers and on sustainable mobility:

Renovation of our current buildings,
Systematic installation of LEDs, presence detectors, time-based controls, daylighting,
Limiting the use of heating and air-conditioning, lowering the temperature in offices (-1.5°C at Group headquarters),
Deployment of photovoltaic solutions, in particular on plant roofs and parking lot shelters,
Reduction of business travel and development of soft mobility and carpooling.











Benchmarking Result - Energy IE Project in  gypsum board dryer process



Saint-Gobain’s  Gypsum business applies World Class Manufacturing (WCM) techniques to identify, prioritize, and implement projects in the environmental, technical reliability, safety, focused improvement, and people development fields.  Saint-Gobain stacks opportunities up against the performance of all major consumers of gas and electricity to compare them against theoretical minimums and worldwide best practices within the company. From there they can identify how they specifically improve certain processes. The project in Moundsville, West Virginia, was initiated when one of these comparisons showed more than $500,000 of excess electricity being spent on the gypsum board dryer process. Saint-Gobain knew there was a significant cost-savings to be achieved through improving the process.

HOW THEY DID IT
After a brief audit, the team saw a potential opportunity to assess the five fans serving the gypsum board dryers. These fans were already equipped with Variable Frequency Drives (VFD) to modulate the speed of the fan motors in response to differing demand conditions so if adjustments needed to be made, the team believed they could be executed quickly.

The facility was given a budget of $10,000 and 12 months to complete the work. They started by installing five thermocouples (one for each of the five fan zones) to check for drastic changes in process conditions. They purchased the thermocouples for $5,000 and five new temperature transmitters for $1,500. All installation and wiring were done in house at no additional cost and was completed by March. The working hypothesis for the test was that significant energy savings could be achieved by lowering the fan speeds without impacting the quality of the ultimate product.

SOLUTION
Once the equipment was installed, the team needed to show all of the operators how testing different fan speeds would affect the running of the equipment. Many had been operating it the same way since the plant was commissioned. To achieve these, the team held individual trainings with each operator showing them that the board quality would remain constant with no changes to operational procedure if the fans were adjusted by using specific techniques that would still allow for the test outcomes.

By the end of April, the facility had completed two trials with each operator (eight trials in total) showing that no adverse effect was present on any of their products.

At the beginning of the project, the team put the goal at 2% reduction in electrical consumption in the dryer, but by the end of the testing, they were able to exceed this. The ultimate total reduction was 3%.

With this now known, the fan speeds were reduced by up to 30% with no effect on product quality. The total electrical savings was $68,000 per year.

EXPANDING COMPANY-WIDE
Once this project was completed, the results were shared to the North American Gypsum Energy Champions, a group that works to replicate best practices for sustainability across the gypsum business, and then they were shared with all of Saint-Gobain’s North America Sustainability Champions which sees what can be done company-wide.





World Class Manufacturing Journey in Saint Gobain


Saint-Gobain India’s 10th World Class Manufacturing (WCM) Conference
Published on July 15, 2019
Pramod Vatsa
SEKURIT Excellence Programs & WCM Director at Saint-Gobain Sekurit International, France
https://www.linkedin.com/pulse/saint-gobain-indias-10th-world-class-manufacturing-wcm-pramod-vatsa/

WCM in Saint Gobain

https://books.google.co.in/books?id=ifMgDAAAQBAJ&pg=PA30#v=onepage&q&f=false


Saint Gobain Glass

https://books.google.co.in/books?id=DG4TsckOQs0C&pg=PA31#v=onepage&q&f=false

Saint-Gobain of France subsidiary British Gypsum - WCM

Published: 20/01/2010

Wilson is now operations manager at what has, since 2005, been Saint-Gobain of France subsidiary, British Gypsum. He presented the WCM joureny British Gypsum plant.   The main issue was around basic conditions. A bearing that is supposed to last for five years if you lubricate it correctly,  stop contamination getting into that bearing and  operate under the correct conditions. But if you don't lubricate it, operate it at the wrong speeds and in wrong conditions, it will fail in weeks or  months.   There were blocked aisles, lots of scrap and wasted energy . A global operations director who came in and thought that really wasn't right. He brought in Professor Yamashina from Kyoto University had worked with the likes of Pirelli, Fiat and Volvo, and was renowned for his methodology.  "He has been working with us for 10 years now. The bulk of the  issues identified were around TPM [total productive maintenance]". It's about the autonomous maintenance that the machine operators are doing; professional maintenance by craftsmen and focus improvement using root cause analysis tools and techniques backed up by the application of those techniques in a safe environment; customer service; quality; process control; people development; and cost reduction. It was necessary to change a culture that had been in place for many years. Plant managers, engineering managers and production managers went off on very intensive practitioner courses."  On getting British Gypsum's policy deployment from strategic level to the shopfloor, he says everything that happens operationally has to link into the overall business strategy. Policy deployment at a company level sets the major strategic drivers for the business based on market conditions that will break down into must-win battles. To reconcile all of this at plant level, integrated business management (IBM) is deployed to manage strategic and supply chain planning via a product review, a demand review and a supplier review that looks over a 36-month horizon with monthly reviews along the way. What Wilson describes as an F-matrix is used for cost deployment – how it looks at losses and puts in correctional improvement programmes. There's a route map to facilitate more reactive measures that mitigate the risk of failure when looking at new tools and techniques, and a compliance module for "all the legal things that all of us have to do". These all feed into pillar plans, with pillar owners and pillar teams, and break down into highly detailed departmental plans and various levels of balanced scorecards to review the whole process. If you attack  30% of cost you're much more likely to achieve 20% of 30% which is 6%." All this is displayed in some detail and visually on boards on the shopfloor. Tools from a simple tag (if a machine may be broken, it is 'tagged' and an operator or first line manager comes to repair it) through to very complex root cause analysis tools utilised by senior chemical process engineers, are deployed in the problem solving processes. Wilson emphasises the importance of putting sustaining activities in place, "something we've got wrong on a few occasions over eight years. We were driving pace and we wanted to go quicker and quicker and get more savings but were not putting rigour into sustaining activities." He advises investing time in making previous improvements right and robust rather than starting lots of new projects. "Those we did first were done first for good reasons – because they were our biggest losses. Plants are a lot safer now.  "Management standards were changed," says Wilson. " Around 2000, the message really got through that managers must now lead by example and set themselves very high standards in the way they conduct themselves and always challenge anything that's unsafe. Auditing is key to that process.

"I don't believe you have a factory that is safe but not very productive, or a factory that is productive but not very safe. Ten years ago, most of our plants were having a lost time incident every month. At East Leake we've had one lost time accident in the last two years which was a guy who was going up some stairs, decided he'd forgotten something and turned round and turned his elbow." Reliability has been the key to machine performance with the programme having eliminated key losses like early bearing failures due to contamination. All the machine stops – those down to supply problems, direct human error, start up delays due to process or engineering, electrical and mechanical breakdown – are measured and have been driven down from nearly 40 to less than 10 between 2006 and 2008. Elsewhere, emissions to air and starting and stopping major items of equipment have largely been eliminated or reduced, and all manufacturing waste is recycled. One project  that dealt with fixing compressor leaks saved £50,000 a year. There has been a significant improvement in service performance driven by taking action on delivery errors, loading errors and delivery time. By such actions, the East Leake plant has taken 10% off its cost base in the last two years.
https://www.manufacturingmanagement.co.uk/features/when-the-dust-settles

WCOM (World Class Operations Management): Why You Need More Than Lean
Carlo Baroncelli, Noela Ballerio
Springer, 03-May-2016 - Technology & Engineering - 271 pages

This book deals with World Class Operations Management (WCOM), detailing its principles, methods and organisation, and the results that this approach can bring about. Utilising real-world case studies illustrated by companies that have adopted this model (interviews with Saint-Gobain, L’Oréal, Tetra Pak, Bemis, and Bel Executives), it describes common patterns drawn from decades of hands-on experience, so as to present a theoretical approach together with the concrete application of its principles.

WCOM, adopted by several multinational companies, is one of the more innovative management practises, as it integrates the best Continuous Improvement approaches (Lean, Total Productive Management, World Class Manufacturing) as well as the most innovative approaches in human dynamics like Change Leadership, Performance Behavior, Shingo Model, to name a few. Every book’s chapter has been authored by an expert in these different fields, thus revealing the synergy among the different practices, which is one of the distinguishing and successful aspects of WCOM

Maximising reader insights into the successful implementation of such an approach, and explaining not only its potentialities, but also its implementation dynamics, the critical points and the ways it can be integrated into different situations, this book is also about how to create a culture of excellence that is sustainable over a long period of time and delivers consistent (or ever-improving) results.
https://books.google.co.in/books?id=ifMgDAAAQBAJ




Total Industrial Engineering - H. Yamashina
http://nraomtr.blogspot.com/2011/11/total-industrial-engineering-h.html

World Class Manufacturing - Yamashina Way
http://nraombakc.blogspot.com/2012/02/world-class-manufacturing-yamashina-way.html

World Class Manufacturing - Explanation
http://nraoiekc.blogspot.com/2012/08/world-class-manufacturing-explanation.html

Total Industrial Engineering - Revison Notes
http://nraoiekc.blogspot.com/2012/03/total-industrial-engineering-revison.html

Total Industrial Engineering
http://kvssnrao-ind-engg.blogspot.com/2010/10/total-industrial-engineering.html

Factory of the Month: The only way is Essex
Posted on 27 Nov 2012 by The Manufacturer
https://www.themanufacturer.com/articles/factory-of-the-month-the-only-way-is-essex/

WCM (WORLD CLASS MANUFACTURING) - NOVEMBER 2020 MISSION
NOVEMBER 16 2020 to NOVEMBER 20 2020
Since the first edition in 1992, more than 700 participants from across all EU Member states have participated in this practical training course.

The 5-day World Class Manufacturing training mission provides an in-depth analysis of Japanese manufacturing methodology and is aimed exclusively at EU managers with knowledge of WCM and an engineering background. It assists the participants to acquire a better understanding of TQC (Total Quality Control), TQM (Total Quality Management), TPM (Total Productive Maintenance), JIT (Just In Time), TIE (Total Industrial Engineering) practices and the current KAIZEN manufacturing methods (continuous improvement).
https://www.eu-japan.eu/events/world-class-manufacturing-november-mission

Lean Production and World Class Manufacturing: A Comparative Study of the Two Most Important Production Strategies of Recent Times
Filippo De Carlo and Gregorio Richardson Simioli
International Journal of Industrial and Operations Research
Volume 1, Issue 1, 2018
https://www.vibgyorpublishers.org/content/ijior/fulltext.php?aid=ijior-1-001

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



More Companies

Samsung Electronics


PULKIT SHARMA
Industrial Engineer at Samsung Electronics
Faridabad, Haryana, India
Experience
Samsung Electronics
Industrial Engineer
Since: Feb 2017
Location: Noida Area, India
https://www.linkedin.com/in/pulkit-sharma-73ba37107/

Sunada Venu Ambati
Industrial Engineer at Samsung
Austin, Texas
Experience
Samsung Electronics
Industrial Engineer
Since: Jun 2018
https://www.linkedin.com/in/sunada-venu-ambati-07693415/

Vivekananda Reddy Kovvuri
Industrial Engineer - Product Operations
Austin, Texas
About
Industrial Engineer with 2 years of experience in production scheduling and planning for a semiconductor foundry. Expertise includes preemptive problem identification/solving, cross-team collaboration, debottlenecking and Supply/Demand planning

Experience
Samsung Electronics
Industrial Engineer II
Since: Oct 2018
Location: Austin, Texas Area

Education
Texas A&M University

Master of Science (MS)Industrial Engineering
2013 – 2015

Maulana Azad National Institute of Technology
B.Tech.Industrial and Production Engineering
2009 – 2013
https://www.linkedin.com/in/vivekananda-reddy-kovvuri-52aaa838/

Christopher Spakoski
Senior Industrial Engineer at Samsung Austin Semiconductor
Austin, Texas Area
Experience
Samsung Electronics
Senior Industrial Engineer
Since: Mar 2020

Industrial Engineer II
Aug 2017 – Mar 2020
Education
State University of New York at Buffalo

Industrial and Systems Engineering
2012 – 2014
https://www.linkedin.com/in/christopher-spakoski-04276963/


SABIC - Sinomach - Sinopharm - Sinochem - Sanofi - SAIC Motor - Samsung Electronics


Updated on 28.7.2024,  15 July 2020, 22 April 2020



Monday, May 20, 2024

Productivity and IE in Tire Manufacturing



Applied Industrial Engineering Module of Industrial Engineering Online Course Notes - Industrial Engineering Various Engineering Branches, Industries and New Technologies

Productivity #Benchmarking. CEAT Tyres - Halol, India Plant - Industrial Engineering 4.0 - WEF - McKinsey Light House Plant



Process of Making Tires



HOW A TIRE IS MADE

As many as two hundred different raw materials combine into a unique mix of chemistry, physics and engineering to become a tire. 

For illustration

Materials used: 
Rubbers: 1) Natural rubber( obtained from hevea tree) 
 RSS ribbed smoke sheet ( RSS 4 is used ) 
 SIR ( standard Indonesian rubber)  
 SMR( standard Malaysian rubber) 

2) Synthetic rubber  Butyl rubber ( import from russia) 30 kg each bale.  SBR 1502 (light yellow) styrene-butadiene rubber (Mostly used in bead wire compound)  SBR 1712 (oil extended rubber) (Import from Korea Used in tred and ply compound)

3.  PBR (orange yellow rubber) poly-butadiene rubber (made in iran)  EPDM ( eyhylene propylene diene monomer) Compounds in which load (strength) is requirement SBR is used and if load and speed both is required PBR is used. 3) Reclaim rubber ( vulcanized rubber) :  Butyl reclaim ( import from india)  Natural reclaim (50 kg each bag)  Natural and butyl rubber cannot be mixed so their setup is separate. Bale cutters and mixers are also separate.  To increase the heat resistance of natural rubber it is blend with SBR  Strength of 1502 is greater than 1712  Butyl rubbers are used to make tubes.  Butyl colours are used to stick on compounds  Hexane is used to separate rubber which stick to each other

4. Fillers ( mechanical holding strength increases): Reinforcing fillers: 1) Carbon black  N-220  N-330  N-339  N550  N-660 Particle size of N330 < N660 55 bags in each palate each of 25 kg. Non- reinforcing fillers: (cost reducing) 1) CaCO3 2) China clay 3) Crumb( recycled rubber from tyre scrap) Activators: 1) ZnO 2) Stearic acid Plasticizers (increase fluidity): 1) Aromatic oil (thick oil green in colour, highly viscous) 2) Paraffin oil (white oil) 3) Napthenic oil (colourless) Retarders (anti scorching): 1) PVI/CTP ( pre vulcanization inhibitor)

5. Accelerators: 1) TMTD 2) MBTS 3) MBT 4) CBS 5) TBBS 

6) DPG Resins (increase tackiness): 1) Koresin 2) Phenolic resin 3) Hydrocarbon resin 4) Rosin china Peptizers (decrease viscosity): 1) Struktol A-91 2) Struktol A-86 3) Peptizol -7 

Homogenizer: 1)Struktol MS-40 Anti-oxidants: 1) 6PPD 2) TMQ 3) Wax ( not used in ply ) 4) PBN Curatives: 1) Resin 1045 2) Sulfur 3) DCP


The basic steps of tire manufacturing process:



MANUFACTURING
The production process begins with the selection of several types of rubber along with special oils, carbon black, pigments, antioxidants, silica, and other additives that will combine to provide the  characteristics wanted. Separate compounds are used for different parts of the tire. 

Banbury Mixer: Banbury mixer combines the various raw materials for each compound into a homogenized batch of black material with the consistency of gum. The mixing process is computer-controlled to assure uniformity. The compounded materials are then sent to machines for further processing into the sidewalls, treads or other parts of the tire.

Assembling the tire: The first component to go on the tire building machine is the innerliner, a special rubber that is resistant to air and moisture penetration and takes the place of an inner tube. Next come the body plies and belts, which are often made from polyester and steel. Plies and belts give the tire strength while also providing flexibility. The belts are cut to the precise angle and size the tire engineer specifies to provide the desired ride and handling characteristics. Bronze-coated strands of steel wire, fashioned into two hoops, are implanted into the sidewall of the tires to form the bead, which assures an airtight fit with the rim of the wheel. The tread and sidewalls are put into position over the belt and body plies, and then all the parts are pressed firmly together. The end result is called a “green” or uncured tire.

Last step - Curing of  the tire. The “green” tire is placed inside a mold and inflated to press it against the mold, forming the tread and the tire identification information on the sidewall. Then it is heated at more than 300 degrees Fahrenheit for twelve to fifteen minutes, vulcanizing it to bond the components and to cure the rubber. (This twelve to fifteen minute curing process is for passenger and light truck tires. Off-road and large tires may take up at a day to cure).

Inspection:  Every tire is then inspected, and sample tires are randomly taken from the line and tested. Some are x-rayed, some are cut apart to look for flaws, others are run on test wheels, or road-tested to evaluate handling, mileage and traction performance.

Every tire is carefully inspected, and random samples are pulled for additional safety tests. As part of these tests, tires are x-rayed, cut apart and examined, run on test wheels, or road-tested to evaluate handling, mileage and traction performance. 

If properly cared for, tires can last a long time – usually from 40,000 to 80,000 miles, depending on the application.



Mitsubishi Heavy Industries

Rubber Mixer
A rubber mixer is a machine that kneads rubber, the raw ingredient of tires, with sulfur and other chemicals using rotating blades. The mixing process is critical to the final quality of rubber and tire products. We offer a full lineup of various rubber mixers to cater to our customers' needs.

https://www.mhi.co.jp/technology/review/pdf/e533/e533043.pdf

https://www.slideshare.net/HassanBilal19/mixing-report-final-66700072  Mixing process described in detail.

Cutter
A cutter is a machine that cuts rubber-coated sheet-form materials, made of numerous cords made of synthetic fibers (such as nylon) and steel, into predetermined sizes and at specific angles.

Molding Machine
The molding machine is used to assemble the sheet-form material cut by the cutter, the tread (thick rubber for the outer circumference of a tire), the bead (a steel ring to fix a wheel and a tire), etc., into a shape close to a tire.

Curing Press
The curing press is a machine used to apply heat and pressure to mold the outer surface of the tire to form grooves and trademark and other designs, as well as to finalize the tire by curing the rubber through a chemical reaction.

https://www.mhi-ms.com/products/rubber_tire/tire_curing_press/
https://www.ltmindia.com/products-services/hydraulic-tyre-curing-presses/
http://www.uzermakina.com/tire-curing-presses
https://www.hf-tiretechgroup.com/en/heizpressen/

https://literature.rockwellautomation.com/idc/groups/literature/documents/wp/oem-wp016_-en-p.pdf

Inspection Machine
Upon completion, the balance and overall uniformity of the tires are tested by the inspection machine to ensure that they satisfied a prescribed level of quality.
https://www.mhi.com/products/industry/rubber_tire_machine.html

Sample cutting machines
https://www.shibuya.co.jp/en/cutting/usm1000.html

Uniformity machine (UFM)
Dynamic balancing machine (DBM)
Combined line of UFM & DBM
https://www.mhi-ms.com/products/rubber_tire/tire_testing/

Top 10 tire companies - India


Electronic air pressure regulators and air flow control valves -Tire Manufacturing Solutions & Applications


Tire Manufacturing Machines https://dir.indiamart.com/impcat/tire-manufacturing-machines.html

Tire Manufacturing Equipment Manufacturers  https://www.globalspec.com/learnmore/manufacturing_process_equipment/manufacturing_equipment_components/tire_roll_manufacturing_equipment

Tire Manufacturing Patents


https://patents.google.com/patent/EP0953435A1/en



Productivity and Cost Reduction in Tire Manufacturing - News and Events


2023

Gudel - Tire & Wheel Handling Solutions - Automation
The competence center for your tire and wheel manufacture.
Sorting, palletizing and de-palletizing, Güdel solutions allow you to automate all post-vulcanization processes right up to the shipment..

Our modular system allows you to increase the level of automation according to your needs. Whether you need individual components, functional packages or turnkey solutions including Material Flow Control MFC, Warehouse Management WMS, conveyor technology, and prime care.

Gudel - Handling, commissioning, and palletizing everything from green to finished tires
Efficient handling of green to finished tires



Industry 4.0 Lighthouse - First Global Tire Facility  - CEAT’s Halol Tyre Manufacturing Facility


CEAT’s Halol Tyre Manufacturing Facility has been designated by the World Economic Forum as an ‘Advanced Fourth Industrial Revolution (4IR) Lighthouse’
CEAT is the first tyre company globally and the first auto ancillary company in India to be recognised for adopting advanced fourth-industrial revolution technologies.
CEAT First Tyre Company In The World To Become Lighthouse Certified
 20-Jan-2023

The company embarked on  Industry 4.0 journey in 2020 and, since then have seen substantial improvements in  operational efficiencies through digital technologies.  

Improved productivity by digitalising 100% of the operator touchpoints. All of these initiatives have resulted in reducing the plant operating cost by 25%. There was growth in  global and OEM sales.


The Amazing Ways Goodyear Uses Artificial Intelligence, Industry 4.0 Technologies And IoT For Digital Transformation


Goodyear uses internet of things technology in its Eagle 360 Urban tyre. The tyre is 3D printed with super-elastic polymer and embedded with sensors. These sensors send road and tyre data back to the artificial intelligence-enhanced control panel that can then change the tread design to respond to current road conditions on the fly and share info about conditions with the broader network. If the tyre tread is damaged, the tyre moves the material and begins self-repair. The tyre has the ability to monitor and track tyre pressure, vehicle data, and road conditions. This data is then analysed by Goodyear’s algorithms to gain insights about maintenance needs and ways to improve the safety and performance of the fleet. 

The Oxygene model, another 3D-printed tyre  has embedded sensors connected to the internet of things and also uses living moss and photosynthesis to power its electronics. The self-generated electricity powers onboard sensors, an AI-processing unit, as well as a light strip that illuminates when a driver brakes or changes lanes.  The tyre is  printed from rubber powder from recycled tyres.

Goodyear has focus on the advancement of mobility-focused on connected, autonomous, and electric vehicles.

At the operational level, Goodyear has also leveraged the power of technology to increase its productivity. 

Goodyear is running an internet of things proof-of-concept using sensor data from the factory floor to inform maintenance needs. Investments in workplace modernization is taking place in  Goodyear operations (in more than 150 countries, 48 manufacturing facilities and research and development centres in Germany, Luxembourg, China, and the United States). The company is also exploring how Microsoft HoloLens and other technologies could impact virtual tyre modelling and design. 

Goodyear - 4.0 Digital Industry 4.0 Tire Plant - Dudelange, Luxembourg - Four Times Fast Production Process


Case Study related to knowledge processes.
Tire Manufacturing: Standardization and Digital Automation Increase Production, Slash Downtime, and Reduce Avoidable Waste

Optimising curing presses with AI

Festo Motion Terminal: the flexible cost-cutter.
The automation platform VTEM speeds up tire production
Global production volume of 1.8 billion car tires per year. VTEM  digitises pneumatics, thereby speeding up processes and reducing costs, for example when transferring the rubber layer to the tire building machine.

Tailored AGV solutions for the tyre industry
Your tyre company will benefit from a combination of proven technology, trustworthy maintenance and expert staff behind Rocla AGV solutions. You can rely on the Rocla AGV modular design, which is based on tried and tested warehouse truck technology from Mitsubishi Logisnext Europe.
https://rocla-agv.com/for-your-industry/agv-solutions-for-the-tyre-industry/

Modern Automation in Tire Plants
https://www.tiretechnologyinternational.com/features/special-report-manufacturing-technology-machine-reasoning.html



2022

Goodyear Plant - Production time for large rim diameter passenger tires four times faster with new process


The Goodyear Tire & Rubber Company officially opened its new manufacturing facility in Dudelange, Luxembourg, following a $77 million investment in its industry 4.0 digital manufacturing process.

The new facility  features a new process focused on small-batch production of large rim diameter ultra-high performance (UHP) and ultra-ultra-high performance (UUHP) tires, which enables Goodyear to produce tires four times faster than a standard production cycle. 

Silicone Free Inside Tire Paints

What it solves
In addition to allowing tire producers to eliminate silicone residues from the inner liners of their finished tires, these water based inside tire paints allow tire manufacturers to more efficiently produce innovative tire options that improve their customers’ mobility.


Rockwell's Kalypso strengthens tire practice with new appointment
20 May 2022



The digital service unit names industry veteran Aleksandar Boskovic as principal

Milwaukee, Wisconsin – Kalypso, the digital services arm of Rockwell Automation, has appointed Aleksandar Boskovic as principal, managing director and partner for tire & automotive operations.

Boskovic has over 20 years of experience in the product development and manufacturing domains, and has led digital transformation projects in the automotive, tire, aerospace and defence industries.

Most recently, he served as the digital manufacturing services director for Accenture, said Kalypso in a recent statement.

He holds a PhD in industrial engineering and robotics from the University of Windsor and a masters of manufacturing engineering degree from the University of Belgrade.
https://www.european-rubber-journal.com/article/2091451/rockwell-digital-service-unit-strengthens-automotive-tire-practice


How Automated Buffer Storage Optimizes Tire Production | Kardex

24 Mar 2022
______________________



https://www.youtube.com/watch?v=gsf6C1IsL_w
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Improvement of Inspection Operations


Tire Component Inspection
Ensuring the quality of each component in the tire manufacturing process is critical to the performance and safety of each tire produced. Traditionally tire component inspection has been a manual process relying on operators to make the determination if the component meets quality standards which can be time consuming and highly variable.

In our continued efforts to provide innovative solutions Bartell has created a full line of bead inspection systems. From mechanical measurement to advanced non-contact imaging our technologies provide the most accurate measurements available and include capabilities such as networking and data storage to provide easy statistical quality analysis and documentation.

Inspection Systems for the Tire Industry - Micro-Epsilon

Tire Manufacture
Inspection Process
Tires are checked to find cracks, distortions, etc. in the inspection process.

Tires are inspected by devices to measure balance, uniformity, etc. Only tires that pass inspection will be shipped out.



Tire Inspection Goes High-speed 3D
A typical 3D vision system uses laser triangulation to capture images by projecting a laser line across the surface of each target object while a high-speed camera captures an image of the laser line as an elevation profile.


Automate Tire Manufacturing Processes and Ensure Quality with High-speed 3D Vision
August 2, 2016

Improve inspection process in tire manufacturing


ASRS Solution for Green Tire Handling.

Automation software development group, DMC successfully defined and deployed a custom ASRS solution for green tire handling. A single ASRS system manages over 5,000 tires daily while maintaining high reliability, with advanced material tracking and flow control customization. Utilizing an engineering team of multifaceted expertise, DMC provided software architecture design and development services from the lowest level machine controls, through external communication interfaces with the plant MES solution.
Customer Benefits
Improved plant floor space
Reduced manual tire handling 
Automated work instruction fulfillment
Improved process flow controls


2021

There is still great potential for savings in the automation of intralogistics along the production line.

The Kardex Group is an experienced intralogistics partner to the tire industry. The portfolio provides various solutions including: automated storage and retrieval solutions (ASRS) for pallets with rubber compounds, customer-specific transport carts, green tires, and rack-supported storage systems for finished goods. The selection of suitable components is usually determined by the desired dynamics and the number and type of logistics units used.
https://www.kardex.com/en/industry-segments/tires

https://www.tirebusiness.com/news/us-tire-production-tanked-2020-dropping-1950s-level

Emerson’s Automation and Control Solutions - Boost throughput, cut downtime and reduce energy consumption throughout the tire-making process

June 2021
Machinery and processes for tire manufacturing need to provide improvements in throughput, quality and sustainability. By implementing Emerson’s automation and control solutions, production efficiency and availability can be increased through greater equipment performance and reliability. The solutions will help identify areas of underperformance and waste, helping you to lower operational costs and achieve your sustainability targets.



2020

Digital is disrupting Indian tyre market: Parag Satpute, Bridgestone India
2 Jul 2020
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https://www.youtube.com/watch?v=bz5YT8gNTh4



https://roboticsandautomationnews.com/2020/07/07/how-is-robotics-shaking-up-the-tire-industry/33825/

https://www.itvoice.in/bridgestone-emea-selects-dassault-systemes-to-boost-their-smart-factory-program
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https://lanhang.en.made-in-china.com/product/kKwnqpCMEEYX/China-High-Productivity-Natural-120L-Rubber-Banbury-Mixer.html

Here are three examples in the tire-manufacturing process where electric actuators have brought new efficiencies to the process:  
https://www.tolomatic.com/blog/artmid/843/articleid/435/how-electric-actuators-keep-tire-manufacturing-up-to-speed

IIoT solution for tire manufacturing plants - Return on Invest (RoI) of less than one year.


Proven Industrial Internet of Things (IIoT) solution for tire manufacturing plants increases tire output by up to 3%, while reducing scrap and process cost with a Return on Invest (RoI) of less than one year.
https://www.identecsolutions.com/home/products/newsroom/tire-manufacturing-how-to-increase-tire-output-in-brown-field-production-plants/


Digital Tire Production: A Better Way to Manage Cost and Complexity



Innovative processes allow reuse of tyre production waste and rubber from old tyres.
2019




Bridgestone is investing  in digitalisation and smart factories across eight European production sites.

The plants in Poland, Hungary, Spain, Italy and France, will be equipped with technology to apply algorithms that can improve the consistency of quality by 15%. A 'smart energy' project will optimise the plants' energy consumption and costs, enabling savings of approximately 10%.

Design engineers  will also gain access to data from tire production which will allow them to design improved tire models and halve the lead time for introducing new tires.

Artificial intelligence (AI) will be used to analyse data and forecast potential faults in machinery enabling smart maintenance. Production data will be analyzed in real time, to take action and cut production reject-levels. The logistics processes will be considerably simplified through digitalisation. In the plant, the digital tracking and managing the path of prepared materials and semi-finished products within the plant will take place.

Bridgestone launches smart factory project. European Rubber Journal, 02664151, 7/1/2019, Vol. 201, Issue 4

875,000 square feet, Sumter, South Carolina, Tire Manufacturing Plant of Continental Tire the Americas, LLC


SSOE led the value engineering effort for this facility, developing more than $17 million in savings opportunities, resulting in more than $11 million in total incorporated changes.
https://www.ssoe.com/project/tire-manufacturing-plant/

2017

Six-sigma application in tire-manufacturing company: a case study

Vikash Gupta, Rahul Jain, M. L. Meena & G. S. Dangayach 
Journal of Industrial Engineering International volume 14, pages511–520(2018)

Wastage of material is happening due to variation in the bead splice of a tire. This wastage is financial loss to the organization. Therefore,  variations in the bead splice has to be reduced to minimize the wastages. The value of process capability index C pk is calculated to be 0.94 which is less than 1.
The Ishikawa diagram was used for finding the root cause of the problem.

First cause of the problem was bead splice setting on higher side caused by slippage of bead tape from gripper. The slippage of bead tape from gripper was generated due to worn out of the griper key.

Second cause was variation in the advancer setting caused due to change in skill of worker. This man-to-man variation was caused due to lack of the standard setup guidelines available.

The third cause was related to the frequency of sensor setting. Setting of sensor is required frequently as the former diameter changes. However, due to non-availability of guideline, sensor setting could not change frequently. 

The last cause was that the workers were not using the measuring tape.

For the the root causes, the corrective actions were taken. The capability index C pk value is improved to 2.66
https://link.springer.com/journal/40092/volumes-and-issues - Page Journal of Industrial Engineering International

2016

100 years of improvement in Banbury Mixer
Fernley H. Banbury received his original patent on Oct. 2, 1916

The original machines had very little horsepower, and the newer machines have four times  connected horsepower.

The advent of finite element analysis helped to optimize heat transfer, temperature uniformity and mechanical strength.

Borzenski had recently patented a “keel” bottom weight technology.
HF Mixing now has the management of Banbury's firm.

2015

Fast, efficient handling of sticky, green tires.

Güdel Introduces New Green Tire Trays -  eliminate damage during conveyor offload - allows tires to travel the conveyor at higher speed

01/21/2015



ANN ARBOR, MICHIGAN. Güdel introduces its new Green Tire Trays which are designed to eliminate damage during conveyor offload, and yet they allow tires to travel the conveyor at higher speeds compared to other trays. These trays can be installed directly into existing conveyor Gudel Green Tire Tray titls at 45-degrees for optimum storage with no loss of quality.systems, and they work with all types of systems from roller to wide-belt or narrow-belt.



2014
This paper provides an overview of how an integrated control and information solution from Rockwell Automation can be used on a tire curing press machine to  help maximise productivity.
With the Rockwell Automation Integrated Architecture system, EtherNet/IP technology and 
PID/PIDe functionality, the MESNAC (MESNAC is a leading tire and rubber tire machinery supplier.) curing press machine was able to:
 Control the temperature within a range of ±1 degrees. The pressure can be controlled within a range 
of ±0.1MPa. 
 Improve productivity by 10% thanks to cycle time reduction, repeatable performance and integrated 
information.


2013
http://www.kneadermixer.com/News/Banbury_mixer_machine_temperature_control_can_effectively_improve_production_efficiency-en.html

2012

CONTINENTAL TIRE PLANT INCREASES PRODUCTIVITY, REDUCES WASTE


After installing AeroScout Wi-Fi-based RFID tags and RTLS software, the company's French factory is producing 5,000 more tires per day, while decreasing waste of materials by 20 percent.
http://www.rfidjournal.com/articles/view?9466

2011

Increased Productivity of Tyre Manufacturing
Process using Lean Methodology
Ajit Chavda, Prof. M.Y.Patil


1992
https://meridian.allenpress.com/rct/article-abstract/65/4/792/91967/Optimizing-Mixing-in-the-Banbury-Mixer-with?redirectedFrom=fulltext

1980
https://patents.google.com/patent/WO1981002849A1/en

1974
https://patents.google.com/patent/US3897070

1954
https://patents.google.com/patent/US2820836A/en

Updated on 20.5.2024,   24.8.2023,  14.5.2022,  3.5.2022, 14.4 2022,  2 June 2021,  9.9.2020
21 Feb 2014