This document provides an introduction and overview of robotics, including definitions of key terms like robots, industrial robots, and humanoid robots. It discusses how factory automation uses robots to control manufacturing processes by regulating important motion parameters. The document also outlines some common tasks performed by industrial robots like welding, cutting, assembly, and material handling.
1. The document summarizes a study on value stream mapping conducted at an automotive manufacturing plant to improve production throughput.
2. Data was collected on current production processes, including cycle times and inventory levels. A current state value stream map was created showing significant waiting times between processes.
3. The analysis found opportunities to reduce waste by balancing processes, reducing set-up times, and standardizing work to improve flow and meet rising customer demand.
This document contains questions from past exams on the topic of production planning and control. It is divided into 5 units which cover introductory concepts, work study, production planning and process planning, production scheduling, and inventory control. The questions range from definitions and short explanations to longer discussions requiring analyses. The document serves as a study guide for students, with questions at different levels of difficulty in each unit to test comprehension of key production planning and control topics.
This document discusses methods engineering and method study. It describes method study as the systematic analysis and examination of work methods to develop more effective procedures. The key steps of method study include selecting processes to study, recording current methods, examining recordings for inefficiencies, developing improved methods, evaluating changes, defining new standards, installing changes, and maintaining improvements. A variety of charts and diagrams are used to record work including flow diagrams, string diagrams, process charts, and therblings analysis which divides tasks into elemental motions. The overall aim is to eliminate unnecessary steps and make processes more efficient.
Work study involves the systematic analysis of work processes with the goal of improving efficiency and reducing costs. It examines how work is done in order to find the best and most efficient use of resources like people, materials, equipment and time. The main techniques used in work study are method study and work measurement. Method study involves analyzing existing and proposed work methods to develop easier and more effective processes, while work measurement establishes the time required to complete a specified job using the improved method. Process charts, flow diagrams and other tools are used to record and analyze work methods as part of work study. The overall aim is to simplify work and set performance standards to increase productivity.
The document discusses production planning and control. It defines key terms like production, production planning and control, and their objectives. It describes the functions of production planning and control like materials, machines, methods, routing, estimating, loading and scheduling, dispatching, expediting, and inspection. It also discusses topics like standardization, work study, production types, and production scheduling techniques.
REDUCTION OF WASTAGES THROUGH PPC TECHNIQUESAsim Aslam
This document discusses production planning and control (PPC) techniques used to reduce wastage. It describes key functions of PPC like planning, routing, loading, scheduling, dispatching, and follow up. For each function, techniques are provided, such as PERT charts for routing, Gantt charts for scheduling, and control boards for follow up. The goal of using these PPC techniques is to efficiently coordinate production activities, monitor progress against plans, and eliminate bottlenecks in order to reduce wastage throughout the manufacturing process.
ISO/TS 16949:2002 is a technical specification that was prepared by the International Automotive Task Force (IATF) and the Japanese Automotive Manufacturers Association (JAMA) to define quality management system requirements for automotive production and relevant service part organizations. It has three main goals: continual improvement, defect prevention, and reducing variation and waste across the supply chain. Key terms covered in the document include APQP, FMEA, SPC, and process approach. The document provides guidance on conducting internal audits and preparing for external audits.
This 3D model was created as part of a concept study for an alternative materials handling conveyor for a mining project in Brazil. The model allows the client to visualize the proposed conveyor arrangement and facilitates discussions of factors like maintenance access, equipment interfaces, earthworks volumes, and conveyor profile. It was incorporated into an overall site model for a client presentation to demonstrate and evaluate the alternative configuration.
1. The document summarizes a study on value stream mapping conducted at an automotive manufacturing plant to improve production throughput.
2. Data was collected on current production processes, including cycle times and inventory levels. A current state value stream map was created showing significant waiting times between processes.
3. The analysis found opportunities to reduce waste by balancing processes, reducing set-up times, and standardizing work to improve flow and meet rising customer demand.
This document contains questions from past exams on the topic of production planning and control. It is divided into 5 units which cover introductory concepts, work study, production planning and process planning, production scheduling, and inventory control. The questions range from definitions and short explanations to longer discussions requiring analyses. The document serves as a study guide for students, with questions at different levels of difficulty in each unit to test comprehension of key production planning and control topics.
This document discusses methods engineering and method study. It describes method study as the systematic analysis and examination of work methods to develop more effective procedures. The key steps of method study include selecting processes to study, recording current methods, examining recordings for inefficiencies, developing improved methods, evaluating changes, defining new standards, installing changes, and maintaining improvements. A variety of charts and diagrams are used to record work including flow diagrams, string diagrams, process charts, and therblings analysis which divides tasks into elemental motions. The overall aim is to eliminate unnecessary steps and make processes more efficient.
Work study involves the systematic analysis of work processes with the goal of improving efficiency and reducing costs. It examines how work is done in order to find the best and most efficient use of resources like people, materials, equipment and time. The main techniques used in work study are method study and work measurement. Method study involves analyzing existing and proposed work methods to develop easier and more effective processes, while work measurement establishes the time required to complete a specified job using the improved method. Process charts, flow diagrams and other tools are used to record and analyze work methods as part of work study. The overall aim is to simplify work and set performance standards to increase productivity.
The document discusses production planning and control. It defines key terms like production, production planning and control, and their objectives. It describes the functions of production planning and control like materials, machines, methods, routing, estimating, loading and scheduling, dispatching, expediting, and inspection. It also discusses topics like standardization, work study, production types, and production scheduling techniques.
REDUCTION OF WASTAGES THROUGH PPC TECHNIQUESAsim Aslam
This document discusses production planning and control (PPC) techniques used to reduce wastage. It describes key functions of PPC like planning, routing, loading, scheduling, dispatching, and follow up. For each function, techniques are provided, such as PERT charts for routing, Gantt charts for scheduling, and control boards for follow up. The goal of using these PPC techniques is to efficiently coordinate production activities, monitor progress against plans, and eliminate bottlenecks in order to reduce wastage throughout the manufacturing process.
ISO/TS 16949:2002 is a technical specification that was prepared by the International Automotive Task Force (IATF) and the Japanese Automotive Manufacturers Association (JAMA) to define quality management system requirements for automotive production and relevant service part organizations. It has three main goals: continual improvement, defect prevention, and reducing variation and waste across the supply chain. Key terms covered in the document include APQP, FMEA, SPC, and process approach. The document provides guidance on conducting internal audits and preparing for external audits.
This 3D model was created as part of a concept study for an alternative materials handling conveyor for a mining project in Brazil. The model allows the client to visualize the proposed conveyor arrangement and facilitates discussions of factors like maintenance access, equipment interfaces, earthworks volumes, and conveyor profile. It was incorporated into an overall site model for a client presentation to demonstrate and evaluate the alternative configuration.
On Sept. 21, 2010, Mr. Jet Li and the International Federation of Red Cross and Red Crescent Societies (IFRC) formally announced that Jet Li has become a Goodwill Ambassador for the IFRC, marking the first time in history that the international humanitarian organization has granted such an appointment.
Mr. Li has always believed that humanity is one big family, and that we must all do our part to make this family better. In this spirit, he founded One Foundation in 2006. As a 21st century non-profit organization, One Foundation seeks to encourage social sector development and broad-based participation in philanthropy as a way of life. One Foundation has promoted a micro-philanthropy model, advocating “every 1 person + every 1 month + donates 1 dollar/yuan = 1 big family,” and has achieved meaningful recognition both in China and internationally.
Mr. Li also deeply respects the core principles and mission of the Red Cross Red Crescent Movement, especially its spirit of “Humanity, Universal Fraternity and Devotion.” In becoming a Goodwill Ambassador for the IFRC, Mr. Li builds upon his extensive relationship with the Red Cross Red Crescent Movement, having served as “Philanthropic Ambassador” for the Red Cross Society of China since 2006.
As Goodwill Ambassador, Mr. Li would like to share One Foundation’s experience and philanthropic model with the rest of the world. Each country’s Red Cross and Red Crescent societies are welcome to extract any useful lessons and adapt them to suit their particular culture, customs and needs. In sharing his ideas and experience, Mr. Li hopes to support the IFRC’s noble humanitarian goals, as well as strengthen international cooperation and caring as one global human family.
This document provides an overview of simple machines, including the lever, inclined plane, wedge, screw, wheel and axle, and pulley. It explains that machines help do work by changing the amount or direction of force applied to an object. Energy is required to do work, which is the result of a force moving an object. Gravity is also discussed as the constant force pulling objects toward Earth. Compound machines combine two or more simple machines to work together.
Dokumen tersebut membahas pentingnya partisipasi masyarakat dalam pemilu bagi kelancaran demokrasi. Pemilu merupakan sarana pelaksanaan kedaulatan rakyat untuk memilih pemimpin dan unsur penting dalam demokrasi. Namun, partisipasi masyarakat masih perlu ditingkatkan, antara lain melalui pendidikan politik oleh penyelenggara pemilu, partai politik, dan berbagai pihak untuk meningkatkan pemahaman tentang dem
This document contains the schedule for the 2010 FIFA World Cup held in South Africa. It lists the 64 matches played from the group stage, through the round of 16, quarterfinals, semifinals, third place playoff, and final. It provides details on the dates, times, locations and participating teams for each match. It also lists the final standings and winner of the 2010 World Cup which was Spain.
Safalaya - Edu-Social Network cum Personal Learning NetworkNirmalya Sikdar
Safalaya.com is an Edu-Social Network cum Personal Learning Network . It is used by teachers , students , educational institutes to share resources with each other . Teachers and students can create their own Personal Learning Network . URL : http://www.safalaya.com
Punta de Bombón ofrece recursos turísticos como playas y una planta turística para visitantes, resumiendo la información clave sobre el destino turístico.
Punta de Bombón ofrece recursos turísticos como playas y una planta turística para visitantes, resumiendo la información clave sobre el destino turístico.
This document discusses the history of empires from ancient times to the modern era. It covers how early empires like Alexander the Great's used concepts of civilization and unity to expand their rule. Later, European empires grew through controlling trade routes and advancing technology. The rise of nationalism in the 19th century challenged empires and led to their decline as smaller political units formed. The document also examines how access to key resources and crops in Eurasia gave those civilizations advantages that enabled imperial expansion.
Predavanje "Dirihleov princip" koje je održao Miloš Cvetković, doktorand na Departmanu za matematiku PMF-a u Nišu, 20. maja u Surdulici u okviru obeležavanja "Maja meseca matematike"
Punta de Bombón ofrece recursos turísticos como playas y una planta turística para visitantes, resumiendo la información clave sobre el destino turístico.
The document discusses a warehouse expansion project and provides information about its activities, including expected completion times, variances, and crashing options. It asks how to shorten the expected completion time to achieve an 80% chance of meeting a 40-week deadline. Calculating the necessary reduction using the normal distribution, the expected completion time would need to be shortened to 38 weeks. It also provides crashing costs and time reductions for each activity and asks to determine the optimal crashing decisions using linear programming to minimize total crashing costs.
This document presents a business plan for a fresh mushroom enterprise in Kuala Terengganu, Malaysia. The summary is:
1) The fresh mushroom enterprise aims to double its annual production from 7 million in 2008 to 14 million by 2010 by focusing on the growing mushroom market in Kuala Terengganu.
2) The enterprise will target the population in Kuala Terengganu, estimated at 1.1 million people in 2010, with a marketing strategy focused on restaurants, farmer's markets, and on-farm outlets.
3) In its first year of operations in 2011, the enterprise forecasts sales of RM942,432 and has allocated a marketing budget of RM3,
This document compares and contrasts different economic systems including capitalism, socialism, communism, and the Islamic economic system. It outlines key principles of each system such as private ownership, profit motive, and egalitarianism. It also discusses flaws like lack of moral limitations in capitalism and loss of individual incentive in socialism. The Islamic system focuses on distribution of wealth, guaranteeing basic needs, and prohibiting interest while encouraging investment. The document recommends positive economics to analyze actual behavior and normative economics to prescribe how behavior should be.
Islamic unit trust funds have become increasingly popular investments in Malaysia. They allow investors to invest in a diversified portfolio of Shariah-compliant securities while being professionally managed. The Malaysian government and Securities Commission regulate Islamic unit trusts and oversee fund managers and trustees to protect investors. Recent trends show investors increasingly choosing Islamic funds over conventional funds.
Application of Taguchi Parametric Technique for the Decrease in Productivity...IJMER
Now a day, working in industry is not as comfortable as in earlier times. The man power is
decreasing day by day and new recruitment is not in same ratio as the persons leaving industries. This is
turn increase the work load on employees which causes physical problems to employees and also
decreases the productivity of worker. The purpose is to determine the optimum combination of three
parameters like Worker weight, component weight and worker age for achieving minimum loss (in
percentage) in productivity of worker. In order to meet the purpose in terms of productivity study will
utilize Taguchi parameter optimization methodology. The study includes selection of parameters
utilizing an orthogonal array, conducting experimental runs, data analysis, determining the optimum
combination, verification finally the modeling of input parameters (worker weight, component weight
and worker age), for a particular job work, for particular machine to minimize fatigue of worker and
loss (in percentage) of productivity in industry.
Economic design of X chart for short run production Vaibhav Kadu
The document presents an economic design for an X control chart for short-run production processes. It develops a probabilistic model considering shifts in the process mean from an in-control state (State I) to an out-of-control state (State II). The optimal design parameters - sampling interval, control limits, and retrospective sample size - are determined to minimize the expected average cost per item produced using a direct search technique. The costs considered include those associated with nonconforming items, false alarms from out-of-control signals, and process adjustments. The proposed approach provides an economic monitoring strategy for quality control in short production runs where conventional control chart methods are not suitable.
IRJET - Productivity Improvement by Time Study and Motion StudyIRJET Journal
This document discusses improving productivity at a thermocole manufacturing plant through time study and motion study. It was found that delays between tasks were affecting production rates. Time study and motion study techniques from work study were used to analyze the processes. The analysis found a lack of proper time standards, uneven task distribution, inefficient space utilization, safety issues, and communication problems. After conducting time studies and setting proper time standards, production increased by 48 extra pieces per month on one machine. Implementing standards from time study and motion study analysis can effectively improve productivity by reducing delays in work processes.
Conducting Process Audits For Municipal GovernmentStephen Deas
This presentation details how to conduct a process audit of local and municipal governments. A process audit is a strong, proactive tool for improving process outputs. Many local governments are adopting a zero overhead growth strategy(ZOG) which is dependent on key continuous improvement tools. Process audting is a wonderful continuous improvement tool.
This document discusses production functions and concepts related to production analysis. It defines a production function as relating inputs like labor, capital, materials and machinery to outputs. It describes short-run and long-run production functions, as well as isoquants which show combinations of inputs producing the same output, and isocosts which represent input combinations costing the same amount. The Cobb-Douglas production function is presented. Concepts around returns to scale and factor productivity are also summarized.
TIME STUDY – A KEY TECHNIQUE FOR PRODUCTIVITY IMPROVEMENTIRJET Journal
This document discusses techniques to improve productivity at a motor manufacturing company through time study analysis. It finds that the assembly line's bottleneck operation is the routine testing process, which takes over 150 seconds. It is suggested to implement a new, faster testing machine that reduces this time to 90 seconds. It also proposes performing some assembly steps simultaneously, such as having one worker mount terminal boxes while another screws lug terminals, which could reduce the overall cycle time from 269 to 185 seconds and increase the production rate. Time study is presented as a key method for identifying opportunities to eliminate unnecessary tasks and activities to minimize human effort and maximize productivity.
On Sept. 21, 2010, Mr. Jet Li and the International Federation of Red Cross and Red Crescent Societies (IFRC) formally announced that Jet Li has become a Goodwill Ambassador for the IFRC, marking the first time in history that the international humanitarian organization has granted such an appointment.
Mr. Li has always believed that humanity is one big family, and that we must all do our part to make this family better. In this spirit, he founded One Foundation in 2006. As a 21st century non-profit organization, One Foundation seeks to encourage social sector development and broad-based participation in philanthropy as a way of life. One Foundation has promoted a micro-philanthropy model, advocating “every 1 person + every 1 month + donates 1 dollar/yuan = 1 big family,” and has achieved meaningful recognition both in China and internationally.
Mr. Li also deeply respects the core principles and mission of the Red Cross Red Crescent Movement, especially its spirit of “Humanity, Universal Fraternity and Devotion.” In becoming a Goodwill Ambassador for the IFRC, Mr. Li builds upon his extensive relationship with the Red Cross Red Crescent Movement, having served as “Philanthropic Ambassador” for the Red Cross Society of China since 2006.
As Goodwill Ambassador, Mr. Li would like to share One Foundation’s experience and philanthropic model with the rest of the world. Each country’s Red Cross and Red Crescent societies are welcome to extract any useful lessons and adapt them to suit their particular culture, customs and needs. In sharing his ideas and experience, Mr. Li hopes to support the IFRC’s noble humanitarian goals, as well as strengthen international cooperation and caring as one global human family.
This document provides an overview of simple machines, including the lever, inclined plane, wedge, screw, wheel and axle, and pulley. It explains that machines help do work by changing the amount or direction of force applied to an object. Energy is required to do work, which is the result of a force moving an object. Gravity is also discussed as the constant force pulling objects toward Earth. Compound machines combine two or more simple machines to work together.
Dokumen tersebut membahas pentingnya partisipasi masyarakat dalam pemilu bagi kelancaran demokrasi. Pemilu merupakan sarana pelaksanaan kedaulatan rakyat untuk memilih pemimpin dan unsur penting dalam demokrasi. Namun, partisipasi masyarakat masih perlu ditingkatkan, antara lain melalui pendidikan politik oleh penyelenggara pemilu, partai politik, dan berbagai pihak untuk meningkatkan pemahaman tentang dem
This document contains the schedule for the 2010 FIFA World Cup held in South Africa. It lists the 64 matches played from the group stage, through the round of 16, quarterfinals, semifinals, third place playoff, and final. It provides details on the dates, times, locations and participating teams for each match. It also lists the final standings and winner of the 2010 World Cup which was Spain.
Safalaya - Edu-Social Network cum Personal Learning NetworkNirmalya Sikdar
Safalaya.com is an Edu-Social Network cum Personal Learning Network . It is used by teachers , students , educational institutes to share resources with each other . Teachers and students can create their own Personal Learning Network . URL : http://www.safalaya.com
Punta de Bombón ofrece recursos turísticos como playas y una planta turística para visitantes, resumiendo la información clave sobre el destino turístico.
Punta de Bombón ofrece recursos turísticos como playas y una planta turística para visitantes, resumiendo la información clave sobre el destino turístico.
This document discusses the history of empires from ancient times to the modern era. It covers how early empires like Alexander the Great's used concepts of civilization and unity to expand their rule. Later, European empires grew through controlling trade routes and advancing technology. The rise of nationalism in the 19th century challenged empires and led to their decline as smaller political units formed. The document also examines how access to key resources and crops in Eurasia gave those civilizations advantages that enabled imperial expansion.
Predavanje "Dirihleov princip" koje je održao Miloš Cvetković, doktorand na Departmanu za matematiku PMF-a u Nišu, 20. maja u Surdulici u okviru obeležavanja "Maja meseca matematike"
Punta de Bombón ofrece recursos turísticos como playas y una planta turística para visitantes, resumiendo la información clave sobre el destino turístico.
The document discusses a warehouse expansion project and provides information about its activities, including expected completion times, variances, and crashing options. It asks how to shorten the expected completion time to achieve an 80% chance of meeting a 40-week deadline. Calculating the necessary reduction using the normal distribution, the expected completion time would need to be shortened to 38 weeks. It also provides crashing costs and time reductions for each activity and asks to determine the optimal crashing decisions using linear programming to minimize total crashing costs.
This document presents a business plan for a fresh mushroom enterprise in Kuala Terengganu, Malaysia. The summary is:
1) The fresh mushroom enterprise aims to double its annual production from 7 million in 2008 to 14 million by 2010 by focusing on the growing mushroom market in Kuala Terengganu.
2) The enterprise will target the population in Kuala Terengganu, estimated at 1.1 million people in 2010, with a marketing strategy focused on restaurants, farmer's markets, and on-farm outlets.
3) In its first year of operations in 2011, the enterprise forecasts sales of RM942,432 and has allocated a marketing budget of RM3,
This document compares and contrasts different economic systems including capitalism, socialism, communism, and the Islamic economic system. It outlines key principles of each system such as private ownership, profit motive, and egalitarianism. It also discusses flaws like lack of moral limitations in capitalism and loss of individual incentive in socialism. The Islamic system focuses on distribution of wealth, guaranteeing basic needs, and prohibiting interest while encouraging investment. The document recommends positive economics to analyze actual behavior and normative economics to prescribe how behavior should be.
Islamic unit trust funds have become increasingly popular investments in Malaysia. They allow investors to invest in a diversified portfolio of Shariah-compliant securities while being professionally managed. The Malaysian government and Securities Commission regulate Islamic unit trusts and oversee fund managers and trustees to protect investors. Recent trends show investors increasingly choosing Islamic funds over conventional funds.
Application of Taguchi Parametric Technique for the Decrease in Productivity...IJMER
Now a day, working in industry is not as comfortable as in earlier times. The man power is
decreasing day by day and new recruitment is not in same ratio as the persons leaving industries. This is
turn increase the work load on employees which causes physical problems to employees and also
decreases the productivity of worker. The purpose is to determine the optimum combination of three
parameters like Worker weight, component weight and worker age for achieving minimum loss (in
percentage) in productivity of worker. In order to meet the purpose in terms of productivity study will
utilize Taguchi parameter optimization methodology. The study includes selection of parameters
utilizing an orthogonal array, conducting experimental runs, data analysis, determining the optimum
combination, verification finally the modeling of input parameters (worker weight, component weight
and worker age), for a particular job work, for particular machine to minimize fatigue of worker and
loss (in percentage) of productivity in industry.
Economic design of X chart for short run production Vaibhav Kadu
The document presents an economic design for an X control chart for short-run production processes. It develops a probabilistic model considering shifts in the process mean from an in-control state (State I) to an out-of-control state (State II). The optimal design parameters - sampling interval, control limits, and retrospective sample size - are determined to minimize the expected average cost per item produced using a direct search technique. The costs considered include those associated with nonconforming items, false alarms from out-of-control signals, and process adjustments. The proposed approach provides an economic monitoring strategy for quality control in short production runs where conventional control chart methods are not suitable.
IRJET - Productivity Improvement by Time Study and Motion StudyIRJET Journal
This document discusses improving productivity at a thermocole manufacturing plant through time study and motion study. It was found that delays between tasks were affecting production rates. Time study and motion study techniques from work study were used to analyze the processes. The analysis found a lack of proper time standards, uneven task distribution, inefficient space utilization, safety issues, and communication problems. After conducting time studies and setting proper time standards, production increased by 48 extra pieces per month on one machine. Implementing standards from time study and motion study analysis can effectively improve productivity by reducing delays in work processes.
Conducting Process Audits For Municipal GovernmentStephen Deas
This presentation details how to conduct a process audit of local and municipal governments. A process audit is a strong, proactive tool for improving process outputs. Many local governments are adopting a zero overhead growth strategy(ZOG) which is dependent on key continuous improvement tools. Process audting is a wonderful continuous improvement tool.
This document discusses production functions and concepts related to production analysis. It defines a production function as relating inputs like labor, capital, materials and machinery to outputs. It describes short-run and long-run production functions, as well as isoquants which show combinations of inputs producing the same output, and isocosts which represent input combinations costing the same amount. The Cobb-Douglas production function is presented. Concepts around returns to scale and factor productivity are also summarized.
TIME STUDY – A KEY TECHNIQUE FOR PRODUCTIVITY IMPROVEMENTIRJET Journal
This document discusses techniques to improve productivity at a motor manufacturing company through time study analysis. It finds that the assembly line's bottleneck operation is the routine testing process, which takes over 150 seconds. It is suggested to implement a new, faster testing machine that reduces this time to 90 seconds. It also proposes performing some assembly steps simultaneously, such as having one worker mount terminal boxes while another screws lug terminals, which could reduce the overall cycle time from 269 to 185 seconds and increase the production rate. Time study is presented as a key method for identifying opportunities to eliminate unnecessary tasks and activities to minimize human effort and maximize productivity.
IRJET- A Case Study for Overall Equipment Effectiveness Improved in Manufactu...IRJET Journal
This document presents a case study on improving overall equipment effectiveness (OEE) in a manufacturing industry. It discusses how OEE is calculated based on availability, performance rate, and quality rate. The study was conducted at Avison Industry in Kolhapur, India. Data was collected on production rates and downtime reasons. It was found that the performance rate was below 95%, indicating room for improvement. Various problems were identified through analysis, such as hole shifting during drilling. Solutions proposed included modifying fixtures, combining drilling and reaming, and changing the production process flow. After implementing solutions, the OEE values improved to above 95%, meeting benchmarks for effective equipment performance.
Statistical Control Process - Class PresentationMillat Afridi
Statistical process control (SPC) is a method of quality
control which employs statistical methods to monitor and
control a process. This helps to ensure that the process
operates efficiently, producing more specification-conforming products with less waste (rework or scrap).
Tools Use in SPC
Pareto Analysis, Flowcharts, Checklists, Histograms,
Scatter Diagrams, Control Charts, Cause-and-Effect Diagrams
IRJET- Improving Quality and Productivity in Switchgear Tank Welding through ...IRJET Journal
This document discusses improving quality and productivity in switchgear tank welding through the use of poka-yoke and waste elimination techniques in a robotic welding shop. It begins with an introduction to the need for continuous quality and productivity improvement in manufacturing to compete in the market. The document then analyzes the current welding process, identifies issues like handling problems and defects, and uses tools like pareto analysis and cause-and-effect diagrams to determine the root causes. It then describes the design of a fixture to address the key issues of handling problems, reduce non-value-added activities, and improve quality. The fixture aims to automate material handling and integration with PLC/SCADA systems. In conclusion, the use of the designed
This document summarizes key findings and recommendations from a study on improving performance and competitiveness in the apparel industry. The study analyzed production and management systems across multiple factories, identifying inefficiencies. Specific case studies found that factories carried 5-16.5% excess dead stock and labor utilization was only 59.5% due to poor line balancing, workflow, and supervision. Recommendations included eliminating dead stock through improved inventory tracking, optimizing fabric usage, establishing standard times, training supervisors, and implementing production monitoring and process improvement systems. The goal was to highlight areas where cost savings could be achieved through operational enhancements.
IRJET- Rejection Analysis in Fuel EquipmentIRJET Journal
This document discusses rejection analysis of an advance housing component used in fuel injection systems. It begins by describing the manufacturing processes used to produce the housing and identifies common defects observed like blow holes, rust, improper drilling. Pareto analysis was used to determine which defects caused the highest percentage of rejections. An Ishikawa diagram identified root causes for the most common defect. Control charts were created to check if component dimensions fell within control limits. Why-why analysis was also used to determine hidden root causes of problems. Suggestions are provided to minimize defects and reduce rejection rates.
PPC is defined as the planning, direction and coordination of the firm’s material and physical facilities towards the attainment of predetermined production objectives in the most economical manner.
Optimization of process parameter for maximizing Material removal rate in tur...IRJET Journal
This document describes an experiment that used the Taguchi method to optimize process parameters for maximizing material removal rate during CNC turning of EN8 steel. Three parameters (cutting speed, feed rate, and depth of cut) were tested at three levels each in an L9 orthogonal array experiment on a CNC lathe. Material removal rate was measured for each test and analyzed using signal-to-noise ratios to determine the optimal parameter settings for maximizing removal rate. The results identified the best cutting conditions and also provided an equation to predict material removal rate based on the process parameters.
Based on the information provided:
A)
Season No. of goals Forecast
1 15
2 18
3 20 (20x50%) + (18x30%) + (15x20%) = 18.5
4 22 (20x50%) + (18x30%) + (15x20%) = 19
5 24 (22x50%) + (20x30%) + (18x20%) = 21
B) I would recommend using exponential smoothing to forecast period 7. Exponential smoothing generally performs better than simple or weighted moving averages for times series data as it places more emphasis on recent observations.
C) Based on the MAD values, exponential smoothing provided the most
Design of an accuracy control system in ship building industryGopalakrishnan P
This document summarizes a study on implementing an Accuracy Control System (ACS) in an Indian shipyard to improve quality and reduce reworks. A pilot study was conducted on the plasma cutting machine. Data on dimensional variations was collected and control charts were developed. The analysis found the process to be out of control. Major causes of variation like fluctuations in power supply voltage and issues with input design data were identified through cause-and-effect analysis and testing. It was recommended to use advanced voltage regulators and calibrate the input design data to minimize variations and improve the plasma cutting accuracy. The ACS is expected to enhance quality and reduce production costs.
This document discusses quality control and its concepts. It begins by defining quality control as total quality control, design quality control, and conformance quality control. It then discusses inspection and building quality into products by moving from no inspection to defect prevention. The document also covers the design of inspection processes including classification by target, data, and frequency. It introduces statistical quality control techniques like control charts. Finally, it discusses the concept and practice of total quality control in Japan including quality circles and quality control tools.
Work study techniques like method study and work measurement are used to systematically examine human work to improve efficiency and reduce costs. Method study involves systematically recording the current work method, critically examining it to identify alternatives, developing an improved method, installing it, and maintaining the new standard. It aims to simplify work processes, reduce fatigue, optimize resource usage, and improve productivity. Various charts can be used to record work including process charts, two-handed process charts, and micro-motion study (SIMO) charts. Macro-motion studies examine overall processes while micro-motion studies analyze individual motions and gestures.
IMPLEMENTATION OF LEAN MANUFACTURING TOOLS FOR IMPROVING PRODUCTIVITY: A CASE...Journal For Research
Present research focuses on the quality improvement at Himachal Pradesh based manufacturing unit a precision machining company for two and three wheeler components. The objective of present research focuses on current Quality Management System (QMS) implemented and to identify the current quality problems that the company faces and to study. Present research is divided into two parts Ethnographic and Qualitative research design. Recommendations and solutions to the problem faced will be suggested to the heads and supervisors, to improve the current quality system, as well as increase efficiency and reduce non conformities. This research only focuses on problem faced in the production section of the company. In the ethnographic part study is focused on plunging of workers and qualitative part research is focused on various causes of rejection. Lean manufacturing tools is considered as the pilot project to solve the problem. Various tools were used such as Multiple activity charts, Pareto chart, PDCA cycles, cause and effect diagram and control chart. With the help of lean tools, plunging of workers come to zero, better working environment is provided to workers, rejection has reduced o 12000ppm from 29000ppm and reduced the loss of organization from 4.02% to 2.79%. Retention of worker saves the training cost. Tool life also increased.
IRJET- Value Stream Mapping (VSM) – A Case Study in Manufacturing FacilityIRJET Journal
This document presents a case study applying value stream mapping (VSM) in a manufacturing facility to identify waste and improve productivity. The researchers created a current state map of the production process, which revealed problems like overprocessing, excess inventory, and waiting times. Their proposed improvements included kitting raw materials, leveling workloads between stations, and adding quality checks. A future state map showed reduced cycle times, inventory, lead time, and better resource utilization. Implementing VSM and lean principles helped improve the process flow and overall efficiency of the assembly line.
1. Work-study is a technique used to systematically examine human work to identify factors that affect efficiency and lead to improvements. It involves method study, which examines existing and proposed work methods, and work measurement, which establishes standard times for jobs.
2. The document discusses various work-study techniques including flow process charts, operation process charts, multiple activity charts, micro-motion study, therbligs, SIMO charts, time study, allowances, and work sampling.
3. The goal of work-study is to establish the most efficient way of performing a job by eliminating unnecessary tasks and establishing time standards for setting production targets and incentives.
1. Introduction to Robotics 5
Management of Resources, Facilities and Business Operation
| Manufacturing Design | j Manufacturing Execution System |
[ Enterprise/Supply-Chain j ; !
j Design & Simulation I j Process Equipment Material |
I | 1 I j Control Control Control |
I Manufacturing System : I ' ' ' ' ' ' I
I Design & Simulation I I Equipment Interface | i
) Product/Process j I proceSs I I Metrology Material
• ^ • • , „ • , • i Handling
| Design & Simulation j Equipment Equipment Equipment
I Manufacturing Processes & Transportation I
I "
Manufacturing Support System ^f j
I Inbound Logistics Outbound Logistics j
! iI 2k I
..—^-.-^j^L--^.- ----- L— ----—, ,.—--•- y.—---- .-^-zzJg^=z^:-...
/^"^Materiii N. ^^ComponenT^X ! j f ~~N. f ^!
|V^Suppliers_^ V ^ ^ u r i l i e j s ^ ^ i l V ^ " ^ ™ ^ ^ ^Consumers^^ j
Fig. 1.2 Outline of a factory in manufacturing.
• Manufacturing Execution System:
This includes process control, material flow control, equipment control
and deployment of labor.
• Manufacturing Design System:
This includes product design & simulation, process design & simulation
and supply-chain design & simulation.
• Enterprise Information and Management System:
This includes the management of resources, facilities and business op-
erations.
1.3 Factory Automation
There are two ways to achieve high yields in manufacturing. The simplest,
yet most expensive way is to increase the number of production lines. An
alternative and more desirable way is to increase the rate of production in
the existing production lines. It is possible to increase the production rate
2. 6 The Fundamentals of Robotics: Linking Perception to Action
/
•°P"" » P r o c e s s / I °^%
^ — - " ^ " ^ Disturbance ^/ ^^~~~~^^^^
Significant inputs Process Optimization ^ 1
A
I,
lO1 *•
Cycle-by-Cycle
Process Control
. FT t/O
*' I O?~~»'
Equipment Control
; . JL
Inputs
~T*
Proces/
Modeling
[Outputs
I *"
I 1 f. | -^TLJ
Feedback /
Statistical Process Control ^ Sampling/Measurement ^J
Monitoring
Fig. 1.3 Illustration of process optimization, process control, and equipment control in
manufacturing.
by reducing the cycle time needed to produce a single part or product.
There are also two ways to reduce cycle time. The first approach is to
improve the manufacturing process. The second approach is to automate
the manufacturing process by using re-programmable and automatically
controlled equipment.
As shown in Fig. 1.3, process optimization always starts with pro-
cess modelling, which consists of establishing a mathematical descrip-
tion that relates a process's input X = {(X,X2, ...,Xn)} to its output
Y = {(Yi,Y2,..., Ym)}. We can identify the subset of significant input
variables by using the scientific method, called the design of experiments.
If we regulate or control these significant input variables, the dynamics of
a process can be optimized, in terms of stability, robustness, time respon-
siveness etc.
Therefore, one important aspect of factory automation is to automati-
cally regulate or control the significant input variables of a process.
Refer to Fig. 1.3. Process control involves two cascaded control loops,
which operate at different rates. The outer loop is the statistical process
control, which aims at maximizing product quality. By definition, quality
is inversely proportional to the output variation . Therefore, the quality
control can be achieved by first monitoring the output variation of a process,
and then automatically acting on a process's inputs for the purpose of
3. Introduction to Robotics 7
minimizing this variation.
The inner loop, in a process control, is equipment control. As I men-
tioned before, the role of manufacturing equipment is to control the in-
teraction in a process, which aims at altering in a controllable manner,
the geometry, property, or appearance of the initial materials, parts, or
components. Equipment control output is the direct input to a process.
Therefore, the rate of equipment control depends on the dynamics of the
process. In general, equipment control must operate in real-time. However,
statistical-process control depends on sampling, measurement, and analysis
of data. Its control cycle will be longer than that of equipment control.
1.3.1 Automation and Robots
As we discussed above, a manufacturing process consists of the interaction
among labor, equipment, and materials, parts, or components. This inter-
action results in energy consumption in mechanical, thermal, chemical or
electrical domains.
The aim of automation is to eliminate the direct involvement of labor in
the process interaction. This is only achievable by setting up automatically-
controlled equipment. In this way, the role of labor in the factory has
shifted, from direct involvement to indirect programming and/or monitor-
ing of automated equipment.
The most typical energy-driven interactions are those which convert
electrical energy to mechanical energy. The manifestation of energy in the
mechanical domain takes the form of motions which can be altered by using
a mechanism. A mechanism is not a machine. An example of a familiar
mechanism is the bicycle. A formal definition of mechanism is as follows:
Definition 1.2 A mechanism is a set of (mechanical) elements arranged
in certain configurations for the purpose of transmitting motions in a pre-
determined fashion.
Motion is the visible form of mechanical energy. An element which
converts electrical energy into motion is called an electric motor or actuator.
If a system includes at least one element intended for energy conversion, this
system is called a machine. A typical example of a machine is a motorcycle
or car. A formal definition of machine can be stated as follows:
Definition 1.3 A machine is a super-set of mechanism(s), and contains
elements which supply energy to drive this mechanism(s).
4. 8 The Fundamentals of Robotics: Linking Perception to Action
In mathematics, motion is fully described by the parameters: position
(p), velocity (v), and acceleration (a). These motion parameters (p,v,a)
are important input variables for many manufacturing processes. A large
family of manufacturing equipment among the variety which exists, is the
one which supplies the motion required by a manufacturing process, such
as: arc-welding, spray painting, assembly, cutting, polishing, deburring,
milling, drilling etc. Of this class of equipment, an increasingly popular
type is the industrial robot.
The English word robot was derived from the Czech word robota, mean-
ing forced workers. The word robot became popular in 1921 because of a
play named "Rossum's Universal Robots" by Czechoslovakian writer, Karel
Kapek. In the play, a scientist called Rossum created human-like machines
that revolted, killed their human masters, and took control of the world.
The American company, Unimation Inc., founded in 1962 by Joseph
Engelberger and George Devol, was the first company to actually produce
industrial robots.
From an engineering point of view, a robot is the embodiment of manip-
ulative, perceptive, communicative, and cognitive abilities in an artificial
body, which may or may not have a human shape. For example, industrial
robots are merely a combination of an arm and a hand. According to the
Robot Institute of America, the formal definition of industrial robot is as
follows:
Definition 1.4 A robot is a programmable, multi-functional manipulator
designed to move material, parts or specialized devices through variable
programmed motions for the performance of a variety of tasks.
However, in view of the evolution of the robot into a sophisticated me-
chanical, electronic, controlling, informative, perceptive, and cognitive sys-
tem, a new definition of robot is necessary:
Definition 1.5 A robot is the embodiment of manipulative, locomo-
tive, perceptive, communicative and cognitive abilities in an artificial body,
which may or may not have a human shape. It can advantageously be
deployed as a tool, to make things in various environments.
Nowadays, the robot is not only gaining more popularity in industry,
but also slowly entering society, in the form of humanoid or animal-like
entertainment robots. Figs 1.4 — 1.7 show some prototypes developed by
Japanese companies. Accordingly, it is necessary to concisely define the
term humanoid robot. A formal definition of humanoid robot is as follows:
5. Introduction to Robotics 9
Fig. 1.4 PINO: An open development platform for a desktop humanoid robot. Photo
by Author.
Definition 1.6 A humanoid robot is the embodiment of manipulative,
locomotive, perceptive, communicative and cognitive abilities in an artificial
body similar to that of a human, which possesses skills in executing motions
with a certain degree of autonomy, and can be advantageously deployed as
agents to perform tasks in various environments.
In this book, robot refers to both industrial and humanoid robots.
In the manufacturing industry, tasks or processes which can typically
be accomplished by using robots include:
• Welding:
This is the process of joining two work-pieces together by applying
molten weld metal. For spot welding, the important motion parameter
is position; for arc welding, an additional important motion parameter
is the speed of travel.
• Cutting:
This is the process of applying thermal or mechanical energy to cut a
6. 10 The Fundamentals of Robotics: Linking Perception to Action
Fig. 1.5 TMSUK's humanoid robot prototype. Photo by Author.
work piece into a specific shape. In this process, the important motion
parameters are position and velocity.
• Assembly:
This is the process of either adding components to form a single entity,
or affixing components to a base unit (e.g. to place components on a
printed circuit board). In this process, the important motion parameter
is position.
• Material Handling:
This is the process of either packaging parts into a compartment (box)
or loading/unloading parts to/from another station. In this process,
position is an important motion parameter.
1.4 Impact of Industrial Robots
The industrial robot, a combination of arm and hand, can advantageously
be deployed in the manufacturing industry to automate many processes,
which have motion parameters as input. Obviously, automation using
robots shifts the use of human labor from direct interaction with a process
to various indirect interactions. These indirect interactions include process
monitoring, process diagnostics, equipment setting, equipment program-