Showing posts with label Top 500. Show all posts
Showing posts with label Top 500. Show all posts

Thursday, April 2, 2026

3D Printing - Additive Manufacturing Industrial Engineering - Productivity Science and Engineering



Applied Industrial Engineering - Application of Industrial Engineering in 3D Printing - Additive Manufacturing Technology to Improve Productivity

Posts on Additive Manufacturing in this blog.


2026

Metal Droplet Jetting - Magnetohydrodynamic Liquid Metal Droplet jetting - A Low-Cost Additive Manufacturing Process

2025

3D Printing Mass Production: 8 Success Stories
05 June 2025

High Volume 3D Printing for Mass Production: Where It Works and Where It Falls Short
11.04.2025


2023

Minimum cost, stability constrained preform optimization for hybrid
manufacturing q
Gregory Corson a
, Christopher Tyler b
, Jake Dvorak a
, Tony Schmitz a,b,⇑
aUniversity of Tennessee, Mechanical, Aerospace, and Biomedical Engineering, Knoxville, TN, USA
bOak Ridge National Laboratory, Manufacturing Science Division, Oak Ridge, TN, USA
Manufacturing Letters
journal homepage: www.elsevier.com/locate/mfglet




17.10.2023

Bibliography - Links







https://www.diva-portal.org/smash/get/diva2:1706162/FULLTEXT01.pdf

https://www.linkedin.com/pulse/productivity-metal-additive-manufacturing-focus-arcam-alison-m--1

https://link.springer.com/article/10.1007/s00170-017-1221-1

https://www.ncbi.nlm.nih.gov/pmc/articles/PMC9586238/

https://pubmed.ncbi.nlm.nih.gov/36080547/

https://www.semanticscholar.org/paper/The-cost-of-additive-manufacturing%3A-machine-of-and-Baumers-Dickens/751ca907ed453d527f0bd1ef0d5f0e26f257b168

https://nexa3d.com/blog/improving-productivity-in-additive-manufacturing-operations/
Discover how to gain 20X productivity in AM

https://www.additivemanufacturing.media/articles/productivity-gains-set-to-transform-am

https://www.tctmagazine.com/additive-manufacturing-3d-printing-industry-insights/technology-insights/redefining-production-3d-systems-high-performance-plastics-batch/

https://ideas.repec.org/a/eee/tefoso/v102y2016icp193-201.html

https://nvlpubs.nist.gov/nistpubs/specialpublications/nist.sp.1176.pdf

https://ieeexplore.ieee.org/document/8615803

https://typeset.io/papers/on-productivity-of-laser-additive-manufacturing-4gzpppgl3l

https://www.americamakes.us/wp-content/uploads/2023/05/IMPACT_Industry-Day-at-Virtual-TRX_June-2023.pdf

https://www.apriori.com/blog/how-to-calculate-the-additive-manufacturing-breakeven-point/

https://www.thesteelprinters.com/news/an-analysis-of-the-impact-of-additive-manufacturing-in-the-mining-industry

https://nottingham-repository.worktribe.com/index.php/output/771130/the-cost-of-additive-manufacturing-machine-productivity-economies-of-scale-and-technology-push


https://research.aalto.fi/files/94250959/1_s2.0_S2405896322019139_main.pdf

https://www.materialise.com/en/inspiration/volume-production-additive-manufacturing

https://www.jabil.com/blog/additive-manufacturing-will-disrupt-your-business.html

https://www.ornl.gov/content/additive-manufacturing



https://iopscience.iop.org/article/10.1088/1757-899X/455/1/012102/pdf


https://www.scielo.br/j/jatm/a/rrW5H7FGWtpDrbJSPtZTJ7d/?lang=en

https://cordis.europa.eu/project/id/313781/reporting/de

https://www.meddeviceonline.com/doc/sensor-fusion-enables-comprehensive-analysis-of-laser-processing-in-additive-manufacturing-0001

















March 30, 2023
Data-Driven 3D Printers: The Real Game-Changers for Manufacturing? Artificial intelligence and machine learning take additive to the next level.

Connected 3D printers can use collected data for artificial intelligence-powered automation. During each print job, 3D printers produce large quantities of data that are sent to and stored in the cloud. This data can help businesses make decisions about which parts to print and how best to print them, while improving the quality of print jobs.


Machine learning can optimize hardware, automatically enhancing 3D printers through software updates to increase printing speeds and improve resolution. AI can help businesses determine which parts, when produced in-house through additive manufacturing, will have the biggest impact on their bottom line. It can use digital catalogs of parts and detect which specific parts are the best candidates to be printed through various additive manufacturing techniques.

3D printers can use machine learning to automatically generate tooling jigs or fixtures to hold the parts they print.  AI-based optimizations  are used during the design stage of new parts — simulating how the digital design for a part, once printed, will perform under specific loads. AI is also employed in additive manufacturing to detect print failures (proactively pausing prints when needed), and to inspect parts as they’re being printed to ensure quality and conformance.

A Closed Loop
The same hardware out in the field is consistently learning, improving and getting smarter with every over-the-air update. As providers advance the quality of information collected during fabrication and build modes of collecting data about how each 3D printed part does its job on the field, manufacturing technology approaches a fully automated “closed-loop” printing process: One that can simply be presented with a real-world manufacturing problem to solve, and then design and build the part using the specific digital fabrication technology that makes the most sense given the defined time, cost, and performance constraints.

This smart, closed-loop automation of fabrication can substantially increase outputs and production speeds. And while additive manufacturing inherently streamlines the process of building parts, each savvy application of data collected by the printers can streamline distinct points within the additive manufacturing process. 



2021

Productivity of 3D Printing - Additive Manufacturing  - High-speed 3D printing and the expanding material choice 


3D Printer manufacturers are focusing on developing technologies that support higher production volumes, and materials that enable advanced AM applications.  As a result, on the hardware side,  the rise of binder jetting and multi-laser powder bed fusion for metals and vat photopolymerisation processes for plastics is occurring. Materials manufacturers are increasingly focusing on high-performance materials, including advanced alloys and composites. 

The introduction of high-speed polymer AM technologies has significantly boosted the growth of 3D printing in dental. As estimated by the market research firm SmarTech, the AM dental and medical industry has topped $3 billion. Over 70% of dental labs in the US are predicted to own 3D printing technology by the end of 2021, with dental 3D printing becoming a $9.2 billion industry in the next five to seven years. 

Metal powder bed fusion: Metal 3D printing encompasses many technologies, but one of the most matured among them remains metal Powder Bed Fusion (PBF). Key market players are launching solutions for automated and integrated production. They offer a high level of automation in a bid to maximise efficiency and reduce the amount of manual labour required.  Thanks to these developments, laser PBF has found its way into many industries and applications. One industry that has been  adopting metal PBF is aerospace. Today, metal PBF 3D-printed parts are powering crucial aircraft and spacecraft systems like engines. This is where the technology’s key capabilities — the production of complex parts with simplified assembly and less material waste — truly shine. 

Research at VTT & Aalto University


New launches of Additive Manufacturing systems with enhanced productivity (e.g. SLM Solutions, ExOne, Nexa3D, Voxeljet, EOS Systems), and a growing number of software companies in the field of AM boost the hope for applying AM technologies for a larger share of components.  We at VTT & Aalto University are supporting productivity improvement of AM and have been developing and testing promising bio-based engineering materials produced from sustainable sources within the ValueBioMat project. We are focusing on advances in material science and innovation that are needed to get prepared for the future of AM, with productivity in line with sustainability.

Filtration technology boosts metal additive manufacturing ( powder-bed fusion process) productivity

Sept. 16, 2021

BOFA International (Poole, UK) has developed an innovation  that makes the exchange of filters in metal additive manufacturing processes safer, faster, and better for productivity. The laser powder-bed fusion process used in metal additive manufacturing needs filters. When new filters are needed for these systems, equipment has to be shut down and moved to a safe area for the saturated filters to be removed and replaced by operatives wearing full PPE—up until now. The new standalone AM 400 system’s technology enables the filters to be exchanged on site without risking a thermal event. The BOFA’s AM 400 filters are contained within a separate housing with a robust seal, enabling filter exchange to be completed quickly and safely without isolating the additive manufacturing equipment. This will reduce downtime of the equipment and  increase productivity.


Application of Industrial Engineering Focus Areas in Additive Manufacturing



Productivity Science - Additive Manufacturing


Productivity science has to indicate process parameters that contribute to productivity improvement.

INFLUENCE OF PROCESS PARAMETERS ON THE MECHANICAL BEHAVIOUR AND PROCESSING TIME OF 3D PRINTING
Ramu Murugan, Mitilesh R.N, Sarat Singamneni
International Journal of Modern Manufacturing Technologies,
 Vol. X, No. 1 / 2018
http://www.ijmmt.ro/vol10no12018/10_Murugan_Ramu.pdf

Ingrassia T., Nigrelli V., Ricotta V., Tartamella C. (2017) Process parameters influence in additive manufacturing. In: Eynard B., Nigrelli V., Oliveri S., Peris-Fajarnes G., Rizzuti S. (eds) Advances on Mechanics, Design Engineering and Manufacturing. Lecture Notes in Mechanical Engineering. Springer, Cham
https://link.springer.com/chapter/10.1007/978-3-319-45781-9_27

Antonio Lanzotti, Marzio Grasso, Gabriele Staiano, Massimo Martorelli, (2015) "The impact of process parameters on mechanical properties of parts fabricated in PLA with an open-source 3-D printer", Rapid Prototyping Journal, Vol. 21 Issue: 5, pp.604-617, https://doi.org/10.1108/RPJ-09-2014-0135
https://www.emeraldinsight.com/doi/full/10.1108/RPJ-09-2014-0135


A Process Modelling and Parameters Optimization and Recommendation System for Binder Jetting Additive Manufacturing Process

Han CHEN
Department of Mechanical Engineering, Faculty of Engineering, McGill University, Montreal
2015 Nov
Master of Engineering – Thesis
http://digitool.library.mcgill.ca/webclient/StreamGate?folder_id=0&dvs=1551929237031~812

Thesis | A process modelling and parameters optimization and recommendation system for binder jetting additive manufacturing process | ID: gf06g5493 | eScholarship@McGill


Product Design Improvement for Productivity - Design for Additive Manufacturing


A design framework for additive manufacturing based on the integration of axiomatic design approach, inverse problem-solving and an additive manufacturing database
by
Sarath Renjith
MASTER OF SCIENCE
Major: Industrial Engineering
Program of Study Committee:
Gül Erdem Okudan Kremer, Major Professor
Michael Scott Helwig, Committee Member
Mark Mba-Wright, Committee Member
Iowa State University
Ames, Iowa
2018
http://www.imse.iastate.edu/files/2018/11/Chennamkulam-RenjithSarath-thesis.pdf

Design for Additive Manufacturing
Authors: Erin Komi
2016
https://www.vtt.fi/inf/julkaisut/muut/2016/VTT-R-03159-16.pdf


Large collection of articles on DFAM

Design for 3D Printing - Additive Manufacturing - Product Industrial Engineering


Process Improvement for Increasing Productivity  of Additive Manufacturing


30 January 2018
To improve additive manufacturing productivity and lower cost per part, Renishaw has launched its latest system, the RenAM 500Q. Featuring four 500 W lasers, the compact machine will greatly improve productivity in the most commonly used platform size
https://www.renishaw.com/en/pioneering-productivity-in-additive-manufacturing--43150


VERY HIGH POWER ULTRASONIC ADDITIVE MANUFACTURING (VHP UAM)
FOR ADVANCED MATERIALS
K. F. Graff, M. Short and M. Norfolk
Edison Welding Institute, Columbus, OH 43221
2010

To extend current ultrasonic additive manufacturing (UAM) to advanced materials, higher
speeds and larger parts, it was essential to greatly increase the process ultrasonic power. EWI,
with Solidica™, several industry, agency and academic partners, and support of Ohio’s Wright
Program, have developed a “Very High Power Ultrasonic Additive Manufacturing System” that
greatly extends current technology. A key part was the design of a 9.0 kW “push-pull”
ultrasonic system able to produce sound welds in materials such as Ti 6-4, 316SS, 1100 Cu and
Al7075. The VHP system can fabricate parts of up to 1.5m x 1.5m x 0.6m.
http://sffsymposium.engr.utexas.edu/Manuscripts/2010/2010-06-Graff.pdf


Industrial Engineering Economic Analysis of Additive Manufacturing


Digital Alloys’ Guide to Metal Additive Manufacturing – Part 5. Economics of Metal Additive Manufacturing
January 31st, 2019
https://www.digitalalloys.com/blog/economics-metal-additive-manufacturing/

Justifying A 3D Printer Investment For Rapid Prototyping
Stratasys 2017 Report

ZHU, Z. ... et al, 2017. Economic analysis of plastic additive
manufacturing for production of end use products: a preliminary study. Presented at the 15th Conference on Rapid Design, Prototyping & Manufacturing
(RDPM2017), Newcastle, UK, 27th-28th April 2017.
https://dspace.lboro.ac.uk/dspace-jspui/bitstream/2134/25269/3/RDRM%20paper_Zhu_Pradel_Bibb_Moultrie.pdf


"An economic analysis comparing the cost feasibility of replacing injection molding processes with emerging additive manufacturing techniques,"
Franchetti, M. & Kress, C. Int J Adv Manuf Technol (2017) 88: 2573. https://doi.org/10.1007/s00170-016-8968-7
https://link.springer.com/article/10.1007/s00170-016-8968-7


Economic Aspects of Additive Manufacturing: Benefits, Costs and Energy Consumption
by Martin Baumers
Doctoral Thesis Submitted in partial fulfilment of the requirements for the award of Doctor of Philosophy of Loughborough University
September 2012
https://dspace.lboro.ac.uk/dspace-jspui/bitstream/2134/10768/3/Thesis-2012-Baumers.pdf


Mathematical Optimization - Engineering Optimization of Additive Manufacturing


A modified genetic algorithm for time and cost optimization of an additive manufacturing single-machine scheduling
International Journal of Industrial Engineering Computations,
Volume 9 Issue 4 pp. 423-438 , 2018,  Pages 423-438
http://growingscience.com/beta/ijiec/2802-a-modified-genetic-algorithm-for-time-and-cost-optimization-of-an-additive-manufacturing-single-machine-scheduling.html

TOPOLOGY OPTIMIZATION FOR ADDITIVE MANUFACTURING
D. Brackett, I. Ashcroft, R. Hague
Wolfson School of Mechanical and Manufacturing Engineering, Loughborough University,
Loughborough, Leicestershire, LE11 3TU, UK
2011
http://sffsymposium.engr.utexas.edu/Manuscripts/2011/2011-27-Brackett.pdf


Statistics Based Optimizations of Additive Manufacturing


Design for Six Sigma (DFSS) for additive manufacturing applied to an innovative multifunctional fan
Alfredo Liverani,  · Gianni Caligiana,  · Leonardo Frizziero,  Daniela Francia,  Giampiero Donnici, ·
Karim Dhaimini
Received: 6 November 2018 / Accepted: 15 January 2019
© Springer-Verlag France SAS, part of Springer Nature 2019
https://link.springer.com/content/pdf/10.1007%2Fs12008-019-00548-9.pdf


Optimal process parameters for 3D printing of dental porcelain structures
Hadi Miyanajia, Shanshan Zhanga, Austin Lassella, Amir Ali Zandinejadb, Li Yanga
Department of Industrial Engineering, J.B. Speed School of Engineering
Department of Oral Health and Rehabilitation, School of Dentistry
University of Louisville, KY, 40292
2015
http://sffsymposium.engr.utexas.edu/sites/default/files/2015/2015-132-Miyanaji.pdf


Human Effort Industrial Engineering of Additive Manufacturing


Research on the Design of FMD Desktop 3D Printer based on a User-Centred Perspective
https://books.google.co.in/books?id=uUNwDwAAQBAJ&pg=PA187#v=onepage&q&f=false

Are 3D printers bad for worker health?
Some printers produce a large amount of particles, causing respiratory symptoms in workers
BY LINDA JOHNSON
02/01/2018| CANADIAN OCCUPATIONAL SAFETY
https://www.cos-mag.com/occupational-hygiene/35967-are-3d-printers-bad-for-worker-health/


3D-PRINTING AND THE WORKING ENVIRONMENT
Jeroen Junte, November 2016
https://osha.europa.eu/sites/default/files/seminars/documents/Draft%20article%20foresight%203D%20printing.pdf

Industrial Engineering Measurements - Cost, Productivity and Time Measurement of Additive Manufacturing



Resource Consumption of Additive Manufacturing Technology
Nanond Nopparat, Babak Kianian
School of Engineering, Blekinge Institute of Technology  Karlskrona, Sweden
2012
Thesis submitted for completion of Master of Sustainable Product-Service System Innovation (MSPI)
Blekinge Institute of Technology, Karlskrona, Sweden.
https://www.diva-portal.org/smash/get/diva2:831234/FULLTEXT01.pdf



TIME ESTIMATION FOR ADDITIVE MANUFACTURING
By
Mina Amini
A thesis submitted to the Graduate Council of Texas State University in partial fulfillment of the requirements for the degree of Master of Science in Technology with a Major in Industrial Technology
December 2014
https://digital.library.txstate.edu/bitstream/handle/10877/5353/AMINI-THESIS-2014.pdf?sequence=1


Implementation of Additive Manufacturing Cost Estimation Tool (AMCET) Using Break-down Approach
Procedia Manufacturing,Volume 17, 2018, Pages 70-77
https://www.sciencedirect.com/science/article/pii/S2351978918311302

Cost Estimation of Laser Additive Manufacturing of Stainless Steel
Physics Procedia
Volume 78, 2015, Pages 388-396
https://www.sciencedirect.com/science/article/pii/S1875389215015436



Productivity Management


September  2018

Technology Adoption
Partnering in Technology Development for Productivity Improvement

Volkswagen  adopts the latest 3D printing technology, the "HP Metal Jet" process, which simplifies and speeds up metallic 3D printing. The process improves productivity by a simply staggering 50 times compared to other 3D printing methods for some components.

This process produces production-ready components for mass production applications in the automotive industry for the very first time. Volkswagen has closely partnered with printer manufacturer HP and component manufacturer GKN Powder Metallurgy in development for mass production use. The  new process was demonstrated at the International Manufacturing Technology Show (IMTS) in Chicago this week.

Volkswagen's Head of Technology Planning and Development, Dr. Martin Goede said that  we are relying on state-of-the-art technologies to ensure a smooth and fast production and  3D printing will play an  important role in manufacturing of individual parts.
https://www.ctvnews.ca/autos/volkswagen-turning-to-3d-printing-to-boost-productivity-1.4090893






85% Cost Reduction Due to Additive Manufacturing - $50,000 to $7,000.

10 sets of inlet booster rake for measuring air flow turbine engine test cells were made for $50,000 using a combination of welding, brazing, EDM, and other conventional medicines. The additive  machining technology center made it for $7,000.

Donald Godfrey, Honeywell, ISABE 2015 Manuscript
https://drc.libraries.uc.edu/handle/2374.UC/745636/browse?type=title

Huge Savings at Company Level - Honeywell Federal Manufacturing & Technologies


Honeywell Federal Manufacturing & Technologies has achieved huge cost reduction. As of FY 2018, they have printed more than 60,000 tooling fixtures for product testing and calculated $125 million in cost avoidance.

Design for Additive Manufacturing - Additive Manufacturing Industrial Engineering are Necessary for Effectiveness and Productivity

3D Printing is not simple.
For industrial parts, There is a workflow before the machine and after the machine with hundreds of variables that need to be specified and controlled to make sure of getting an industrial-grade part reliably, repeatably at reduced cost.
https://www.industryweek.com/technology-and-iiot/state-3d-printing-2019-all-grown-ready-work



2019



Huge Hybrid Manufacturing Machine is Ready to Start 3D Printing Construction Parts and Structures and Give Higher Productivity

31 JAN 2019

The machine will be tested to manufacture demonstrator parts, such as large cantilever beam structures, airplane panels and wind turbine parts. The machine and the process technologies are expected  provide a more productive solution for the hybrid manufacturing of large engineering parts and deliver a projected 20% reduction in time and cost expenditure, as well as a target 15% increase in productivity for high-volume additive manufacturing production.
https://adsknews.autodesk.com/news/huge-hybrid-manufacturing-machine-ready-to-start-3d-printing-construction-parts

http://www.constructionmanagermagazine.com/news/massive-construction-3d-printer-goes-live/

3D printing 100 times faster with light


Rather than building up plastic filaments layer by layer, a new approach to 3D printing lifts complex shapes from a vat of liquid at up to 100 times faster than conventional 3D printing processes, University of Michigan researchers have shown.
Michigan Engineering
January 11, 2019
https://news.engin.umich.edu/2019/01/3d-printing-100-times-faster/


SLA 3D Printing 100 Times Faster
________________


________________



MIT Researchers Developed FDM 3D Printing Head that makes Build Speed 10X


 A. John Hart, an associate professor of mechanical engineering and director of the Laboratory for Manufacturing and Productivity and the Mechanosynthesis Group at MIT.

Screw mechanism for feeding the wire and a laser in the printhead to melt the wire more thoroughly were incorporated into the print head.

https://www.wideformatimpressions.com/article/mit-accelerates-3d-printing/


---------------
February 2016 information

Productivity Drivers - 3D Printing


The output per unit time of  3D printer depends on

–Size of extrusion nozzle opening: ; The bigger the opening the more the material flow.

–Size of part to be printed. More volume, more time

–Part orientation on the build bed. X-Y orientations can usually be built faster than parts set up to build in the Z orientation.

–Complexity of part to be printed. Parts with many angles, curves and other geometric features will take longer to build than a straightforward box type shape.

–Material choice. In extrusion systems, every material flows at a different rate.

–Type of laser used in powder-bed systems.

–Type of material used in powder-bed systems. Plastics and metals will build at different rates.

–Required print resolution; Fine resolutions mean slower build rates.

–Part density. Fully dense parts can take longer to build than those with filler support.

The Ultimaker desktop 3D printer, gives its depositio rates as: With a 0.25 size nozzle, it is up to 8 mm3/s, a 0.40 nozzle it is  up to 16 mm3/s, a 0.60 nozzle up to 23 mm3/s, and a 0.80 nozzle can deposit up to 24 mm3/s.

Professional 3D printer, the SLM Solutions 500HL gives deposition rates for its two-laser version as 55 cubic centimeters/hour, and its four-laser version as 105 cubic centimeters/hour.


Comparison of FDM, SLA and SLM

Fused Deposition Modeling (FDM)

Fused Deposition Modeling is the most widely used form of 3D printing at the consumer level. ,  FDM 3D printers build parts by melting and extruding thermoplastic filament, which a print nozzle deposits layer by layer in the build area. FDM works with a range of standard thermoplastics, such as ABS, PLA, and their various blends. The technique is well-suited for basic proof-of-concept models, as well as quick and low-cost prototyping of simple parts. .

Stereolithography (SLA)

Stereolithography was the world’s first 3D printing technology, invented in the 1980s, and is one of the most popular technologies for professionals. SLA uses a laser to cure liquid resin into hardened plastic in a process called photopolymerization. SLA parts have the highest resolution and accuracy, the clearest details, and the smoothest surface finish of all plastic 3D printing technologies.  Material manufacturers have created innovative SLA resin formulations with a wide range of optical, mechanical, and thermal properties to match those of standard, engineering, and industrial thermoplastics.

Selective Laser Sintering (SLS)

Selective laser sintering is the most common additive manufacturing technology for industrial applications. SLS 3D printers use a high-powered laser to fuse small particles of polymer powder. The unfused powder supports the part during printing and eliminates the need for dedicated support structures. SLS is ideal for complex geometries, including interior features, undercuts, thin walls, and negative features. Parts produced with SLS printing have excellent mechanical characteristics, with strength resembling that of injection-molded parts.

https://formlabs.com/blog/fdm-vs-sla-vs-sls-how-to-choose-the-right-3d-printing-technology/



2018

Beyond prototyping: Scaling up to additive manufacturing for production
Charlie Wood
Friday, September 28, 2018
http://exclusive.multibriefs.com/content/beyond-prototyping-scaling-up-to-additive-manufacturing-for-production/manufacturing


Design for Additive Manufacturing
David Rosen
Georgia Institute of Technology
Conference Paper, January  2014

https://www.researchgate.net/publication/269231954


Igor Yadroitsev, Ina Yadroitsava, Philippe Bertrand, Igor Smurov, (2012) "Factor analysis of selective laser melting process parameters and geometrical characteristics of synthesized single tracks", Rapid Prototyping Journal, Vol. 18 Issue: 3, pp.201-208, https://doi.org/10.1108/13552541211218117

http://www.emeraldinsight.com/doi/abs/10.1108/13552541211218117


Paper available for review in the Google Book

https://books.google.co.in/books?id=tMndCgAAQBAJ&pg=PA121#v=onepage&q&f=false


Nowadays to increase productivity of SLM process, high laser power up to 400 W and high scanning speed up to 3 m/s are used.

Smaller thickness of layer allows for better accuracy of the manufactured part. But increases manufacturing time. (page 122 of the book)

Related Articles from this Blog


Design for 3D Printing - Additive Manufacturing - Product Industrial Engineering

3D Printing Materials

3D Printing - Production Applications

Additive Manufacturing - 3D Printing - Human Effort Industrial Engineering



Updated on 5.9.2025, 18.1.2024,  17.10.2023,  31.3.2023, 22.4.2022,  29 Sep 2021,  7 March 2019,   2 Feb 2019 29 January 2019,
5 October 2018, 4 August 2017









Posted by at 21 comments:
Labels: , ,

Saturday, March 28, 2026

Industrial Engineering in Electrical Engineering


Ubiquity of Industrial Engineering Principle - Industrial Engineering is applicable to all branches of engineering.





Thermal Electricity Generation - Five Operations in the Process and Industrial Engineering of Those Operations

ASME - Gilbreth Process Chart for Productivity Improvement


The process chart records all activities taking place in the process under 5 major operations of the process.

1. Operation - Processing the inputs into the process.

2. Inspection - Inspection activities

3. Transportation and mechanical and manual handling activities in the process.

4. Delays occurring the in the process - Electricity may not be produced. Equipment may remain idles. Delays occur due to problems purchase planning, production quantity planning, manpower planning, maintenance planning etc.

5. All stores and items stored in the process. The incremental cost of stores has to be brought down. Stores procedures may lead to elongation of cycle times and delays.


News Related to Operations/Processes for Industrial Engineers in Power Plants


1. Operation - Processing the inputs into the process.

New Paths to Productivity in Power Generation
AUGUST 07, 2017 


Methods of Improving the Efficiency of Thermal Power Plants
Tongjun Zhang,  2020,  J. Phys.: Conf. Ser. 1449 012001

[1] Harvey, Abby et al. 2017 History of Power: The Evolution of the Electric Generation Industry 
Powermag. [Online] Available: https: //www. powermag. com/
2019].
[2] BP p.l.c. 2019 BP Statistical Review of World Energy (68th edition). UK: Pureprint Group Limited.
[3] Swapan Basu and Ajay Kumar Debnath 2019 Power Plant Instrumentation and Control Handbook 
(2nd Edition). Academic Press p 1152
[4] W He, H Zhu, Y G. Liu, G Z Yi, and S C Pan 2019 Forest for ultra-super critical power generation 
technology China Energy and Environmental Protection vol 41 chapter 6 pp 77-81
[5] Augusto Di Gianfrancesco 2016 Materials for Ultra-Supercritical and Advanced 
Ultra-Supercritical Power Plants Woodhead Publishing 
[6] Q C Fei, C Liang 2012 Analysis on Energy Saving for Water Cooling System in Thermal Power 
Plants Electric Power vol 9
[7] L J Chen, L J Mi, C Xu,and Y Lei 2010 Development and Analysis of Direct and Indirect Air 
Cooling under New Situation Power System Engineering vol 26 chapter 6
[8] Y Q Kong, W J Wang, X W Huang, L J Yang, X Z Du,and Y P Yang 2017 Direct dry cooling 
system through hybrid ventilation for improving cooling efficiency in power plants Applied 
thermal engineering: Design, processes, equipment, economics vol 119 5 June pp 254-268
[9] Y Y Jiang, X Z Du, H M Hu, and Z G Li 2018 Thermodynamic characteristics of thermal power 
plant with hybrid (dry/wet) cooling system Energy 2018
[10]G Xu, L Zhou,S Zhao, F Liang, C Xu, and Y Yang 2015 Optimum superheat utilization of 
extraction steam in double reheat ultra-supercritical power plants Applied Energy vol 160 pp 
863–872
[11]Y J Ye and S L Shen 2011 Characteristics of European High-Efficiency Coal Fired Units and 
Their Implications for Chinese Power Plant Electric Power Construction vol 32 chapter l pp 
54-58
[12]K L Xu, Y H Xiong, H 2015 Pan Reheat Pressure and Feed-water Enthalpy Rise Optimization of 
Double Reheat Unit Turbine Technology vol 57 chapter 10 pp 371-373
[13]K Wang, Y Q Chen, B H Huang, X F Chen 2011 Performance Research on Domestic Gas-Steam 
Combined Cycle Unit North China Electric Power 4 pp 18-21


2. Inspection - Inspection activities


Thermal Power Plant Performance Testing: Major Equipment Performance Testing, Boilers, Turbines, Condensers, Pumps, Fans, Test Methodology and Code Requirements, Equipment Efficiency, Heat Rate Calculations, Correction Factors

Introduction
This seminar provides detailed description of the all performance testing methods for all thermal power plant equipment including boilers, turbines, condensers, pumps, fans, deaerators, and feedwater heaters. The methodology, and code requirements for the performance tests for all thermal power plant equipment will be covered thoroughly in this seminar. The preparatory work and instrumentation required for each test will be described in detail in this seminar.
 
The efficiency calculations for all the equipment used in circulating fluidized-bed (CFB) boiler and pulverized coal boiler power plants will be covered in-depth in this seminar. All the processes, operational and maintenance activities, capital projects, technical options, potential initiatives and incentives to implement upgrades/repairs for increasing the power plant equipment efficiency will also be covered in detail. This seminar will also provide a thorough explanation of CFB and pulverized coal boiler technology including hydrodynamics, combustion, emissions, design considerations, gas-solid separators, design of CFB and pulverized coal boiler components, management of solid residues, materials, stoichiometric calculations, and model for sulfur capture. The operation, maintenance, testing, and refurbishment options of all the equipment and systems used in CFB and pulverized coal power plants will be covered in detail including, boilers, superheaters, reheaters, turbines, condensers, feedwater heaters, deaerators, pumps, compressors, fans, electric generators, instrumentation and control systems, and governing systems, etc. All the factors which affect CFB and pulverized coal boiler power plant efficiency and emissions will be explained thoroughly. All the methods used to calculate the heat rate of CFB and pulverized coal power plants will be covered in detail. All the areas in CFB and pulverized coal boiler power plants where efficiency loss can occur will be explained. This seminar will also provide up-dated information in respect to the following methods used to improve CFB boiler and pulverized coal boiler power plant heat rate:

Optimizing the Combustion Process and Sootblowing
Controlling the Steam Temperature
Recovering Moisture from Boiler Flue Gas
Performing Steam Turbine Maintenance
Lowering Condenser Back Pressure
Pre-drying High Moisture Coal and Reducing Stack Temperature

Seminar Outcome

Thermal Plant Performance Testing: Gain a thorough understanding of all the performance testing methods for all thermal power plant equipment including boilers, turbines, condensers, pumps, fans, deaerators, and feedwater heaters.

Performance Test Methodology and Code Requirements: Understand the methodology, and code requirements for the performance tests of all thermal power plant equipment

Performance Test Preparatory Work and Instrumentation: Learn about the preparatory work and instrumentation required for each equipment performance test in a thermal power plant

Equipment Efficiency Calculations: Gain a thorough understanding of the efficiency calculations for all the equipment used in circulating fluidized-bed (CFB) boilers and pulverized coal boilers power plants
Calculating the Heat Rate of CFB and Pulverized Coal Boiler Power Plants: Learn all the methods used to calculate the heat rate of CFB and pulverized coal boiler coal power plants

Benefits of Lowering the Heat Rate of CFB and Pulverized Coal Boiler Power Plants: Understand all the benefits of lowering the heat rate of circulating fluidized-bed boiler coal power plants

Methods Used to Improve CFB and Pulverized Coal Boiler Power Plants Heat Rate: Gain a thorough understanding of all the methods used to improve the heat rate of CFB and pulverized boiler coal power plants

Processes, Operational and Maintenance Activities in CFB and Pulverized Coal Boiler Power Plants: Discover all the processes, operational and maintenance activities used to improve the heat rate of CFB and pulverized coal power plants

Capital Projects Used to Improve the Heat Rate of CFB and Pulverized Coal Boiler Power Plants: Learn about all the capital projects used to improve the heat rate of CFB and pulverized coal power plants

Technical Options for Improving the Heat Rate of CFB and Pulverized Coal Boiler Power Plants: Understand all the technical options used to improve the heat rate of CFB and pulverized coal boiler power plants

Potential Initiatives and Incentives to Implement Upgrades/Repairs for Improving the Heat Rate of CFB and Pulverized Coal Bed Boiler Power Plants: Discover all the potential initiatives and incentives to implement upgrades/repairs for improving the heat rate of CFB and pulverized coal power plants

Factors Affecting CFB and Pulverized Coal Boiler Power Plants Efficiency and Emissions: Learn about all the factors which affect CFB and pulverized coal boiler power plants efficiency and emissions
Areas in CFB and Pulverized Coal Power Plants where Efficiency Loss Can Occur: Discover all the areas in CFB and pulverized coal power plants where efficiency loss can occur

Optimize the Operation of CFB and Pulverized Coal Power Plant Equipment and Systems to Improve the Plant Heat Rate: Understand all the techniques and methods used to optimize the operation of CFB and pulverized coal power plant equipment and systems to improve the plant heat rate

CFB and Pulverized Coal Power Plant Equipment and Systems: Learn about various types of CFB and pulverized coal power plant equipment and systems including: boilers, superheaters, reheaters, steam turbines, governing systems, deaerators, feedwater heaters, coal-handling equipment, transformers, generators and auxiliaries

Special Feature
 
Each delegate will receive a digital copy of the following materials written by the instructor:
“POWER GENERATION HANDBOOK” second edition published by McGraw-Hill in 2012 (800 pages)

Excerpt of the relevant chapters from the “POWER PLANT EQUIPMENT OPERATION AND MAINTENANCE GUIDE” published by McGraw-Hill in 2012 (800 pages)
THERMAL POWER PLANT PERFORMANCE TESTING MANUAL (includes practical information about all the performance testing methods for all thermal power plant equipment - 300 pages)

Course Materials

Each participant will receive a complete set of course notes and handouts that will serve as informative references.

Toshiba Group Develops Inspection Technology for Plant Facilities and Equipment in High Inaccessible Places
- To provide safe and secure inspection solution by combining Group’s cyber and physical technologies.
October 29 2019
Toshiba Corporation
Toshiba Energy Systems & Solutions Corporation



3. Transportation and mechanical and manual handling activities in the process.


Materials Handling In Power Plants
MATERIAL HANDLINGTECHNOLOGY
On Nov 30, 2013

4. Delays occurring the in the process - Electricity may not be produced. Equipment may remain idles. Delays occur due to problems purchase planning, production quantity planning, manpower planning, maintenance planning etc.

5. All stores and items stored in the process. The incremental cost of stores has to be brought down. Stores procedures may lead to elongation of cycle times and delays.


Related Information

Increasing power plant productivity to cover the ever-rising demand for energy.
The world’s largest producers of power generation equipment build on Oerlikon advanced materials, functional coatings or process technologies to improve performance and cut the environmental impact of energy generation systems.

Recently, our products improved the wear resistance of steam turbine components by a factor of 25. (2021).

Oerlikon materials and coating technologies for hydropower turbine components reduce material erosion by a factor of up to 50 and increase the service life of components three to five times compared to uncoated components. (2021)


Productivity Science of Power Plants


FACTORS AFFECTING PRODUCTIVITY IN THE LARGE THERMAL POWER GENERATION STATIONS IN KENYA
Mungatana Mwaka
2007, MBA Thesis




Thermal Power Plant - Technical Note
http://www.slideshare.net/mastersheel007/thermal-power-plant-s

Manual on Best Practices for Thermal Plants in India
ftp://asiapacificpartnership.org/PowerGenTF/Power_Plant___All_pages.pdf
CII - USAid - ICICI Bank Report



Detailed Note on Cost Reduction Opportunities Power Systems
http://nraoiekc.blogspot.com/2013/11/cost-reduction-opportunities-in-power.html


International Comparison

Comparison of Power Plants Efficiency among 73 Countries, by Tser-Yieth Chen, Tsai-Lien Yeh, and Yi-Ting Lee, Journal of Energy
Volume 2013 (2013), Article ID 916413, 8 pages
http://www.hindawi.com/journals/jen/2013/916413/



Productivity in Generation

Productivity of Grid connected plants in Nicaragua
http://mpra.ub.uni-muenchen.de/49356/1/MPRA_paper_49356.pdf

Energy Conservation in 210 MW Thermal Plant
http://www.emt-india.net/Presentations2009/3L_2009Jan29-30_PowerPlant/Day1/2.%20NPC-%203L%20programme_%2029.%2001.%2009.pdf

Productivity in Distribution

Improving Efficiency in Transmission and Distribution System
Mallesh Gadeppanavar and , Vinay Pattanashetti
Electrical and Electronics Engineering department, Angadi institute of technology and management Belgaum-590008, India
International Journal of Emerging Technology and Advanced Engineering
Website: www.ijetae.com (ISSN 2250-2459, ISO 9001:2008 Certified Journal, Volume 3, Issue 3, March 2013)




Productivity of Boilers in Thermal Plants

An Investigation Of Productivity In Boilers Of Thermal Power Plants With Fuzzy Gain Scheduled PI Controller, January 2010
http://ijerad.kku.edu.tr/sayi_3/IJERAD1001_09.pdf





Optimization of Components and Products


Steam Turbine


Steam Turbine Optimization

Multiobjective optimization of a steam turbine stage

Increasing Steam Turbine Power Generation Efficiency

Design and Materials for Modern Steam Turbine up to 700 MW

Transformers
Transformer design optimization
Modern Transformer Design


Motors


5 Factors That Mess Up Motor Efficiency and How To Improve It
http://electrical-engineering-portal.com/5-factors-that-mess-up-motor-efficiency-and-how-to-improve-it


Generators

Auxiliary Systems of Power Plants
Energy Efficient Design of Auxiliary Systems in Fossil-Fuel Power Plants - ABB Energy Efficiency Handbook
http://www05.abb.com/global/scot/scot221.nsf/veritydisplay/5e627b842a63d389c1257b2f002c7e77/$file/Energy%20Efficiency%20for%20Power%20Plant%20Auxiliaries-V2_0.pdf


Optimization of Systems

Distribution system


Productivity of Human Factor
Line men
Safety and Health of Employees


Product Industrial Engineering

PDF Available
Value Analysis Method, Leverage for Cost Reduction and Technological Change in the Electrical Engineering Field
December 2013, Universal Journal of Industrial and Business Management 1(4):162-170
DOI:10.13189/ujibm.2013.010404
LicenseCC BY 4.0
Authors:
Cristina Mihaela Gheorghe
Universitatea Națională de Știință și Tehnologie Politehnica București
Mircea Covrig, Mihai Virgil Popescu
1. Faculty of Electrical Engineering, University Politehnica of Bucharest, 313 Splaiul Independentei, Bucharest, 060042, Romania 2. Electrical Machine Works Bucharest, Romania 
*Corresponding Author: cristina.gheorghe  at the rate upb.ro 




Value Engineering for Electrical Construction
POSTED 10-15-23

Carpenter Electrification
Complete Guide to Electric Motor Optimization: From Design to Testing
February 21, 2025 


© January 2020 IJSDR | Volume 5, Issue 1 

Implementation of Value Engineering and Zero Defect Principle in Manufacturing of Go-Kart 

Samarth Gurudatt Gaikwad1, Chaitanya Milind Parchure2, Apurva Vinay Patil3, Akshay Chandrakant Vibhute4 

1,2B. E Student, Department of Mechanical Engineering, DKTE Society's Textile & Engineering Institute Ichalkaranji, Maharashtra, India. 
3,4B.E Student, KIT College Of Engineering Kolhapur, Maharashtra, India. 



Value Engineering service from Patronics Services - Electrical Engineering Excellence
The Oval, Wing A, 5th Floor Jalaram Road
/ Ring Road Parklands, Nairobi, Kenya
P.O Box 18245 – 00500



Advances in electric motors: a review and benchmarking of product design and manufacturing technologies
Open access
Published: 15 July 2025
Volume 142, pages 312–345, (2025)
https://link.springer.com/article/10.1007/s00502-025-01331-3


Open Access Articles on Electric Motors


Course

Industrial Engineering - Electrical Engineering.

What can you expect in this profession?
Bachelor of Engineering in industrial engineering (focus on electrical engineering) are particularly qualified for activities in the increasingly important operational interfaces between the economic and technical areas, as they have a broad knowledge of both disciplines. 
 Therefore, you can be employed in a wide range of areas, preferably in departments where technical and business topics meet, such as in purchasing or sales, where you analyze technical issues from an economic point of view or sell complex technical products.

Which fields of activity are relevant for you?
Project Management national and International
Strategic Procurement
Production Control.


Posted by at 3 comments:
Labels: ,

Friday, March 6, 2026

Jidoka - Automation and Mechanization - Process Engineering, Facilities and Industrial Engineering in Toyota Production System

Industrial engineering has two important components - Machine Effort Industrial Engineering and Human Effort Industrial Engineering. 

Jidoka - Human Effort Engineering and Industrial Engineering in Toyota Production System  

Jidoka refers to Process Design and Process Improvement in Toyota Production System. It also includes operator work design and training. Jidoka is development of full process involving machines and operators.

"The deeper meaning of Jidoka is improving production process and machines so they can always do work that adds value instead of just spinning their gears. Ohno’s choice of spelling for Jidōka (See image below) emphasizes that if we remove non-value added work and improve value-added work the defects will ultimately be eliminated." - Jun Nakamuro, Fully Endorsed Expert for Organizational Transformation Based on the Ohno Method and TPS

Re-Translating Lean from Its Origin, January 5, 2017

"The concept of jidoka originated in the early 1900s when Sakichi Toyoda, founder of the Toyota Group, invented a textile loom that stopped automatically when any thread broke. Previously, if a thread broke the loom would churn out mounds of defective fabric, so each machine needed to be watched by an operator. Toyoda’s innovation let one operator control many machines. In Japanese, jidoka is a Toyota-created word pronounced exactly the same (and written in kanji almost the same) as the Japanese word for automation, but with the added connotations of humanistic and creating value."

https://www.lean.org/lexicon-terms/jidoka/

自動化



The word below in the picture is used in Toyota for Jidoka. It indicates machines with human touch or intelligence. It is automatic machines with human touch. It can be interpreted as a system having machines and people with appropriate roles that provides quality and productivity (lack of waste of resources).

Mr. Michel Baudin described some aspects of machine effort engineering and machine  effort industrial engineering in Toyota Production System in his "Working with Machines: The Nuts and Bolts of Lean Operations with Jidoka." Baudin also discussed human effort engineering and industrial engineering in the book.


A Toyota Leader on Misunderstandings About the Toyota Production System

It's a talk given by Nampachi Hayashi at the “Building on Success 2018 Conference.”

Mr. Hayashi says the name “should have been TPS = Toyota Process Development System.”

Jidoka = Toyota Process Development System.

Built-in quality and improved flow leading to lower cost… as a result. Cost reduction isn't the primary lever that's pulled (as we see attempted in so many Western companies)… it's a result. Simple cost-cutting might not lead to better quality and flow (it's often quite the opposite that happens). But better flow and better quality always leads to lower cost, in my experience. Productivity is also a forward activity. It focuses on fully utilizing the machine and man to do a job with less resources. This it results in lower cost.



Autonomation describes a feature of machine design to effect the principle of jidoka (自働化)（じどうか jidouka), used in the Toyota Production System (TPS) .

Etymology
The word "autonomation" 自働化, a loan word from the Sino-Japanese vocabulary, is a portmanteau of "autonomous" and "automation" 自動化, which is written using three kanji characters: 自（じ ji） "self", 動（どう dou）movement, and 化（か ka）"-ization". In the Toyota Production System, the second character is replaced with 働（どう dou） "work", which is a character derived by adding a radical representing "human" to the original 動.


Two Pillars of TPS - Jidoka and JIT

Jidoka - Process designs (Process engineering, Process Planning and Process Industrial Engineering) that eliminate waste

https://global.toyota/en/company/vision-and-philosophy/production-system/

JIT - Material procurement and flow system that eliminates waste.


Jidoka is based on engineering - Product engineering, process engineering, facilities engineering. product industrial engineering, process industrial engineering, facilities industrial engineering,  human effort industrial engineering.


Toyota Production System - Vision & Philosophy (From Company's Website)


Toyota Production System is a production system based on the philosophy of achieving the complete elimination of all waste in pursuit of the most efficient methods.

This production control system was established  with the objective of making the vehicles ordered by customers in the quickest and most efficient way, in order to deliver the vehicles as swiftly as possible. The Toyota Production System (TPS) was established based on two concepts: "jidoka" (which can be loosely translated as "automation with a human touch"),  and the "Just-in-Time" concept, in which each process produces only what is needed for the next process in a continuous flow.

Based on the basic philosophies of jidoka and Just-in-Time, TPS can efficiently and quickly produce vehicles of sound quality, one at a time, that fully satisfy customer requirements.

TPS and its approach to cost reduction are the wellsprings of competitive strength and unique advantages for Toyota. 


The TPS concept

For Toyota, jidoka means that  machines come to a safe stop whenever an abnormality occurs.  

To develop such intelligent machines and processes incorporating these machines, engineers meticulously build each new line component to exacting standards and further improve them  through incremental kaizen (industrial engineering - continuous improvement). Engineers simplify the operations. They create instruction sheets so that the skills of engineers are transferred to operators. The process instruction sheet and the training associated with it enables any operator to use the line to produce the same result.

Once the line is producing the required quality production, the jidoka mechanism is incorporated into actual production lines. Through the engineering repetition of this process by engineers, machinery becomes simpler and less expensive, while maintenance becomes less time consuming and less costly, enabling the creation of simple, slim, flexible lines that are adaptable to fluctuations in production volume.

The work done by engineers by their own hands in this process is the bedrock of engineering skill. Machines and robots do not think for themselves or evolve on their own. Rather, they evolve as we transfer our skills and craftsmanship to them. In other words, craftsmanship is achieved by learning the basic principles of manufacturing through actual work, then applying them on the factory floor to steadily make improvements. This cycle of improvement in both human skills and technologies is the essence of Toyota's jidoka. Advancing jidoka in this way helps to increase machine capabilities and human resource capabilities.

Human wisdom and ingenuity are indispensable to delivering ever-better cars to customers. Going forward, we will maintain our steadfast dedication to constantly developing human resources who can think independently and implement kaizen.


Just-in-Time

―Improving productivity―

Making only "what is needed, when it is needed, and in the amount needed"

Producing quality products efficiently through the complete elimination of waste, inconsistencies, and unreasonable requirements on the production line (known respectively in Japanese as muda, mura, muri).

In order to fulfill an order from a customer as quickly as possible, the vehicle is efficiently built within the shortest possible period of time by adhering to the following:

When a vehicle order is received, production instructions must be issued to the beginning of the vehicle production line as soon as possible.

The assembly line must be stocked with the required number of all necessary parts so that any kind of ordered vehicle can be assembled.

The assembly line must replace the parts used by retrieving the same number of parts from the parts-producing process (the preceding process).

The preceding process must be stocked with small numbers of all types of parts and produce only the numbers of parts that were retrieved by an operator from the next process.


"Sakichi Toyoda worked with the problem and resolved it. Now the machine no longer has to stop. Hence, it is the ultimate form of jidoka: Make a machine that can run without stops!"   Christoph Roger in   https://www.allaboutlean.com/jidoka-3/

My comment on Rogers' post in Linkedin

Jidoka is to be interpreted as better and better machines and processes. It is better and better engineering. The interpretation of lean theory has distorted the meaning. Its interpretation has to better and better combination of machines and people (process).

Jidoka - Excellent Machines - Excellent Operators - Process Engineering and Industrial Engineering in Toyota Production System

https://nraoiekc.blogspot.com/2021/04/jidoka-automation-and-mechanization.html


How to implement Jidoka in Lean Manufacturing ? Autonomation

Knowledge Factory-Lean Six Sigma
"Jidoka, also known as automation with a human touch, comes from the Japanese word for 'autonomation'. It's about creating a system where machines, not humans, identify and resolve errors."


Shigeo Shingo on  Toyota Production System Industrial Engineering

Shigeo Shingo - Toyota Production System Industrial Engineering (TPS IE) Part 1

https://nraoiekc.blogspot.com/2014/02/industrial-engineering-foundation-of.html


Shigeo Shingo - Toyota Production System Industrial Engineering (TPS IE) Part 2

http://nraoiekc.blogspot.com/2013/12/toyota-production-system-industrial.html


Shigeo Shingo - Introducing and Implementing the Toyota Production System Industrial Engineering - Part 3

http://nraoiekc.blogspot.com/2013/12/introducing-and-implementing-toyota.html


Michel Baudin - "Working with Machines: The Nuts and Bolts of Lean Operations with Jidoka."

Steps of Automation for Machining


1. Introduction of power feed.

2. Automatic stop and return to start position at the end of a cut

3. Automatic unloading of the workpiece

4. Automatic loading of the workpiece

5. Automatic error diagnosis

6. Automatic transportation between operations


Chapter 12: The Lean Approach to Automation


Toyota uses machines and automation at all appropriate places. In this if follows the principle advocated by Barnes. For each step in a process/operation, the best of automation, mechanization or manual work is to be used.


Jidoka is machine - people (machine-man) system. Toyota added man to classical machine symbol and created the symbol for Toyota's Jidoka (Baudin).


Mechanization designates the replacement of human or animal muscle with machines to perform work.

After mechanization of many activities, automation was started by engineers. In automation, machines are told through mechanical means, electrical means, hydraulic means, electronic means or through computer instructions when to start and when to stop and what to do.

Automation reduces amount of human intervention in working of machines. Any change that results in fewer or shorter operator intervention in work of the machines is automation.


Seven Steps in Automating Machining Operations

In early days Toyota engineers had a list of tasks to be done in automating machining. Now all their machines are automated to a very large extent. But engineers of companies that are in the process of automating can learn from the Toyota's automation steps list.


1. Adding a power drive:  As we know, most of the machines now provide power to the work piece in case of lathe and to the rotary tool in case of milling machines.

2. Adding power feed: In case of lathe, tool feed is done through power. Still an operator is required to stop the cut.

3. Automatic stopping of the cut:  If the machine can stop the cut automatically as specified, the operator can start the cut and go and attend another machine. If the tool can come to the starting position after completing a cut, it will save some more time of the operator.

4. Automatic unloading: If the operation is completed, the machine can eject the completed part.

5. Automatic loading: If the machine can eject the completed part and pick and load the new blank, it is the next level of automation. The operator's role and required time further gets reduced.

6. Automatic problem detection: If the machine can detect problems in its functioning through sensors, operator is further relieved of some monitoring functions. If a problem is detected, machine will stop and announce the situation through alarms. Operator can come and take care of the problem.

7.Automatic transportation: In this automation step, the completed part of a machining operation is moved to the next machine automatically.


What Baudin emphasizes is that automation is done in steps so that labor productivity increase takes and operators do not lose the jobs all of a sudden. The system's output expands to provide work to all operators and share the productivity benefit. The automation exercise is carried out taking into consideration the stability of the employment.


Principles Underlying Automation in TPS


1. Productivity improvement must not lead to layoffs.

In USA, large automation projects are implemented, layoffs are implemented. Not so in Toyota.

2. Capability of in-house development

Toyota develops capability to do custom development of machines it buys from standard outside vendors.

3. Decentralized control

Two machines can communicate and manage work in between them. Centralized control is not needed for local events.

4. Automation levels and skill management

As automation proceeds step by step on various operators also upgrade themselves step by step. 


Chapter 13 Improving Legacy Automated Systems


In the chapter Baudin discussed the utility of automated production systems or facilities available like transferlines, FMS, rotary index machines and stacked conveyor loops in lean manufacturing systems.


Transfer lines


Transfer lines are arranged in a straight line for convenience of automatic material handling. The manufactured part moves in a fixed sequence through all the machines to become the machined part.

Transfer line is similar to automated machining cell for a group of a parts.

The machines in the transfer line are being replaced by high speed machining centers with pallet exchangers that can machine various features in a single piece production. 


Toyota Engineers


Kiyohide Motiki - Casting Engineer - https://toyotatimes.jp/en/feature/028.html


 GR Company GRZ Chief Engineer Yasunori Suezawa, who had served as Chief Engineer for the Yaris (Toyota Car Model) -  https://toyotatimes.jp/en/chief_editor/065.html


Jidoka - Kiyoshi Suzaki

In the Process of the Challenge, and the Use of the Jidoka Concept

Kiyoshi Suzaki in Target, Spring 1988, pp. 4-9.


What is the target?

Is it to produce required products, at the required time, in the quantity required with highest quality at lowest cost? 

Is it a challenge to continuous improvement? 

Or is it simply the elimination of waste?



Jidoka is to manufacturing what disciplined exercise is to the nervous and muscle systems of our body. As we increase our athletic skills through training, our body eventually responds to necessary changes much more quickly and accurately than before. There is a similar need to train ourselves in manufacturing to compete and survive. But how we can effectively practice this Jidoka concept is clearly the challenge.


.In order to make changes effectively by incorporating people with the Jidoka concept, there are a few points worth summarizing:

1. Persons in charge of operations (operators) should satisfy their customer's needs (that is, the next process) in cost, quality, and delivery according to the prescribed standards. Naturally, this practice of following the standard procedure requires discipline.

2. Supervisors) should  solve problems exposed from the procedures currently in place. Without standards, we can see no abnormality. If standards are not practiced by subordinates, the supervisor is not fulfilling his role.

3. Production managers  should have an even broader knowledge, balanced perspective, a higher level of commitment to achieve goals, and the ability to lead the organization toward such goals. This person should be able to develop or introduce new standards on Jidoka mechanisms (Process and process improvement) into the organization and make sure each procedure, standard, and mechanism is well maintained.

Jidoka - More Online Resources

What Exactly Is Jidoka?

July 17, 2018 by Christoph Roser

https://www.allaboutlean.com/jidoka-1/


https://mag.toyota.co.uk/jidoka-toyota-production-system/

https://www.apo-tokyo.org/resources/p_glossary/jidoka-2/

https://leanmanufacturing.online/jidoka/

https://in.kaizen.com/blog/post/2016/10/12/jidoka-the-forgotten-pillar.html

Ohno's goals for Jidoka

http://www.process-improvement-japan.com/toyota-history.html

https://papers.ssrn.com/sol3/papers.cfm?abstract_id=3738342  41 page book

https://www.sciencedirect.com/science/article/pii/S2405896319312844  Article in science direct.

Rethinking Jidoka Systems under Automation & Learning Perspectives in the Digital Lean Manufacturing World

DavidRomero1 PaoloGaiardelli2 DarylPowell3 ThorstenWuest4 MatthiasThürer5

IFAC-PapersOnLine, Volume 52, Issue 13, 2019, Pages 899-903


An Application of SMED and Jidoka in Lean Production

January 2019

DOI:10.1007/978-3-319-92267-6_45

In book: Proceedings of the International Symposium for Production Research 2018 (pp.530-545)

Authors:

Mahmut Tekin et al.

https://www.researchgate.net/publication/327041611_An_Application_of_SMED_and_Jidoka_in_Lean_Production

Jidoka means “Intelligent people and machines." 
Masters Thesis

https://michelbaudin.com/tag/jidoka/


Recent References - Jidoka


Ansari et al., 2018a

F. Ansari, S. Erol, W. Sihn

"Rethinking Human-Machine Learning in Industry 4.0: How Does the Paradigm Shift Treat the Role of Human Learning?"

Procedia Manufacturing: 8th Conference on Learning Factories - Advanced Engineering Education & Training for Manufacturing Innovation, 23 (2018), pp. 117-122


Ansari et al., 2018b

F. Ansari, M. Khobreh, U. Seidenberg, W. Sihn

"A Problem-Solving Ontology for Human-Centered Cyber Physical Production Systems"

CIRP Journal of Manufacturing Science and Technology, 22 (2018), pp. 91-106


Bainbridge, 1983

L. Bainbridge

"Ironies of Automation"

Automatica, 19 (6) (1983), pp. 775-779


Baxter et al., 2012

Baxter, G.; Rooksby, J.; Wang, Y. and Khajeh-Hosseini, A. (2012). "The Ironies of Automation… Still Going Strong at 30?", 30th European Conference on Cognitive Ergonomics, pp. 65-71.


Billings, 1996

C.E. Billings

"Aviation Automation: The Search for a Human-Centered Approach", CRC Press (1996)


Bao et al., 2018

Z. Bao, Y. Wang, Z. Yang, C. Zhu, C. Jin

"Design on the Virtual Maintenance Training System of Some-Type Equipment Based on the Virtual Reality"

International Conference on Man-Machine-Environment System Engineering, Lecture Notes in Electrical Engineering, 527 (2018), pp. 479-487


Camarinha-Matos and Afsarmanesh, 1995

L.M. Camarinha-Matos, H. Afsarmanesh

"Introduction: Towards Balanced Automation", Balanced Automation Systems: Architectures and Methods, Springer (1995), pp. xi-xii


Camarinha-Matos and Afsarmanesh, 1996

L.M. Camarinha-Matos, H. Afsarmanesh

"Introduction: Implementation Challenges for Balanced Automation", Balanced Automation Systems II: Implementation Challenges for Anthropocentric Manufacturing, Springer (1996), pp. xiii-xiv


Camarinha-Matos et al., 1997

L.M. Camarinha-Matos, R. Rabelo, L. Osório

"Balanced Automation", in Management and Control of Manufacturing Systems, S.G. Tzafestas (Ed.), Springer-Verlag (1997), pp. 376-413


Chen et al., 2010

H. Chen, R.R. Lindeke, D.A. Wyrick

"Lean Automated Manufacturing: Avoiding the Pitfalls to Embrace the Opportunities"

Assembly Automation, 30 (2) (2010), pp. 117-123




Hold et al., 2017

P. Hold, S. Erol, G. Reisinger, W. Sihn

"Planning and Evaluation of Digital Assistance Systems"

Procedia Manufacturing: 7th Conference of Learning Factories, 9 (2017), pp. 143-150


Jackson et al., 2011

M. Jackson, M. Hedelind, E. Hellstrӧm, A. Granlund, N. Friedler

"Lean Automation: Requirements and Solutions for Efficient Use of Robot Automation in the Swedish Manufacturing Industry"

International Journal of Engineering Research and Innovation, 3 (2) (2011), pp. 36-43


Kelleher et al., 2015

J.D. Kelleher, B. Mac Namee, A. D’Arcy

"Fundamentals of Machine Learning for Predictive Data Analytics: Algorithms, Worked Examples, and Case Studies", MIT Press (2015), pp. 1-3

17, 117, 179, 247, 323.


Lenz et al., 2018

J. Lenz, T. Wuest, E. Westkaemper

"Holistic Approach to Machine Tool Data Analytics"

Journal of Manufacturing Systems, 48 (2018), pp. 180-191

DOI: 10.1016/j.jmsy.2018.03.003.




Mora et al., 2017

E. Mora, P. Gaiardelli, B. Resta, D. Powell

"Exploiting Lean Benefits Through Smart Manufacturing: A Comprehensive Perspective", The Path to Intelligent, Collaborative and Sustainable Manufacturing, Lödding, H. et al. (Eds.), IFIP, APMS, AICT 513, Part I, Springer (2017), pp. 127-134







Romero et al., 2016a

D. Romero, P. Bernus, O. Noran, J. Stahre, Å. Fast-Berglund

"The Operator 4.0: Human Cyber-Physical Systems & Adaptive Automation towards Human-Automation Symbiosis Work Systems", Production Management Initiatives for a Sustainable World, Nääs, I. et al. (Eds.), IFIP, AICT 488, Springer (2016), pp. 677-686


Romero et al., 2016

Romero, D.; Stahre, J.; Wuest, T.; Noran, O.; Bernus, P.; Fast-Berglund, Å. and Gorecky, D. (2016b). "Towards an Operator 4.0 Typology: A Human-Centric Perspective on the Fourth Industrial Revolution Technologies", International Conference on Computers & Industrial Engineering, Tianjin, China, pp. 1-11.


Romero et al., 2018

D. Romero, P. Gaiardelli, D. Powell, T. Wuest, M. Thürer

"Digital Lean Cyber-Physical Production Systems: The Emergence of Digital Lean Manufacturing and the Significance of Digital Waste"

Part I, IFIP AICT, 535 (2018), pp. 11-20




Sheridan and Parasuraman, 2015

T.B. Sheridan, R. Parasuraman

"Human-Automation Interaction"

Reviews of Human Factors and Ergonomics, 1 (89) (2015), pp. 89-129

Google Scholar

Sezer et al., 2018

Sezer, E.; Romero, D. Guedea, F.; Macchi, M. and Emmanouilidis, C. (2018)."An Industry 4.0-enabled Low Cost Predictive Maintenance Approach for SMEs:AUse Case Appliedto aCNC Turning Centre", 24th International ICE-Conference on Engineering, Technology and Innovation, pp. 1-8, DOI: 10.1109/ICE.2018.8436307.


Strauch, 2017

B. Strauch

"Ironies of Automation: Still Unresolved After All These Years"

IEEE Transactions on Human-Machine Systems, 48 (5) (2017), pp. 419-433




Webel et al., 2013

S. Webel, U. Bockholt, T. Engelke, N. Gavish, M. Olbrich, C. Preusche

"An Augmented Reality Training Platform for Assembly and Maintenance Skills"

Robotics and Autonomous Systems, 61 (4) (2013), pp. 398-403



Systematic combination of Lean Management with digitalization to improve production systems on the example of Jidoka 4.0

Jochen Deuse, Uwe Dombrowski, Fabian Nöhring, ...

International Journal of Engineering Business Management

First Published August 25, 2020 Research Article

https://doi.org/10.1177/1847979020951351

https://journals.sagepub.com/doi/full/10.1177/1847979020951351   - Open Access


Meanings   自働化 - Jidoka or Jidouka - Japanese - English


jidoka (自働化)（じどうか jidouka),


Entry Details for 自働化


Definition and Synonyms for 自働化

1. 自動化 高度な技術を用いた手段

Automation the act of implementing the control of equipment with advanced technology

Synonyms: 機械化, 自動化

2. 自動化 自動にする、制御するまたは自動に作動する

Automate make automatic or control or operate automatically

Synonyms: 自動化

3. 自動化 自動制御または操作を達成させるのに使用される装置

Automation equipment used to achieve automatic control or operation

Synonyms: 自動化

4. 自動化 自動的に操作または制御される状態

Automation the condition of being automatically operated or controlled

Synonyms: 自動化

5. 自動化 通常電子ハードウェアを含むこと

Automation usually involving electronic hardware

Synonyms: 機械化, 自動化

https://www.tanoshiijapanese.com/dictionary/entry_details.cfm?entry_id=30456&element_id=41599

kikai (Japanese)

Romanization

kikai

Romaji transcription of きかい


This is the meaning of きかい:


きかい (Japanese)

Noun

きかい

機会: opportunity

機械, 器械: machine

奇怪: strange, mysterious

棋界: the shogi world


https://www.wordsense.eu/kikai/


自動化, 自働化, じどうか

jidōka


Definition:  automation


Related Kanji

自

oneself

動

move, motion, change, confusion, shift, shake

化

change, take the form of, influence, enchant, delude, -ization

働

work, (kokuji)

https://nihongomaster.com/japanese/dictionary/word/30387/jidouka


自働化


Meaning of 自働化 in Japanese

It seems that your search contains the follows:

自  働化


Definition of 自働化

じどうかjidouka  【 自動化 ·自働化 】自動化働 Kanji Details

(n, vs) automation

http://www.romajidesu.com/dictionary/meaning-of-%E8%87%AA%E5%83%8D%E5%8C%96.html



Automation of Operations in Flow Process Chart









MACHINE EFFORT INDUSTRIAL ENGINEERING - Neglected Component of Industrial Engineering of F.W. Taylor.

"Through this lowering of the selling price the whole public, the buyer and user, of the joint product of the labor and machinery have profited by getting what they buy cheaper." - Taylor in Testimony.

Note products of industrial establishments are the joint product of the labor and machinery.

Celebrate the birthday of F.W. Taylor in your Industrial Engineering Department and Company. Share what you are implementing in your company from Taylor's Ideas.


Birthday of F.W. Taylor 20th March. Modern Industrial Engineering March  2026 Issue - Taylor Month of IE - Contribution of F.W. Taylor to Industrial Engineering and Productivity Management - Implemented and Neglected
Access Essays on F.W. Taylor's Writing - Belt Drive Design, Productivity System and Section, Shop Management, Productivity Science of Machining, and Scientific Management



Updated on 14.1.2025, 10.8.2023,  7.10.2021, 20 May 2021,  3 May 2021

Published on 24 April 2021







Posted by at 7 comments:
Labels: , , ,
Subscribe to: Posts (Atom)