Friday, August 24, 2018

F.W. Taylor - Shop Management - Essays with Links

Halsey Plan - F.W. Taylor's Comments
http://nraoiekc.blogspot.com/2013/08/halsey-plan-fw-taylors-comments.html



Shop Management - Themes

1. Definition of Management 

2. Difference in Production Quantity between a first class man and an average man

3. Developing and Employing First Class People in an Organization

4. Confronting Soldiering - Slow Pace of Work

5. Halsey Plan - F.W. Taylor's Comments

6. Task Management

7. Investment for Increasing Productivity or Efficiency

8. Importance of people - organization

9. Modern Engineering and Modern Shop Management

10. Task Management - Starting and Ending Times

11. Task Work - Some More Thoughts

12. Usefulness of Gantt's system

13. Time Study by F.W. Taylor

14. Bicylcle Ball Inspection Case Study

15. Need for Functional Foremanship or Functional Organisation of Foremen

16. Functional Foremanship

17. Production Planning and Control

18. Role of Top Management in Managing Change to High Productive Shop

19. Train Operators in High Productivity One by One and Then in Small Batches

20. Organizing a Small Workshop for High Productivity

21. Introducing Functional Foremanship

22. Personal Relations Between Employers and Employed

23. Don't be in a hurry - It Takes Time to Manage Change

24. Best Practices in Shop Management



Intereresting to note

New Shop Floor Management - by Kiyoshi Suzaki
https://books.google.co.in/books?id=WM1b8NXzYZ4C&printsec=frontcover#v=onepage&q&f=false


Updated 24 August 2018
29 March 2016

Thursday, August 23, 2018

Cost Reduction - Indian Companies


ET 500 List

https://economictimes.indiatimes.com/marketstats/pageno-1,pid-58,sortby-CurrentYearRank,sortorder-asc,year-2017.cms


We have a good visibility on cost reduction in FY18: Girish Wagh, Tata Motors
We are  doing value engineering (reducing the cost of a part without reducing the value to the customer) and value analysis (increase value delivered at the same cost).
9 November, 2017, Business Standard
https://www.tatamotors.com/media-press-coverage/we-have-a-good-visibility-on-cost-reduction-in-fy18-girish-wagh-tata-motors/

Sunday, August 19, 2018

Manufacturing Processes - Recent Introductory Textbook Topics


Manufacturing Processes



Individuals who will be involved in design and manufacturing of finished products need to understand the grand spectrum of manufacturing technology. Comprehensive and fundamental, Manufacturing Technology: Materials, Processes, and Equipment introduces and elaborates on the field of manufacturing technology—its processes, materials, tooling, and equipment. The book emphasizes the fundamentals of processes, their capabilities, typical applications, advantages, and limitations. Thorough and insightful, it provides mathematical modeling and equations as needed to enhance the basic understanding of the material at hand.

Designed for upper-level undergraduates in mechanical, industrial, manufacturing, and materials engineering disciplines, this book covers complete manufacturing technology courses taught in engineering colleges and institutions worldwide. The book also addresses the needs of production and manufacturing engineers and technologists participating in related industries.

Manufacturing Technology: Materials, Processes, and Equipment
Helmi A. Youssef, Hassan A. El-Hofy, Mahmoud H. Ahmed

March 29, 2017 by CRC Press
Reference - 948 Pages
https://www.crcpress.com/Manufacturing-Technology-Materials-Processes-and-Equipment/Youssef-El-Hofy-Ahmed/p/book/9781138072138

Heat Treatment of Metals and Alloys
Introduction
Heat Treatment of Steels
Basic Heat Treatment Operations of Steels
Heat Treatment of Cast Iron
Heat Treatment of Nonferrous Alloys and Stainless Steels
(Precipitation Hardening)

Smelting of Metallic Materials
Introduction
Smelting of Ferrous Metals
Smelting and Extraction of Nonferrous Metals

Casting of Metallic Materials
Introduction and Classification
Historical Development of Casting
Expendable Mold Casting Processes
Permanent Mold Castings
Melting Furnaces
Cleaning and Finishing of Castings
Quality of Castings
Modeling of Casting

Fundamentals of Metal Forming
Introduction
Simple Stresses and Strains
Two- and Three-Dimensional Stresses and Strains
Yield Criteria
General Plastic Stress–Strain Relations (Theory of Plasticity)
Effect of Temperature on Plastic Deformation
Cold, Warm, and Hot Forming
Effect of Strain Rate on Plastic Deformation
Superplasticity
Effect of Friction and Lubrication in Metal Forming

Bulk Forming of Metallic Materials
Introduction
Classification of Forming Processes
Forging Processes
Rolling Processes
Extrusion
Rod, Wire, and Tube Drawing

Sheet Metal Forming Processes
Introduction and Classification
Shearing Processes
Bending Processes
Stretch Forming
Deep Drawing
Rubber Pad Forming (Flexible-Die Forming)
Hydroforming (Fluid-Forming Processes)
Spinning
Superplastic Forming of Sheets
Blow Forming and Vacuum Forming
Thermoforming Methods
Sheet Metal Formability

High-Velocity Forming and High-Energy-Rate Forming
Introduction and Classification
Characteristics of HVF and HERF Processes
High-Velocity Forming Machines
High-Energy-Rate Forming Processes
Future of HVF and HERF

Powder Metallurgy and Processing of Ceramic Materials
Introduction
Historical Development of Powder Metallurgy
Metal Powder Production
Powder Metal Characterization
Blending and Mixing of Powders
Powder Compaction
Sintering
Secondary Operations
Ceramic Materials
Ceramic Manufacturing Processes

Polymeric Materials and Their Processing

Introduction
Historical Development of Polymeric Materials
Polymerization
Thermoplastic Polymers (Thermoplastics TP)
Thermosetting Polymers (Thermosets)
Elastomers.
Thermoplastic Elastomers
Processing of Polymeric Materials

Composite Materials and Their Fabrication Processes

Introduction
Classification and Characteristics of Composites
Fiber-Reinforced Composites
Particulate Composite Materials
Laminated Composite Materials
Combinations of Composite Materials
Fabrication of Composite Materials
Molding Processes
Prepreg Fabrication
Filament Winding
Pultrusion

Fundamentals of Traditional Machining Processes

Introduction
Basics of Chipping Processes
Basics of Abrasion Processes

Machine Tools for Traditional Machining

Introduction
General Purpose Machine Tools
Special Purpose Machine Tools

Fundamentals of Nontraditional Machining Process

Introduction
Classification of Nontraditional Machining Processes
Jet Machining
Ultrasonic Machining
Chemical Machining
Electrochemical Machining
Electrochemical Grinding
Electric Discharge Machining
Electron Beam Machining
Laser Beam Machining
Plasma Arc Cutting
Concluding Characteristics of NTMPS

Numerical Control of Machine Tools

Introduction
NC Concepts
Movements in CNC Systems
Control of NC Machine Tools
CNC Machine Tools
Input Units
CNC Instructions
Program Format
Features of CNC Systems
Part Programming

Industrial Robots and Hexapods

Introduction
Industrial Robots
Hexapods

Surface Technology

Introduction
Surface Smoothing
Surface Cleaning
Surface Protection
Roll Burnishing and Ballizing
Deburring

Joining Processes

Introduction
Fusion Welding
Solid-State Welding
Solid–Liquid State Welding
Welding of Plastics
Metallurgy of Welded Joints
Welding Defects
Welding Quality Control
Mechanical Joining

Advanced Manufacturing Techniques

Introduction
Near Net Shape Manufacturing
Microfabrication Technology
Nanotechnology
Semiconductor Device Fabrication
Sustainable and Green Manufacturing

Materials, Processes, and Design for Manufacturing

Introduction
Function, Material, Process, and Shape Interaction
Manufacturing Process Capabilities
Process Selection Factors
Manufacturing Process Selection
Design for Manufacturing

Quality Control

Introduction
Statistical Quality Control
Total Quality Control
The ISO 9000 Standard
Dimensional Control
Measuring Quality Characteristics
Measuring Tools and Equipment
Coordinate-Measuring Machine
Surface Measurements
Nondestructive Testing and Inspection
Destructive Testing

Automation in Manufacturing Technology

Introduction
Mechanization versus Automation
Automation and Production Quantity
Necessity for Introducing Automation
Manufacturing Systems
Flexible Manufacturing Systems
Computer Integrated Manufacturing.
Integrated Manufacturing Production System-Lean Production
Adaptive Control
Smart Manufacturing and Artificial Intelligence
Factory of Future
Concluding Remarks Related to Automated Manufacturing


2011 Edition
https://books.google.co.in/books/about/Manufacturing_Technology.html?id=KGbNBQAAQBAJ


https://books.google.co.in/books/about/Machining_Technology.html?id=IleBqfaGK1oC


Updated on 20 August 2018
21 March 2018

Sunday, August 12, 2018

Productivity Improvement Process - Role of Science, Engineering, Industrial Engineering and Management

R.M. Currie who developed work study out of Motion and Times Study, described six steps as lines of attack to improve productivity.

1. Improve basic processes by research and development.
2. Improve existing, and provide new plant and equipment
3. Simplify and improve the product and reduce the variety.
4. Improve existing methods of plant operation.
5. Improve the planning of work and the use of manpower.
6. Increase the effectiveness of all employees

Work study has application in lines 4,5 and 6.


The Development and Scope of Work Study
R. M. Currie, M.I.C.E., First Published June 1, 1954 Research Article
Proceedings of the Institution of Mechanical Engineers
http://journals.sagepub.com/doi/abs/10.1243/PIME_PROC_1954_168_063_02?journalCode=pmea

What would be the role of industrial engineers in the lines of attack indicated by Currie? That answer is not available at the moment with me. I have to search if any industrial engineer has answered such a question.



Detailed List of Activities in Productivity Improvement Process




In principle,  increasing productivity of various economic activities is a responsibility shared by many intellectual and professional disciplines.

In engineering activities, we can identify, scientists, engineers, industrial engineers and managers as principal categories of professionals that have responsibility for increasing productivity of engineering activities.

We can identify the following as activities or tasks that are to be carried out to improve productivity in engineering activities. No doubt, industrial engineers have taken up the specialist responsibility of improving productivity in engineering activities. They describe themselves, efficiency engineers, productivity engineers, productivity service providers and management service providers.

An attempt is made to create a detailed list of activities to bring into focus many subjects that have a role to play in productivity improvement and industrial engineering activities.


Research


1. Research to create knowledge that helps development of new materials, products, equipment and processes.
2. Research that creates knowledge that helps in making existing products and processes more productive. Industrial engineering researchers have an important role in this type of research.
3.Research in the area of management

Development


3. Development of new materials, products, equipment  and processes.
4. Development of productivity improvement devices, attachments, tools and features.
5. Development process modifications that improve productivity.

Design


Design is scaling up the developed solutions to fit the dimensions of application. Design involves form design and strength design. The form design is based on the developed solution. Strength design is based on stress analysis and strength of the material being used. Concurrent industrial engineering needs to be practiced in this stage.

6. Design of new products that are more productive
7. Design of equipment that is more productive
8. Design of new processes that are more productive
9. Design of production systems that are more productive.
10. Design of management procedures that are more productive.
11. Using optimization in design
12. Using samples in processes.
13. Engineering economic analysis
14. Design of payment systems and incentive systems
15. Design of communication systems
16. Design of data processing system

Redesign


17. Replacement decision
18. Productivity analysis and engineering of products
19. Productivity analysis and engineering of processes
20. Productivity analysis and enhancement of equipment
21. Productivity analysis and enhancement of tools and accessories

Operations - Day to Day working


Production planning - IEs to evaluate and improve planning procedures.
Project planning - IEs to evaluate and improve planning procedures.
Employee involvement in productivity improvement suggestions.
Productivity improvement workshops, events


Control of Staff Overhead



https://books.google.co.in/books?id=5yuuCwAAQBAJ&printsec=frontcover#v=onepage&q&f=false

Control of Staff-related Overhead

Arthur Brearley
Springer, 18-Jun-1976 - Business & Economics - 181 pages

Woodworking Tools



1. The claw Hammer
2. Tape measure
Utility knife
Moisture meter
Chisel
Level
Screwdriver
Nail set
Sliding bevel
Layout square

https://www.wagnermeters.com/moisture-meters/wood-info/top-40-woodworking-tools/

Written by Ron Smith

https://www.wagnermeters.com/top-40-woodworking-tools-2/