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ÇimSA Çimento Sanayi ve Ticaret A.S needed a decision optimization solution to help manage its supply chain network and enable management to find opportunities to improve service while cutting costs.
ÇimSA used CPLEX Optimization Studio to run complex “what-if” scenarios quickly, optimizing business decisions to improve customer service and reduce cement manufacturing, warehousing and distribution costs.
Results
Estimated 10% reduction of inventory costs
An estimated 3% increase in working capital turnover
Estimated 3% reduction of manufacturing, warehousing and distribution costs
With several kilns, grinding mills and silos in more than 10 locations and seven international distribution terminals, ÇimSA established a complex network of facilities. The company also incurred significant overhead costs related to supply chain management, cement manufacturing and transportation. To optimize operations—while factoring in fluctuations in currency exchange rates, taxes, demand and manufacturing capacity changes—ÇimSA managers increasingly used a legacy computing tool for sales and operations planning.
The CPLEX Optimization Studio toolset uses data science and decision optimization technology to model and solve complex business optimization problems. It also enables users to develop and deploy optimization models quickly and create custom applications designed to improve business results.
After deciding to deploy the CPLEX Optimization Studio toolset, ÇimSA’s first step towards implementation was to acquire all the relevant business data necessary to develop accurate optimization models. “Preparing the data and ensuring data completeness was the biggest challenge,” “We then developed a mathematical model through the advanced modeling techniques of CPLEX. After the model was written, we could start the fine-tuning and testing processes to solve large-scale supply chain problems which include millions of decision variables and constraints.”
For the first modeling project, IBM Lab Services, IBM Data Science Elite and Lumtify tackled one of ÇimSA’s most important optimization priorities: the design of its global supply chain network. “With so many different production facilities in different locations, you need to make decisions based on different ‘what-if’ scenarios,”. “These questions are not easy to solve manually or with a spreadsheet, but CPLEX can run through millions of solution variables to make supply chain optimization successful.”
In addition to expenses related to transportation and electricity, the cost of burning fuel to heat cement kilns to 2,000 degrees Celsius represents one of the largest cost inputs in the cement industry. Determining whether to use coal, petroleum coke, natural gas or other fuels at a production facility and deciding on the supplier, the price and delivery schedule is an especially difficult and ongoing challenge. Which is why ÇimSA made fuel-mix optimization its second major CPLEX optimization project. “CPLEX answers key fuel-mix questions like when, from whom, the amount and the price.” “There are big cost savings when you can get that right.”
Issue: Rising demand - How to cater to it profitably?
Solution: Machine-tending automated cells
Provider: CNC Solutions
Results: 25% increase in production, 50% less scrap
Return on Investment: 1.5 years per cell
As demand for bows grew, Mathews’ production lines faced mounting challenges. Manual machine tending struggled to keep pace with rising orders, and ongoing labor shortages added pressure to the 375-employee company. Mathews needed a solution to increase capacity without overburdening employees. They work five days a week, 24 hours a day, and sometimes on Saturdays. A system that could run unattended on weekend days is required.
CNC Solutions engineered two new automated machining cells for Mathews’ riser production.
First Automated Cell
The FANUC robotic arm lifts a raw bow riser forging from the conveyor for machining. It was designed for flexibility, it can process multiple riser models and adapt to frequent design updates without slowing production. The first cell focused on Operation 20, where rough-machined risers are finished. Engineers integrated a FANUC M-20iD/12L robot mounted on a 7th-axis rail to service five Haas UMC-1000SS machines. There is flexibility to run machines manually when needed. A robot-guided vision system simplified raw-part loading. The first cell achieved a full return on investment in just 18 months.
Second Automated Cell
This stage handled 28–33-inch aluminum forgings weighing up to 12.5 pounds. The cell centers on six Haas VF-3YT machines, serviced by a FANUC M-710iC/50 robot mounted on a 7th-axis rail for extended reach. It was designed to run 16 hours unattended, minimizing operator intervention. Material flow is fully automated: raw forgings arrive via two infeed conveyors, and the system can process two models simultaneously. Finished parts move to outgoing conveyors for minor hand deburring, about two minutes per riser, before proceeding to the next automated cell for Bridge-Lock™ machining.
The system allows to load raw forgings on Friday and retrieve finished risers by Monday
The cell supports machining and other processes: raw forgings are machined, flipped, and machined on the opposite side. Air blasts remove coolant between operations, which include drilling, milling, tapping, and partial in-machine deburring. Custom dual-gripper tooling allows the robot to handle raw and finished parts in a single motion, reducing cycle times and minimizing manual handling. Instead of a fixed regrip station, CNC Solutions engineered a traveling regrip station mounted to the robot carriage, saving open-door time and improving efficiency. Inspection drawers at each machine enable operators to perform random quality checks without interrupting production. The system was built for flexibility to accommodate evolving bow designs.
Bastian’s India team and Toyota Material Handling India Pvt Ltd teamed up under the
Toyota Industries Corporation umbrella to showcase powerful, integrated automation solutions!
At a recent tech conclave focused on India’s agricultural value chain, we shared how digital innovations in ASRS pallet handling, case handling and material handling can drive big results—no matter the project size.
Here are a few technologies transforming the warehouse processes.
🔹 Tilt-tray Sorters: Trays that tilt at just the right moment to drop parcels into their correct chute. Perfect for high-speed, high-volume operations.
🔹 Cross-belt Sorters: Small belts ride on a main track, shifting parcels sideways with pinpoint accuracy. Ideal for handling a mix of shapes and sizes.
🔹 Shoe Sorters: Sliding “shoes” gently guide packages off the main conveyor. Fast, reliable, and kind to fragile items.
🔹 Robotic Arm Sorters: AI-powered and built for complexity. These flexible arms can scan, pick, and place with precision that rivals human dexterity.
Why do I care so much about sortation?
Because I’ve seen firsthand how even a 1% improvement in accuracy can have a ripple effect—less rework, better inventory control, faster deliveries, and a smoother experience for both teams and customers.
In logistics, it’s often the smallest efficiencies that lead to the biggest gains.
Machine vision increases hourly output of bottling line
March 2013
Machine vision in automated systems improves productivity, increases throughput, and eliminates human error.
Beer Bottles Inspection Case Study
Malted beverages are extremely popular in China, and 95% of all beer bottles are returned for recycling. They are inspected for damage, sterilized, and refilled. Bottle inspection is performed manually in most plants. There are roughly 3,000 bottling lines in China. They run at 18,000 to 24,000 bottles/hr and use human operators. Each line employs three shifts of 18 to 20 well-trained workers who inspect bottles on a fast-moving conveyor belt. The manual inspection is labor intensive and can cause eyestrain and fatigue.
Machine vision can be used to perform inspection tasks. Shangdong-based Mingjia Packaging Inspection Technology Co. Ltd. and Waterloo, Ontario-based Teledyne DALSA, a manufacturer of multicamera and digital-imaging products, are developing automated inspection systems for the Chinese-beer industry. “Checking that bottles are fit for reuse is a task that can be accomplished quickly and efficiently by machine vision according to Teledyne DALSA.
Some companies are already using machine- vision inspection systems purchased from abroad Mingjia was founded to design and develop affordable equipment to help beer producers adopt machine-vision inspection in place of manual bottles manually.
Mingjia started its relationship with Teledyne DALSA in 2008. Zhang had approached the Canadian firm for initial equipment development: The design called for a multicamera system capable of scanning bottles from multiple angles. Teledyne DALSA’s VA41 Vision Appliance is so used for its ability to survey many views simultaneously. This compact machine-vision controller supports up to six cameras — three analog and another three based on the IEEE 1394 serial-bus interface. Serial communications include RS-232, USB, and Ethernet for connecting the controller to the factory network. Mingjia’s configuration of the VA41 uses four analog cameras from a Japanese OEM, runs Teledyne DALSA’s Sherlock machine-vision software, and has enabled inspection rates of up to 42,000 bottles/hr.
Bottle-inspection System
The inspection equipment is placed immediately before the filling machines on a bottling line. Glass bottles, on a moving conveyor belt, pass through the equipment’s inspection chamber at high speed and each of the four cameras connected to the VA41 performs a specific task.
A camera positioned in the chamber at Stage 2 scans and checks the entire surface of the sidewall of an empty bottle, looking for defects, abrasions, and foreign matter. A similar process is repeated at Stage 5, once the bottle has been rotated through a 90° angle. Full-body scanning also makes use of mirrors to reduce the number of cameras required. A group of three mirrors, one behind the bottle and two oriented at 45° to the camera, enable 160% of the bottle’s body to be viewed and accurately checked. The camera at Stage 3, positioned above the bottle, scans the mouth for scratches, cracks, chips, and other irregularities, while the Stage 4 camera checks the base. “Inspecting the base is challenging because, when scanned, the nonslip surface texture molded into the glass bottom of each bottle generates unwanted signals and produces an image that is confusing to inspection algorithms.” Noise present in the image makes it difficult for the global-analysis software to distinguish between the ribbed background pattern and particles of dirt or other contamination adhering to the glass. To address the issue, optics and special lighting illuminate bottles from above and below, avoiding false alarms and preventing good bottles from being rejected.
The machine vision is also useful for detecting a bottle’s fill level and checking that labels have been applied correctly.
Upgrade to further increase productivity
Mingjia is developing an upgrade to the machine-vision hardware of its bottle inspection system by replacing the VA41 with a controller named GEVA. The Sherlock application software will be used. GEVA, Teledyne DALSA’s latest industrial controller, offers excellent cost savings for multicamera vision applications. Encased within an aluminum chassis, it provides the basis for a powerful industrial vision system. Unlike the VA41, which uses analog and IEEE 1394 serial-bus architectures, GEVA provides expandable Gigabit Ethernet (GigE) camera interfaces that significantly reduce cost. At the heart of the platform is a dualcore processor equipped with highspeed memory resources.
The controller has two camera ports that both support eight 640 × 480 mono cameras performing simultaneous inspection procedures. As part of the upgrade, Mingjia is also planning to replace third-party cameras with Teledyne DALSA’s Genie systems, which employ GigE technology and transmit data over standard CAT-5e and CAT-6 cables.
“GEVA is about two and a half times faster than VA41. This upgrade will enable Mingjia to substantially speed up inspections — to 64,000 bottles/hr, or possibly even 72,000.
The company's achieved significant productivity gain through a Schleuniger machine, CrimpCenter 36 S fully automatic crimping machine. "We process a substantial amount of sealed wire leads, and the CrimpCenter's throughput is amazing. We have easily increased productivity by 50 to 100%, improved quality and instantly unlocked new abilities, even attracting new customers," said Haring.
The MultiStrip 9480 cut and strip machine, eliminated manual stripping of inner conductors when processing multiconductor cable, increasing efficiency. They are even looking at adding to their Cut & Strip line to serve a niche they have built for processing larger gauge cable.
DECA Manufacturing Boosts Productivity with Schleuniger
DECA Manufacturing, located in Lexington, OH, has been manufacturing high-quality wire harnesses and cable assemblies for over 40 years. When President Cameron Haring decided to modernize the facility’s equipment, Schleuniger's technology, expertise, and support caught his eye.
Prior to restructuring, DECA used a menagerie of legacy equipment to facilitate its processes. To streamline manufacturing, Haring knew finding a supplier who would partner with DECA and add value to the overall business would be critical to the company’s success. According to Haring, “Schleuniger Direct Sales Representative, Bruce Moore, provided a full-service approach to creative solutions for advancing our capabilities.”
DECA now owns several Schleuniger machines, but Haring attributes the company’s significant productivity gain and overall growth to their investment in the CrimpCenter 36 S fully automatic crimping machine. “We process a substantial amount of sealed wire leads and the CrimpCenter’s throughput is amazing. We have easily increased productivity by 50 to 100 percent, improved quality, and instantly unlocked new abilities, even attracting new customers,” says Haring.
In addition to the success of the CrimpCenter, Haring noted that with the MultiStrip 9480 cut and strip machine, they’ve been able to eliminate manual stripping of inner conductors when processing multiconductor cable, increasing efficiency. They’re even looking at adding to their Cut & Strip line to serve a niche they’ve built for processing larger gauge cable.
For other small manufacturers considering equipment upgrades, Haring shared, “The important thing is to invest in the training offerings that are available at the time of purchase, [because] once you know what you are doing, you can shift work from old techniques to new ones and reap the benefits. Schleuniger provided exceptional, responsive support to help get us up and running."
Many links may have to be removed as Blogger made the remark that some malware or virus is there in this blog post. How to locate and remove the malaware and virus. Does blogger has any feature that scans blog posts?
Why Machine Work Study?
Improvement Possibilities - "Replacement of Machines Opportunity" to "Work Aids Provision" and "Incremental Machine Level Automation"
Automatic machines are now available for replacing currently used machines. Do replacement analysis. Replacement analysis is industrial engineering. It is specially taught in IE Engineering Analysis.
Highlighted case study
Improving Productivity by Using Extra Mechanical Automation on Different Sewing Machine. Interesting case study.
One machine was changed. Automation increased on some machine. Due to these machine related changes, manpower was reduced from 70 to 62 in this line.
"Sweater production process" has many results in google search.
Difference between Single Jersey and Interlock Circular Knitting Machine
30/05/2022 by textileblog
Single Jersey Circular Knitting Machine:
Single jersey circular knitting machine is the most used knitting machine in textile knitting industry. Latch needle, cylinder and sinker ring revolve through the stationary knitting cam systems
Interlock Circular Knitting Machine:
Interlock circular knitting machine is also a very commonly used machine in country to make interlock knitted fabric. The machine has two sets of needles on two different beds, one set on cylinder one in the dial bed
In this study, the KITECH logo was designed over the sports bra pattern using technical embroidery techniques. embroidery techniques. For this, a technical embroidery machine (SGVA 0109-825, ZSK Stickmaschinen, Krefeld, Germany) was used.
Automatic cutting machines can cut single or multiple plies of a wide variety of fabrics, from lightweight apparel fabric to high-performance industrial fabrics. Cutting can be performed using a laser, knife, or water-jet. The advantages of automatic cutting are the increased efficiency and accuracy, ease of cutting single and multiple plies, and perfect cutting the first time.
In this study, several embroidered fabrics were placed on the automatic cutting machine (P-CAM 161, Shima Seiki, Wakayama, Japan) for cutting into the patterns. For matching the embroidered logo on the accurate position, a full-size pattern piece was projected on the fabric as it was spread over the cutting surface using an overhead projector.
Robot Handling with a Gripping System
As a result, an electric needle gripper (SNGi-AE, Schmalz, Glatten, Germany), which can electrically adjust the length of the edle stroke, was chosen for this study; It showed robust performance for numerous fabric types without noticeable damage.
Automatic Sewing
In this study, two tasks were performed to realize automatic sewing technology. First, an automatic feeding system was developed to develop an automatic sewing process using a motor and acceleration sensor. The automatic feeding system was located on the right side of the industrial pattern sewing machine (ASM-224, JUKI, Tokyo, Japan), as shown in Figure 21a, and was designed to move the cut material to the sewing position. Two templates were then produced, as shown in Figure 21b. Each was placed above and below the pattern that will be sewn to be moved using an automatic feeding system. The template was designed using two polycarbonate materials by drilling two shoulder lines and two
SewBot Is Revolutionizing the Clothing Manufacturing Industry
FEBRUARY 19, 2018
In Bangladesh the labor cost to produce a denim shirt is about $0.22. If made by U.S. workers, that labor cost jumps to $7.47, but with a robotic production line, it’s just $0.33 per t-shirt.
Work aids are Additional devices that can be added to basic sewing machines such as folders, guides, and pressure feet. If work aids are used effectively operation cycle time can be reduced many folds than existing cycle time.
At Amazon, more than 750 000 robots are in operation. More than 1 billion packages in 2022 were sorted by their system called "Robin." Amazon has become the world's largest industrial robot manufacturer.
JUN 26, 2023 6:00 AM
Amazon’s New Robots Are Rolling Out an Automation Revolution
A wave of advanced machines is coming to the company’s facilities thanks to better AI and robots smart enough to work with—and without—humans.
Amazon created one of the most sophisticated supply chains in the world. From the introduction of Amazon Prime, to the use of advanced technology for package delivery, Amazon consistently drives change from the front of the pack.
Amazon is now searching for an innovative and solutions-oriented Sr. Manager, Industrial Engineering to be a part of our global initiative of developing and delivering the next generation of world-class fulfillment systems. Successful candidates are natural self-starters who have prior engineering experience in the integrated automation project life cycle, including development, design, implementation, enhancement, and support.
As a Sr. Manager, Industrial Engineering for Amazon Fulfillment, you will work with some of the most talented engineers in the design, development, and delivery of physical distribution systems around the globe. You will lead a team of engineers that executes complex cross-functional projects and programs that focus on the building of new, the alteration of existing, and the closing of end-of-life material handling and technology systems. As a senior manager, you are responsible for establishing the right engineering team structure and overall execution strategy to meet long-term business needs. You have a strategic focus, and you partner with business leaders, technical managers, and senior engineers to deliver the long-term strategy of program growth and project execution.
You must be responsive, flexible, and able to succeed within an open collaborative environment. Amazon’s culture encourages innovation and expects engineers to take a high-level of ownership in solving complex problems.
Key job responsibilities
Responsibilities
Own the design and development of engineering solutions for complex material handling challenges considering human/equipment interactions for the North America fulfillment network
Lead and coordinate concept and design development efforts for optimal solutions for the North America fulfillment network through equipment specification, material flow, process design, ergonomics, associate experience, operational considerations and site layout
Lead and manage a team of talented engineers handling multiple projects at a time
Work closely with vendors, suppliers, and other teams to create innovative solutions
Simultaneously manage multiple high-visibility projects and tasks while effectively influencing, negotiating, and communicating with internal and external business partners, contractors, and vendors
Innovate with complex automated material handling equipment, packaging technologies, and systems, including robotics and mechatronics, across many new fulfillment and logistics centers that are being built each year
Provide technical leadership for large-scale industrial engineering projects using MS Excel, AutoCAD, and MS Project
Work with complex MHE, packaging lines, and process design based on Lean Manufacturing tools and techniques
Drive engineering best practices (e.g., operational excellence, safety, security, quality, performance, etc.) and set standards for project execution and installation management
Coordinate with local site management to ensure proper operator training, procedural compliance, maintenance, and safety practices are followed for new and existing equipment
Build strong relationships with partner organizations within the company such as North America Start-up, North America Launch team, Worldwide Design team, North America Procurement, Information Technology, Loss Prevention, Facilities, Safety, Change Management and North America Operations
BASIC QUALIFICATIONS
Bachelor’s in Mechanical/Industrial/Process Engineering or related STEM field; or 2+ years related Amazon experience
10+ years of experience in a similar field or related occupation of Design/Innovation, Research & Development, Manufacturing/Process/Industrial Engineering
5+ years of experience managing and leading a team of 10+ engineers
Experience with MHE and packaging lines or process design based on Lean Manufacturing techniques
Experience using MS Excel, MS Project, and CAD software
Experience leading engineering design projects and interacting with cross-functional teams
Preferred Qualifications
MBA/Master’s Degree, or other advanced degree in Mechanical/Industrial/Process Engineering, Operations, Business Administration or related field and at least 5 years of progressively responsible experience in the specialty
Experience with complex automated material handling equipment, packaging technologies, and systems including robotics and high-speed manufacturing
Proficiency using AutoCAD 3D
Proficiency using advanced simulation modeling tools (Flexsim, Arena, Simio, etc)
Proficiency in running SQL queries and data mining
Experience in engineering and estimating material handling and storage systems
Operations Management/ Fulfillment/Distribution Center experience preferred
Capital project management skills
Proficiency with concepts like system architecture, optimization, system dynamics, system analysis, statistical analysis, and reliability analysis
Design-in-Safety experience
Experience with process design based on Lean Principles.
Six Sigma certification
Proficiency using business/technical software like MS Excel, MS Project, and CAD software.
Proficiency with concepts like system architecture, optimization, system dynamics, system analysis, statistical analysis, reliability analysis, and decision making.
Economies of Density in E-Commerce: A Study of Amazon’s Fulfillment Center Network
Our results suggest that Amazon’s expansion led to significant shipping cost savings, facilitated the realization of aggregate economies of scale, and lowered the external costs of e-commerce. We use the estimated model to quantify the distortionary effects of nexus tax laws on the firm’s distribution network and shipping cost, relative to non-discriminatory taxation.
Amazon changes worker-productivity yardstick blamed for warehouse injuries
Company's decision to overhaul its productivity targets coincides news reports that the rate of injuries at Amazon warehouses is higher than its peers in logistics.
The 30,000 Kiva robots at Amazon warehouses have reduced the online retail giant's operating expenses by 20% -- and inspired several tech companies to create the mechanical material handler of the future.
Idea and Implementation by one of the CNC programmers in a machine shop.
He eliminated the need for sending any parts from a cell to the common deburring department by inserting a deburring operation in the CNC programs of all the parts in the cell's part family and using one of the milling cutters already in the tool magazine of the Haas Mill that the cell had.
A good example of operation and process improvement.
Vadain, the custom curtains manufacturer in the Netherlands, together with software developers from Sycade, OMRON machine vision technology, and machine builder Eisenkolb, developed an automated solution to detect and analyze errors in curtain fabrics.
Sycade - Vadain machine vision case video
__________________
https://www.youtube.com/watch?v=QT4a5yZtP7w
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Sycade is an expert in the field of quality improvement through automation in the manufacturing industry. With the expertise of Vadain, the technology and innovative automation concept of OMRON, hardware of Eisenkolb and a camera light supplier, Sycade set up a solution using a 'standard' rolling machine to unroll rolls from position A and roll up again to position B. The unrolled fabric passes over an assessment surface with an integrated cutting unit, located inside a dark unit with vision technology.
Detect, cut, register
After a defect is detected and assessed, the roll is cut and defect portion is separated. The partial roll is marked with a sticker with the parent roll plus partial roll marking, including the number of meters. This makes it possible to have an account of meters of flawless fabric is in stock and in which cuts. This ensures that the workshop knows exactly which partial—and error free—roll can be used most efficiently for a particular order. The total of the sub-rolls remains linked to the original meters of the parent roll, making it easy and efficient to reorder fabrics.
Suggestions on the above process - I posted in Linkedin, and FaceBook
On Linkedin
Michel Baudin
Takt Times Group
It's wonderful of you to post this example. It's clearly a target-rich environment and great to use in classes.
It's wonderful of you to post this example. It's clearly a target-rich environment and great to use in classes.
More context would be helpful. From the video, we can infer quite a bit but it may not be correct. In particular, we don't know the company's pain points. Is it struggling with productivity, quality, delivery? Does it have many injuries? How is the employee turnover? Are they able to retain employees?
In terms of process technology, work methods, layout, flow, safety, etc., this shop looks 50 to 100 years behind the times. It also does not look like a company that can invest in state-of-the-art CNC lathes or would know how to use them.
On the other hand, they most likely could afford safety glasses, go/no-go gauges, posted work instructions, chucking that doesn't require manually tightening bolts, and powered positioning to replace cranks... And they could have a one-piece flow cell at least through the lathes and drill press.
Also, the video looks to be in fast motion. It's good to visualize the entire process but not for time studies.
The key question after that is where to start improving.
Comments On the video
yarrdayarrdayarrda
Seemingly primitive fixtures to drill the oil passages, and yet he hit the middle of the main journal, nice!
Jeff Yates
Saw the castings were Perkins, the way we do them in the States at Caterpillar and how they do it there shows how far we’ve come. I am surprised Caterpillar has their subsidiary still do like Henry Ford did it in the 20’s
Machining Description of machining CTQ characteristic pertaining
Operation no. operation to the machining operation
10 Facing and centering Center to center distance
Diameter and chamfer angle of
locating hole
20 Milling of crankshaft web Flatness of web
30 CNC Rough turning of journals Diameter of journal
40 Whirling of pins Phase-out of pins
Throw of pins
Pin diameter after whirling
Journal diameter after whirling
50 Finish turning of journals Journal diameter after finish
turning
60 Gun drilling of oil hole Diameter of oil hole
70 Finish turning of flange end Diameter of flange
Circularity of flange
80 Drilling and tapping of bolt Pitch circle diameter of bolt holes
holes over the PCD Thread pitch of bolt holes
90 Stub end boring and Stub-end-hole diameter
chamfering using a Chamfer angle
combination boring-cum
chamfering inserts tool bar
100 Grinding of journals Finish diameter of journals
Circularity of journals
110 Grinding of pins Finish diameter of pins
Circularity of pins
120 Detection of magnetic cracks Check for internal cracks
130 Sursulfing Hardeness of journals and pins
after sursulfing operation
140 Pins and journals lapping Surface roughness of journals
and pins after lapping
150 Final inspection quality check
Thesis chapter on grinding
http://shodhganga.inflibnet.ac.in/jspui/bitstream/10603/194947/11/11_chapter%205.pdf
Rough- and finish-grinding of a crankshaft in one set-up
Abstract
Method of grinding a concentrically clamped crankshaft, a crankshaft grinding machine for carrying out the method, and a crankshaft of high-alloy steel or cast material. The method provides for pin journals and main journals of the crankshaft to be ground in one set-up such that first, at least the main journals are rough-ground and then the pin journals are finish-ground and after that the main journals are finish-ground. The crankshaft grinding machine forms a machining center by means of which corresponding rough-grinding and finish-grinding is possible in a single set-up.
B24B5/42 Single-purpose machines or devices for grinding crankshafts or crankpins
Application US09/980,764 events: 1999-04-30 Application filed by Erwin Junker Maschinenfabrik GmbH: 2000-04-20 Assigned to ERWIN JUNKER MASCHINENFABRIK GMBH: 2004-02-20 Application granted: 2005-04-12
Publication of US6878043B1: 2020-02-29
Application status is Active: 2020-04-20
The JUNKER Group drives forward with digitalization
Process-optimized production with the digital twin
09/06/2019
Combining real and virtual machines results in an intelligent system able to predict characteristics and operating behavior from the production planning stage and throughout the product lifecycle. The digital twin for JUNKER grinding machines is a virtual representation of the real system, enabling comprehensive digital exchange between the virtual and real world. https://www.junker-group.com/news/detail/news/process-optimized-production-with-the-digital-twin/
Reference machines for worldwide production
The Renault Group opts for JUNKER machines for hybrid project
07/29/2019
Prototype production takes place at the French main plant Cléon, where Renault have opted for the ZEMA NUMERIKA G 1500 Plus and the JUCRANK 6S 10-10. These two machines supply reference data for series production worldwide. The results then form the basis for global production at the Renault Group’s other sites. This means that the JUNKER reference machines set the standard for efficient production throughout the entire Group. The ZEMA NUMERIKA cylindrical grinding machine grinds flanges and journals for crankshafts in a single clamping set-up using corundum grinding wheels, while the JUCRANK non-cylindrical grinding machine machines the main and pin bearing in a single work step using CBN grinding wheels. https://www.junker-group.com/news/detail/news/the-renault-group-opts-for-junker-machines-for-hybrid-project/
Hyundai Compact Line Center for Crankshaft Machining WH40RS
Video in the page demonstrates the working of the machine.
(See the video WFL M60 MillTurn Complete Crankshaft Machining - MARTECH Machinery, NJ - USA, 26 Jul 2012 https://www.youtube.com/watch?v=81UjjSH2iFw also)
Special -Purpose Machine for Crankshaft both end MBE
Special-Purpose Machine for Crankshaft Oil Holes MOH
Fixture for Crankshaft Oil Holes Machining CRANKMASTER Series https://www.horkos.co.jp/english/products/mc/spm.php
2008 Developed the CNC crankshaft rough milling machine
2009 Developed the Crankshaft pin turner
CLAAS Tractor’s modern facility - Innovative design and manufacturing Using 3D modeling and virtual simulation.
At the CLAAS Tractor’s modern facility, new technology platform enables the company to adopt innovative design and manufacturing methods, including 3D modeling and virtual simulation. It is a long-time user of Dassault Systèmes’ design application CATIA, the company made the decision to adopt Dassault Systèmes’ 3DEXPERIENCE® platform and ENOVIA to establish digital continuity among its departments. It selected DELMIA to virtually model its assembly line to improve product quality, boost output, and handle its increasingly complex and diversified product range.
By developing the new model virtually in 3D, designers and engineers could assess the feasibility of the new design and set up the assembly line before production.
Using the 3DEXPERIENCE platform the factory was modeled and everything related to production, such as lifting and clamping tools, could be validated virtually because of that. We have been able to adapt our design to the new equipment installed in the factory. For example, the rear caterpillar tracks of the AXION 900 TERRA TRAC completely change the architecture of the tractor. As the caterpillar tracks are longer than tires, the tanks had to be moved above the tracks, next to the cabin. We have to lift them to fix them to the tractor. Having the new factory digitalized enabled us to make sure it was possible to make it.”
MASTERING COMPLEXITY
CLAAS Tractor produces machines for customers worldwide. At any one time, there can be 20 different models on the same assembly line, and in these models more than 300 options exist. The 3DEXPERIENCE platform was the only way to anticipate the integration of specific options and to plan the process upfront.”
Backed by the 3DEXPERIENCE platform, CLAAS Tractor is now able to consider customizations early in the product development process and account for how they will need to be managed on the assembly line.
“Thanks to the platform, you can view the customized tractor in its final configuration as well as its specific assembly process. It’s very easy.”
Using the simulation capabilities in DELMIA, engineers can determine how each product will be manufactured and flag any issues before they occur.
“The platform allows us to simulate, verify and optimize the different assemblies in relation to various options,” said a methods engineer. “We can then check that each combination won’t be an issue during the assembly process. It also allows us to control that the product is compatible with the process at each workstation.”
The platform allows process engineers to co-design the product with product engineers, anticipate assemblies and improve the process and product quality.”
Close collaboration between process and design is especially important as the product design office is located in VélizyVillacoublay, 200 kilometers away from the Le Mans production plant.
“The platform makes it possible to share data on a single environment and bring together employees from the design office, methods and factory teams that are not located on the same site,” “It has enhanced communication and helped us collaborate on the product-process design.”
The design engineers created the AXION 900 TERRA TRAC and exchanged the 3D model with the process engineering team in Le Mans. The process team was then able to virtually test the assembly of the new tractor on the virtual assembly line and report any issues to the design office. Establishing a continuous digital thread across the entire product lifecycle empowers everyone to carry out their role to the best of their ability and build each machine first-time right.
“Digital continuity is an asset. “It links the product designer and the assembly operator who will use the operating instructions. The platform makes it possible to verify that the design concept can be used by the operator, in compliance with industrial, ergonomic and quality requirements throughout the development cycle of our tractors.”
VIRTUAL TWIN VALIDATION
3D models are now used across all departments at CLAAS Tractor. “The 3DEXPERIENCE platform makes it possible to use 3D at all levels within the company,” “Virtually immersed in their future working environment, operators understand the assembly of the future product and how to use their future equipment. The plant manager can make the right decisions regarding the material and its maintenance. And the customer can view the product they ordered, including all the options, before it’s even produced.”
Having a virtual twin of both its products and the factory is having a particularly positive impact on CLAAS Tractor’s design to manufacturing process, helping to ensure that each component can be produced within the Le Mans factory using existing equipment and will work within the finished tractor.
“We model the different parts of the tractor in 3D like sheet metal, hydraulic pipes and electrical harnesses,” and “We share this 3D model with the factory to make 100% sure the parts can be assembled. In the design office, we use CATIA to create the tractor parts. In product architecture, we especially use the Mechanical System Design feature, which allows us to represent the kinematics of the tractor. It enables us to create mobile parts in 3D and make sure they do not interfere with other parts when the tractor is in action.”
This approach also helps the design team handle changes effectively and rectify errors quickly.
“As an architect, we use the Volume Filters feature a great deal,” Dufourg said. “For example, when an assembly issue or damage is reported, a part must be modified. The Volume Filter highlights the area around the part that is affected. Then the platform provides the bill of materials to make sure we do not forget any options or create interference with nearby parts.”
IMPROVING UNDERSTANDING AND TRAINING
With the 3DEXPERIENCE platform, we can anticipate assembly operations with overviews, and carry out assembly tests even before we receive the parts and without any physical prototype. Operators really appreciate it.”
It’s now far easier for CLAAS Tractor to train its operators and prepare them to work on new models.
“Today, with DELMIA, we are one step ahead,” Dassé said. “I can run through the tractor manufacturing process in detail, and operators can be trained and understand the assembly processes before the tractor physically exists.”
Being able to share virtual models of the new factory and future tractor designs also helped CLAAS Tractor get its workforce onboard with its company-wide digital transformation.
“The AXION 900 TERRA TRAC has been designed to be assembled on the future assembly line, but operators couldn’t imagine the future process,” Dassé said. “As they were able to see the tractor and factory model in 3D, they quickly realized that the new approach would be much clearer and more fluid.”
EXPANDING CAPABILITIES
Based on the success of the implementation, plans are now in place to bring CLAAS Tractor’s new capabilities to other organizations and factories within the wider CLAAS Group. “This is the pilot project for CLAAS Group that will be deployed in other factories involving a product design office,” “For me, this experience made it possible to innovate at CLAAS Tractor, to connect departments around the same data and to anticipate production rather than endure it.”
“To sum up this transformation, I would say that it has been about passion, exciting new tools, openness to new innovative solutions, but above all delivering on our objective to serve the customer with the best products,” Bourasseau concluded.
