International Journal of Engineering Research and Applications (IJERA) is an open access online peer reviewed international journal that publishes research and review articles in the fields of Computer Science, Neural Networks, Electrical Engineering, Software Engineering, Information Technology, Mechanical Engineering, Chemical Engineering, Plastic Engineering, Food Technology, Textile Engineering, Nano Technology & science, Power Electronics, Electronics & Communication Engineering, Computational mathematics, Image processing, Civil Engineering, Structural Engineering, Environmental Engineering, VLSI Testing & Low Power VLSI Design etc.
Application of value stream mapping tool to reduce wastes in bearing industryijmech
In today’s highly competitive business environment, companies require improvement in Production Lead
Times, costs and customer service levels to survive. Because of this, companies have become more
customers focused. The result is that companies have been putting in significant effort to improve their
efficiency.
This paper present the practical application of Value Stream Mapping (VSM) tool implement in a bearing
industry. A value stream is an assortment of all actions (value added as well as non-value added) that are
required to bring a product through the essential flows, starting with raw material and ending with the
customer. For drawing current state value stream mapping, all relevant data has been collected and analyzed. Then analysis of current state map has been done for identifying non-value adding activities, in
other words waste and suggestions on how to remove or reduce different wastes. From the results achieved
by current VSM, it was observable that the two processes Annealing and CNC Machining have higher cycle
time and WIP. In order to increase their capacity, their cycle should be reduced.
By implementing some lean principles and changes in the production line, the future state map was created and the reduction the different types of wastes reduced. The total processing time was reduced from 409
seconds to 344 seconds.
This document discusses production and operations management. It begins with definitions of production management and operations management. It then provides a historical overview of the evolution of the field from Adam Smith's specialization of labor to more modern contributions. The rest of the document defines concepts related to production systems including inputs, transformation processes, outputs, and classifications like job shop, batch, mass, and continuous production.
This document provides an overview of production and operations management. It defines key terms like production, operations, production systems, and discusses different types of production systems like job shop production, batch production, mass production, and continuous production. It also outlines the objectives, inputs, transformation process, and outputs of a typical production system. Finally, it describes the main duties and responsibilities of operations management like facility location, plant layout, product and process design, production planning and control, quality control, materials management, and maintenance management.
This document discusses product planning, value, customer satisfaction, logistics processes, and economic batch quantity modeling. It notes that product planning identifies market requirements to define a product's features and serves as the basis for pricing, distribution, and promotion decisions. It also defines value as the ratio of function to cost, which can be increased by improving function or reducing costs. Additionally, it lists factors that can lead to customer dissatisfaction and outlines key considerations for logistics like products, processes, capacity, orders, and resources. Finally, it provides background on economic batch quantity modeling including assumptions, variables, and the formula for calculating optimal batch size.
Learn about Transformation Process
and Steel Making
-A case study on BMM ISPAT
For more knowledge around marketing, check out my YouTube channel and subscribe. I also upload 1 video content per week on YouTube - https://bit.ly/SubscribeSindhuBiswal
Analysis of Process Parameters for Optimization of Plastic Extrusion in Pipe ...IJERA Editor
The objective of this paper is to study the defects in the plastic pipe, to optimize the plastic pipe manufacturing process. It is very essential to learn the process parameter and the defect in the plastic pipe manufacturing process to optimize it. For the optimization Taguchi techniques is used in this paper. For the research work Shivraj HY-Tech Drip Irrigation pipe manufacturing, Company was selected. This paper is specifically design for the optimization in the current process. The experiment was analyzed using commercial Minitab16 software, interpretation has made, and optimized factor settings were chosen. After prediction of result the quality loss is calculated and it is compare with before implementation of DOE. The research works has improves the Production, quality and optimizes the process.
This document discusses production management, including definitions, objectives, functions, factors affecting plant location and layout, and types of plant layouts. The key points are:
1) Production management aims to produce quality products in the right quantities, on time, and at the right cost to meet customer needs.
2) Functions of production management include product selection, process selection, capacity planning, production planning and control, inventory control, and quality/cost control.
3) Important factors for plant location are availability of materials, labor, utilities, transportation, and proximity to markets.
4) Plant layout depends on the manufacturing process, product type, volume, and equipment used. Common layout types described are product,
Simulative study of cause-effect interdependencies in tool logisticsIDES Editor
Today, the forging industry is facing new challenges.
The day-to-day business is characterized by fluctuating order
quantities and the production of high numbers of variants.
Under this condition the tool logistics is gaining more
importance in order to minimize production downtimes
through guaranteeing high tool availability with minimal tool
costs. This paper presents an approach for a synchronisation
of tool supply processes to production requirements by
evaluation of the cause-effect interdependencies from tool life
quantity and tool stock level on production performance and
tool utilization. Therefore the developed simulation model and
its usage for an extensive simulation study is specified in this
paper. It presents the findings from the cause-effect analysis
and is subdivided into four sections. In the first section the tool
logistic is described by a typical tool loop in massive forging
industries which is confirmed by a survey in 27 German forging
companies. Elements of a tool loop and the influencing factors
are specified. From this, the objectives of tool logistics (e. g.
high tool availability and low tool stock level) are deduced in
the second section. For the quantification of objectives in tool
logistics basic key indicators are defined and described
mathematically. In the third section an ideal tool loop is defined
and associated key indicators, such as “Maximum production
output rate per tool” are calculated. The modular structure of
the simulation model and the experimental design for the
simulation study is described in section four. The simulation
study is carried out in order to describe cause-effect
interdependencies between influencing factors and objectives
(e. g. tool availability) in tool logistics. Therefore a one by one
factor study gives significant value ranges for fully factorial
experiments. This is used to analyze the effects of interactions
between influencing factors on the tool logistics objectives.
Finally the basic conclusions from the experimental simulation
study are described as well as the ongoing research which is
facing an approximation function, that enables to calculate tool
operating points.
Application of value stream mapping tool to reduce wastes in bearing industryijmech
In today’s highly competitive business environment, companies require improvement in Production Lead
Times, costs and customer service levels to survive. Because of this, companies have become more
customers focused. The result is that companies have been putting in significant effort to improve their
efficiency.
This paper present the practical application of Value Stream Mapping (VSM) tool implement in a bearing
industry. A value stream is an assortment of all actions (value added as well as non-value added) that are
required to bring a product through the essential flows, starting with raw material and ending with the
customer. For drawing current state value stream mapping, all relevant data has been collected and analyzed. Then analysis of current state map has been done for identifying non-value adding activities, in
other words waste and suggestions on how to remove or reduce different wastes. From the results achieved
by current VSM, it was observable that the two processes Annealing and CNC Machining have higher cycle
time and WIP. In order to increase their capacity, their cycle should be reduced.
By implementing some lean principles and changes in the production line, the future state map was created and the reduction the different types of wastes reduced. The total processing time was reduced from 409
seconds to 344 seconds.
This document discusses production and operations management. It begins with definitions of production management and operations management. It then provides a historical overview of the evolution of the field from Adam Smith's specialization of labor to more modern contributions. The rest of the document defines concepts related to production systems including inputs, transformation processes, outputs, and classifications like job shop, batch, mass, and continuous production.
This document provides an overview of production and operations management. It defines key terms like production, operations, production systems, and discusses different types of production systems like job shop production, batch production, mass production, and continuous production. It also outlines the objectives, inputs, transformation process, and outputs of a typical production system. Finally, it describes the main duties and responsibilities of operations management like facility location, plant layout, product and process design, production planning and control, quality control, materials management, and maintenance management.
This document discusses product planning, value, customer satisfaction, logistics processes, and economic batch quantity modeling. It notes that product planning identifies market requirements to define a product's features and serves as the basis for pricing, distribution, and promotion decisions. It also defines value as the ratio of function to cost, which can be increased by improving function or reducing costs. Additionally, it lists factors that can lead to customer dissatisfaction and outlines key considerations for logistics like products, processes, capacity, orders, and resources. Finally, it provides background on economic batch quantity modeling including assumptions, variables, and the formula for calculating optimal batch size.
Learn about Transformation Process
and Steel Making
-A case study on BMM ISPAT
For more knowledge around marketing, check out my YouTube channel and subscribe. I also upload 1 video content per week on YouTube - https://bit.ly/SubscribeSindhuBiswal
Analysis of Process Parameters for Optimization of Plastic Extrusion in Pipe ...IJERA Editor
The objective of this paper is to study the defects in the plastic pipe, to optimize the plastic pipe manufacturing process. It is very essential to learn the process parameter and the defect in the plastic pipe manufacturing process to optimize it. For the optimization Taguchi techniques is used in this paper. For the research work Shivraj HY-Tech Drip Irrigation pipe manufacturing, Company was selected. This paper is specifically design for the optimization in the current process. The experiment was analyzed using commercial Minitab16 software, interpretation has made, and optimized factor settings were chosen. After prediction of result the quality loss is calculated and it is compare with before implementation of DOE. The research works has improves the Production, quality and optimizes the process.
This document discusses production management, including definitions, objectives, functions, factors affecting plant location and layout, and types of plant layouts. The key points are:
1) Production management aims to produce quality products in the right quantities, on time, and at the right cost to meet customer needs.
2) Functions of production management include product selection, process selection, capacity planning, production planning and control, inventory control, and quality/cost control.
3) Important factors for plant location are availability of materials, labor, utilities, transportation, and proximity to markets.
4) Plant layout depends on the manufacturing process, product type, volume, and equipment used. Common layout types described are product,
Simulative study of cause-effect interdependencies in tool logisticsIDES Editor
Today, the forging industry is facing new challenges.
The day-to-day business is characterized by fluctuating order
quantities and the production of high numbers of variants.
Under this condition the tool logistics is gaining more
importance in order to minimize production downtimes
through guaranteeing high tool availability with minimal tool
costs. This paper presents an approach for a synchronisation
of tool supply processes to production requirements by
evaluation of the cause-effect interdependencies from tool life
quantity and tool stock level on production performance and
tool utilization. Therefore the developed simulation model and
its usage for an extensive simulation study is specified in this
paper. It presents the findings from the cause-effect analysis
and is subdivided into four sections. In the first section the tool
logistic is described by a typical tool loop in massive forging
industries which is confirmed by a survey in 27 German forging
companies. Elements of a tool loop and the influencing factors
are specified. From this, the objectives of tool logistics (e. g.
high tool availability and low tool stock level) are deduced in
the second section. For the quantification of objectives in tool
logistics basic key indicators are defined and described
mathematically. In the third section an ideal tool loop is defined
and associated key indicators, such as “Maximum production
output rate per tool” are calculated. The modular structure of
the simulation model and the experimental design for the
simulation study is described in section four. The simulation
study is carried out in order to describe cause-effect
interdependencies between influencing factors and objectives
(e. g. tool availability) in tool logistics. Therefore a one by one
factor study gives significant value ranges for fully factorial
experiments. This is used to analyze the effects of interactions
between influencing factors on the tool logistics objectives.
Finally the basic conclusions from the experimental simulation
study are described as well as the ongoing research which is
facing an approximation function, that enables to calculate tool
operating points.
IRJET- A Study on Productivity of Concreting Work in Building Construction in...IRJET Journal
This document summarizes a study on productivity in building construction projects in Bengaluru, India. Data was collected over 90 days from 8 construction sites on productivity for formwork, rebar work, and concreting. Productivity for formwork ranged from 0.4-0.84 sqm/man-hr for conventional formwork, and 2.7-4.2 sqm/man-hr for Mivan formwork. Concreting productivity was 0.91-1.88 cum/man-hr, and rebar productivity ranged from 0.02-0.14 MT/man-hr. Factors like type of formwork, crew composition, and quantity of work were found to influence productivity.
IRJET- Optimization of Cycle Time by using Various Techniques: A ReviewIRJET Journal
The document reviews various techniques for optimizing manufacturing cycle times, which are affected by factors like machining conditions, human involvement, bottlenecks, and idle time. It discusses approaches like establishing machine performance capabilities, automating non-value added tasks, and focusing on eliminating sources of error to reduce cycle times. The goal is to optimize cycle times in cylinder block manufacturing to improve productivity, competitiveness, and ability to respond to customer demands.
Job order costing and process costing are two different costing systems. Job order costing tracks costs for unique jobs or orders, while process costing is used for mass production of standardized products. Under job order costing, a separate cost record is kept for each job, while process costing accumulates costs for each production process over a period of time. Job order costing is suitable when products differ for each order, while process costing is more appropriate for continuous, large-scale production of homogeneous items.
IRJET- Analysis of Constructions Productivity based on Progress Payment Certi...IRJET Journal
This document summarizes a research study on construction productivity in India. The study had three parts: 1) A literature review of construction productivity issues in India. 2) A survey of contractors to understand perceptions of productivity factors. 3) Measurement of productivity on building projects. Productivity was measured using equations that calculated output per man-hour. The research found productivity varied by project and was generally low early and high when architectural work increased. It concluded that improving training, collaboration, and management could increase productivity in India's construction industry.
This document discusses various operations management principles including plant layout, location factors, and types of production. It provides definitions and objectives of plant layout from various sources. Plant layout aims to arrange facilities and machinery to minimize costs and meet output needs. Factors influencing plant location include proximity to materials, markets, labor, and transportation. The document also discusses types of production including job, batch, and mass production. It covers the benefits of work study which involves method study and work measurement to standardize processes and improve productivity. Different types of organization structures are listed including line, functional, and matrix structures along with their key characteristics.
This document evaluates the quality performance of a ready mix concrete (RMC) plant in Mumbai, India using the Six Sigma approach. The study found that the existing sigma level of the RMC production process was 1.23, which is very low compared to manufacturing industry standards. The process capability was also low at 0.54, and control charts showed the process to be out of statistical control. Various quality tools identified issues like high variation, an unstable process, and weak correlation between compressive strength and date of casting. The study concludes that Six Sigma can help identify root causes of variation, improve process stability and capability, and achieve more consistent quality for the RMC plant through a proactive quality management approach.
IRJET-Productivity Improvement in a Pressure Vessel using Lean PrinciplesIRJET Journal
This document discusses improving productivity in a pressure vessel manufacturing company through implementing lean principles. The company was facing issues like production line stoppages and long lead times due to an unstructured inventory management system. Value stream mapping revealed long wait times and a very low inventory turnover ratio of 0.17%. To address this, a Kanban system was proposed and implemented in the supply chain for outsourced dish components. This changed the production from a push to a pull system. After implementing Kanban, line stoppages were reduced by 68% and lead time decreased from 6.5 to 4.3 days. The inventory turnover ratio also improved to 0.35%. In conclusion, implementing lean tools like Kanban helped optimize the supply chain and
The document discusses production processes and how they are organized. It describes the three main steps in production as sourcing parts, making the item, and sending it to the customer. Production processes can be organized in different ways, such as project layouts, workcenters, manufacturing cells, assembly lines, or continuous processes. The choice of production process depends on factors like product design and volume. Tools like break-even analysis, process flow charts, and assembly drawings can help design the manufacturing process flow.
This document discusses manufacturing operations and production facilities. It covers key topics like manufacturing industries and products, production facilities, lean production, and manufacturing metrics. Different types of production facilities are described based on production quantity and product variety, including job shops, batch production, and flow line production. The relationships between product quantity, variety, and complexity are also covered.
The main objective of this study is to increase the productivity against the demand. The Quality related issue regarding material&
material shortage online is not in the scope of this study. Taking a value stream perspective means working on the big picture, nota just
individual process; and not a just optimization but an actual improvement. It covers value adding as well as non-value-adding activities. This
study also includes layout improvement and time study report.
This research shows marking benefit associated with the implementation of lean program because this project shows an industrial case
study of MCCB manufacturing Assembly line.
This document provides an overview of facility layout and maintenance management concepts. It discusses types of plant layouts including product oriented, process oriented, fixed position, and combination layouts. Factors affecting layout and objectives of layout design are outlined. Material handling equipment types are described including hoists, conveyors, surface equipment, robotics, and computer controlled conveyors. Flexible manufacturing systems are defined including components, types based on operations and flexibility level. Finally, the document covers maintenance management topics such as types of maintenance, reasons for maintenance, costs of maintenance activities, and advantages and disadvantages of different maintenance approaches.
This document discusses different types of manufacturing processes:
1) The manufacturing process takes raw materials and transforms them into finished products through various steps.
2) The extractive process involves digging raw materials like minerals out of the earth through mining or quarrying.
3) The analytical process breaks raw materials down into their component parts, like refining minerals or packaging meat.
4) The synthetic process combines different raw materials to create new products, such as plastics, drugs, and concrete.
5) The fabricating process forms materials into new shapes through steps like stamping metal or assembling product parts.
This document provides an overview of production planning and control. It discusses product design, types of production systems and manufacturing processes. It also outlines the benefits of production planning and control for small entrepreneurs, and describes the key steps involved: routing, scheduling, loading, dispatching, inspection, and corrective actions. The overall goal of production planning and control is to efficiently coordinate production operations and ensure optimal capacity utilization, inventory control, quality, and on-time delivery.
Process Characteristics in Operations: Volume, Variety, Flows, Types of Processes & Operations System, continuous flow & intermittent flow system. Process Product Matrix: Job production, batch production, Assembly line & Continuous flow process & production layout Service System Design Matrix: Design of Service system, Service Blue print
Job-order costing is used for unique products or services built to customer specifications. Costs are accumulated by individual job on a job order cost sheet. This allows the profitability of each job to be determined. Important documents include material requisitions, job order cost sheets, and employee timecards. Manufacturing overhead includes indirect costs like depreciation, utilities, and supervision. Overhead is allocated to jobs using a predetermined overhead rate based on an allocation base like direct labor hours.
Om lect 04_a(r0-aug08)_facility location & layout_mms_siesvideoaakash15
This document discusses factors to consider when selecting a location and designing the layout for a manufacturing plant. It outlines key steps in the plant location process, including selecting a country, region, locality, and exact site based on availability of resources. The document then covers different types of plant layouts like process, product, and cellular layouts and considerations for each. It also discusses factors that influence layout design like the type of product, workers, and machinery used. The overall goal of location and layout selection is to allow for efficient material and information flow at the lowest possible cost.
The document discusses process costing systems used in manufacturing. Process costing is used for continuous production of similar goods and involves accumulating costs by department. Key points include:
1. Costs are accumulated by department and a unit cost is calculated for each department by dividing total costs by units produced.
2. Costs and units are transferred between departments until reaching finished goods.
3. Inventory of work in process is tracked and assigned costs for incomplete units.
Introduction to Production Planning & Control & Manufacturing.pptxTarek Erin
The document provides an overview of production planning and control (PPC) in manufacturing. It discusses key concepts like the necessity of PPC, objectives, functions and phases of PPC. The phases include pre-planning, planning and control. Activities in a PPC system are outlined such as planning, routing, scheduling, loading, dispatching, follow up and expediating. Different categories of production systems like unit, batch, mass and continuous production are also described. The goal of PPC is efficient and profitable production through resource planning and management across the manufacturing process.
QUALITY IMPROVEMENTS USING STATISTICAL PROCESS CONTROL
Using this method the assignable causes for rejections were found out and therefore there was no rejection to very less rejection of the products which was controlled using SPC.
By now, most professional have a LinkedIn profile unless they have chosen to ignore one of the most productive social media business tools. Yet, how do we maximize LinkedIn? How do we harness the power of LinkedIn?
In this workshop, we will explore specific areas that can produce measurable results, such as:
• Daily Post
• Groups
• LinkedIn Ads
• Lead Generation
• Adding Links
• And more
Your speaker, J.R. Atkins has been working with individuals, executives and small businesses since 1993 and on Social Media since 2008. He has a BA from Texas A&M University and an MBA from The University of Phoenix, Dallas Campus. He has published 3 books Success Simplified, Social Media 2.0 and Road Map to Success.
This document describes a system that allows remote control of home appliances over the internet. The system is divided into three modules: input, computation, and output. In the input module, a user interface is provided for a remote user to control appliances. In the computation module, the microcontroller processes input signals and controls the appliances. In the output module, devices like lights, fans, and a display can be controlled remotely. The system uses an IP address to connect appliances to the internet and allow remote control from any location through a web application. This provides benefits like reduced electricity waste and labor by allowing appliances to be controlled without being physically present.
IRJET- A Study on Productivity of Concreting Work in Building Construction in...IRJET Journal
This document summarizes a study on productivity in building construction projects in Bengaluru, India. Data was collected over 90 days from 8 construction sites on productivity for formwork, rebar work, and concreting. Productivity for formwork ranged from 0.4-0.84 sqm/man-hr for conventional formwork, and 2.7-4.2 sqm/man-hr for Mivan formwork. Concreting productivity was 0.91-1.88 cum/man-hr, and rebar productivity ranged from 0.02-0.14 MT/man-hr. Factors like type of formwork, crew composition, and quantity of work were found to influence productivity.
IRJET- Optimization of Cycle Time by using Various Techniques: A ReviewIRJET Journal
The document reviews various techniques for optimizing manufacturing cycle times, which are affected by factors like machining conditions, human involvement, bottlenecks, and idle time. It discusses approaches like establishing machine performance capabilities, automating non-value added tasks, and focusing on eliminating sources of error to reduce cycle times. The goal is to optimize cycle times in cylinder block manufacturing to improve productivity, competitiveness, and ability to respond to customer demands.
Job order costing and process costing are two different costing systems. Job order costing tracks costs for unique jobs or orders, while process costing is used for mass production of standardized products. Under job order costing, a separate cost record is kept for each job, while process costing accumulates costs for each production process over a period of time. Job order costing is suitable when products differ for each order, while process costing is more appropriate for continuous, large-scale production of homogeneous items.
IRJET- Analysis of Constructions Productivity based on Progress Payment Certi...IRJET Journal
This document summarizes a research study on construction productivity in India. The study had three parts: 1) A literature review of construction productivity issues in India. 2) A survey of contractors to understand perceptions of productivity factors. 3) Measurement of productivity on building projects. Productivity was measured using equations that calculated output per man-hour. The research found productivity varied by project and was generally low early and high when architectural work increased. It concluded that improving training, collaboration, and management could increase productivity in India's construction industry.
This document discusses various operations management principles including plant layout, location factors, and types of production. It provides definitions and objectives of plant layout from various sources. Plant layout aims to arrange facilities and machinery to minimize costs and meet output needs. Factors influencing plant location include proximity to materials, markets, labor, and transportation. The document also discusses types of production including job, batch, and mass production. It covers the benefits of work study which involves method study and work measurement to standardize processes and improve productivity. Different types of organization structures are listed including line, functional, and matrix structures along with their key characteristics.
This document evaluates the quality performance of a ready mix concrete (RMC) plant in Mumbai, India using the Six Sigma approach. The study found that the existing sigma level of the RMC production process was 1.23, which is very low compared to manufacturing industry standards. The process capability was also low at 0.54, and control charts showed the process to be out of statistical control. Various quality tools identified issues like high variation, an unstable process, and weak correlation between compressive strength and date of casting. The study concludes that Six Sigma can help identify root causes of variation, improve process stability and capability, and achieve more consistent quality for the RMC plant through a proactive quality management approach.
IRJET-Productivity Improvement in a Pressure Vessel using Lean PrinciplesIRJET Journal
This document discusses improving productivity in a pressure vessel manufacturing company through implementing lean principles. The company was facing issues like production line stoppages and long lead times due to an unstructured inventory management system. Value stream mapping revealed long wait times and a very low inventory turnover ratio of 0.17%. To address this, a Kanban system was proposed and implemented in the supply chain for outsourced dish components. This changed the production from a push to a pull system. After implementing Kanban, line stoppages were reduced by 68% and lead time decreased from 6.5 to 4.3 days. The inventory turnover ratio also improved to 0.35%. In conclusion, implementing lean tools like Kanban helped optimize the supply chain and
The document discusses production processes and how they are organized. It describes the three main steps in production as sourcing parts, making the item, and sending it to the customer. Production processes can be organized in different ways, such as project layouts, workcenters, manufacturing cells, assembly lines, or continuous processes. The choice of production process depends on factors like product design and volume. Tools like break-even analysis, process flow charts, and assembly drawings can help design the manufacturing process flow.
This document discusses manufacturing operations and production facilities. It covers key topics like manufacturing industries and products, production facilities, lean production, and manufacturing metrics. Different types of production facilities are described based on production quantity and product variety, including job shops, batch production, and flow line production. The relationships between product quantity, variety, and complexity are also covered.
The main objective of this study is to increase the productivity against the demand. The Quality related issue regarding material&
material shortage online is not in the scope of this study. Taking a value stream perspective means working on the big picture, nota just
individual process; and not a just optimization but an actual improvement. It covers value adding as well as non-value-adding activities. This
study also includes layout improvement and time study report.
This research shows marking benefit associated with the implementation of lean program because this project shows an industrial case
study of MCCB manufacturing Assembly line.
This document provides an overview of facility layout and maintenance management concepts. It discusses types of plant layouts including product oriented, process oriented, fixed position, and combination layouts. Factors affecting layout and objectives of layout design are outlined. Material handling equipment types are described including hoists, conveyors, surface equipment, robotics, and computer controlled conveyors. Flexible manufacturing systems are defined including components, types based on operations and flexibility level. Finally, the document covers maintenance management topics such as types of maintenance, reasons for maintenance, costs of maintenance activities, and advantages and disadvantages of different maintenance approaches.
This document discusses different types of manufacturing processes:
1) The manufacturing process takes raw materials and transforms them into finished products through various steps.
2) The extractive process involves digging raw materials like minerals out of the earth through mining or quarrying.
3) The analytical process breaks raw materials down into their component parts, like refining minerals or packaging meat.
4) The synthetic process combines different raw materials to create new products, such as plastics, drugs, and concrete.
5) The fabricating process forms materials into new shapes through steps like stamping metal or assembling product parts.
This document provides an overview of production planning and control. It discusses product design, types of production systems and manufacturing processes. It also outlines the benefits of production planning and control for small entrepreneurs, and describes the key steps involved: routing, scheduling, loading, dispatching, inspection, and corrective actions. The overall goal of production planning and control is to efficiently coordinate production operations and ensure optimal capacity utilization, inventory control, quality, and on-time delivery.
Process Characteristics in Operations: Volume, Variety, Flows, Types of Processes & Operations System, continuous flow & intermittent flow system. Process Product Matrix: Job production, batch production, Assembly line & Continuous flow process & production layout Service System Design Matrix: Design of Service system, Service Blue print
Job-order costing is used for unique products or services built to customer specifications. Costs are accumulated by individual job on a job order cost sheet. This allows the profitability of each job to be determined. Important documents include material requisitions, job order cost sheets, and employee timecards. Manufacturing overhead includes indirect costs like depreciation, utilities, and supervision. Overhead is allocated to jobs using a predetermined overhead rate based on an allocation base like direct labor hours.
Om lect 04_a(r0-aug08)_facility location & layout_mms_siesvideoaakash15
This document discusses factors to consider when selecting a location and designing the layout for a manufacturing plant. It outlines key steps in the plant location process, including selecting a country, region, locality, and exact site based on availability of resources. The document then covers different types of plant layouts like process, product, and cellular layouts and considerations for each. It also discusses factors that influence layout design like the type of product, workers, and machinery used. The overall goal of location and layout selection is to allow for efficient material and information flow at the lowest possible cost.
The document discusses process costing systems used in manufacturing. Process costing is used for continuous production of similar goods and involves accumulating costs by department. Key points include:
1. Costs are accumulated by department and a unit cost is calculated for each department by dividing total costs by units produced.
2. Costs and units are transferred between departments until reaching finished goods.
3. Inventory of work in process is tracked and assigned costs for incomplete units.
Introduction to Production Planning & Control & Manufacturing.pptxTarek Erin
The document provides an overview of production planning and control (PPC) in manufacturing. It discusses key concepts like the necessity of PPC, objectives, functions and phases of PPC. The phases include pre-planning, planning and control. Activities in a PPC system are outlined such as planning, routing, scheduling, loading, dispatching, follow up and expediating. Different categories of production systems like unit, batch, mass and continuous production are also described. The goal of PPC is efficient and profitable production through resource planning and management across the manufacturing process.
QUALITY IMPROVEMENTS USING STATISTICAL PROCESS CONTROL
Using this method the assignable causes for rejections were found out and therefore there was no rejection to very less rejection of the products which was controlled using SPC.
By now, most professional have a LinkedIn profile unless they have chosen to ignore one of the most productive social media business tools. Yet, how do we maximize LinkedIn? How do we harness the power of LinkedIn?
In this workshop, we will explore specific areas that can produce measurable results, such as:
• Daily Post
• Groups
• LinkedIn Ads
• Lead Generation
• Adding Links
• And more
Your speaker, J.R. Atkins has been working with individuals, executives and small businesses since 1993 and on Social Media since 2008. He has a BA from Texas A&M University and an MBA from The University of Phoenix, Dallas Campus. He has published 3 books Success Simplified, Social Media 2.0 and Road Map to Success.
This document describes a system that allows remote control of home appliances over the internet. The system is divided into three modules: input, computation, and output. In the input module, a user interface is provided for a remote user to control appliances. In the computation module, the microcontroller processes input signals and controls the appliances. In the output module, devices like lights, fans, and a display can be controlled remotely. The system uses an IP address to connect appliances to the internet and allow remote control from any location through a web application. This provides benefits like reduced electricity waste and labor by allowing appliances to be controlled without being physically present.
Este documento describe el programa de la 2a Jornada Nacional de Conocimiento Abierto Bioinspirado e Inteligencia Colectiva que se llevará a cabo los días 11 y 12 de abril de 2013 en Madrid. El evento explorará sistemas colaborativos complejos basados en conocimiento abierto, inteligencia colectiva y modelos de sabiduría colectiva aplicados a empresas. Se presentará BUAALA.TV como un ejemplo de televisión inteligente e interactiva. Los objetivos son mostrar la alianza entre ZINCSHOWER y WETHEBIO
Stockholm a scene for creativity - Presentation for MICEboardMICEboard
The document appears to be a Swedish job posting for a position as a machine operator at a manufacturing company. It lists responsibilities like operating machinery, ensuring quality standards are met and following safety procedures. The ideal candidate would have experience operating machinery in a manufacturing environment.
O documento discute a importância da leitura para a construção da identidade social e como tornar leitores comuns em leitores ideais. Aponta três perspectivas de leitura e defende que a leitura deve ser um processo reflexivo, não apenas a captação de informações. Também reflete sobre como incentivar a leitura entre aqueles que não costumam ler.
HOJITA EVANGELIO DOMINGO XX CICLO A SERIENelson Gómez
COMUNIDAD PARROQUIAL NUESTRA SEÑORA DE LOS DOLORES
MISA DOMINICAL NIÑOS PARA LA PASTORAL NIÑOS
PEREIRA 17 DE AGOSTO DE 2014, DOMINGO XX TIEMPO ORDINARIO CICLO A
EVANGELIO SEGÚN SAN MATEO 15, 21-28
- Mujer, qué grande es tu fe -
PEREIRA – RISARALDA
COLOMBIA
2014
International Journal of Engineering Research and Applications (IJERA) is an open access online peer reviewed international journal that publishes research and review articles in the fields of Computer Science, Neural Networks, Electrical Engineering, Software Engineering, Information Technology, Mechanical Engineering, Chemical Engineering, Plastic Engineering, Food Technology, Textile Engineering, Nano Technology & science, Power Electronics, Electronics & Communication Engineering, Computational mathematics, Image processing, Civil Engineering, Structural Engineering, Environmental Engineering, VLSI Testing & Low Power VLSI Design etc.
Undang-undang ini mengatur tentang pengelolaan sumber daya air di Indonesia. Sumber daya air dikelola secara terpadu dan berwawasan lingkungan untuk kemakmuran rakyat. Negara menjamin hak setiap orang untuk mendapatkan air minimum sehari-hari dan menguasai sumber daya air untuk kepentingan umum. Undang-undang ini mengatur tentang pengelolaan, hak guna air, dan penentuan wilayah pengelolaan sumber daya air.
International Journal of Engineering Research and Applications (IJERA) is an open access online peer reviewed international journal that publishes research and review articles in the fields of Computer Science, Neural Networks, Electrical Engineering, Software Engineering, Information Technology, Mechanical Engineering, Chemical Engineering, Plastic Engineering, Food Technology, Textile Engineering, Nano Technology & science, Power Electronics, Electronics & Communication Engineering, Computational mathematics, Image processing, Civil Engineering, Structural Engineering, Environmental Engineering, VLSI Testing & Low Power VLSI Design etc.
The document discusses the benefits of exercise for mental health. Regular physical activity can help reduce anxiety and depression and improve mood and cognitive function. Exercise causes chemical changes in the brain that may help protect against mental illness and improve symptoms.
International Journal of Engineering Research and Applications (IJERA) is an open access online peer reviewed international journal that publishes research and review articles in the fields of Computer Science, Neural Networks, Electrical Engineering, Software Engineering, Information Technology, Mechanical Engineering, Chemical Engineering, Plastic Engineering, Food Technology, Textile Engineering, Nano Technology & science, Power Electronics, Electronics & Communication Engineering, Computational mathematics, Image processing, Civil Engineering, Structural Engineering, Environmental Engineering, VLSI Testing & Low Power VLSI Design etc.
Linux es un sistema operativo libre y de código abierto similar a Unix. Fue desarrollado inicialmente en 1991 por Linus Torvalds como un proyecto personal. Desde entonces ha crecido mucho y ahora es usado ampliamente en servidores, estaciones de trabajo y computadoras personales. El software libre de Linux respeta las cuatro libertades fundamentales de acceso, uso, modificación y redistribución.
A Pfizer contratou a Symnetics para implantar o Balanced Scorecard (BSC) em sua fábrica em Guarulhos para alinhar os recursos da organização, melhorar os custos e prazos de entrega. Inicialmente 15 líderes e 20 funcionários da segunda linha participaram do projeto, que agora envolve 40 pessoas. A Pfizer espera que até outubro de 2008 todos os 400 funcionários estejam envolvidos na nova filosofia trazida pelo BSC.
A production - Inventory model with JIT setup cost incorporating inflation an...IJMER
A production inventory model with Just-In-Time (JIT) set-up cost has been developed in which inflation and time value of money are considered under an imperfect production process. The demand rate is considered to be a function of advertisement cost and selling price. Unit production cost is considered incorporating several features like energy and labour cost, raw material cost and development cost of the manufacturing system. Development cost is assumed to be a function of reliability parameter.
Considering these phenomena, an analytic expression is obtained for the total profit of the model. The model provides an analytical solution to maximize the total profit function.A numerical example is presented to illustrate the model along with graphical analysis. Sensitivity analysis has been carried out to identify the most sensitive parameters of the model.
This document describes a simulation program developed to monitor and improve the performance of a production system. The program calculates Overall Line Effectiveness (OLE) metrics to identify weaknesses in a line with multiple interconnected machines. It was applied to a case study of a bathtub manufacturing company with 6 departments. Data showed significant time losses from issues like breakdowns, setups, idle time, and rejects. The simulation software helped analyze this data and identify areas for improvement, increasing the OLE value from 46.84% to 68.94% after implementing recommended changes.
Line Balancing and facility optimization of Machine Shop with Work Study and ...IRJET Journal
1) The document describes a study conducted at a machine shop to improve productivity and optimize facility usage through work study methods and simulation modeling.
2) Time and motion studies were used to calculate standard times for machining processes on an MK 25 hub part. Simulation software was then used to model the existing system and test improvements.
3) Experiments showed dividing the system into two groups that run alternate shifts improved machine utilization above 70% while meeting daily production targets. This addressed issues of low output and machine idle time in the existing setup.
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.
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.
A MULTIPLE PRODUCTION SETUPS INVENTORY MODEL FOR IMPERFECT ITEMS CONSIDERING ...orajjournal
This paper presents an imperfect manufacturing system in which production ability can produce items in m
production setups and rework the imperfect quality items in one rework setup. Rework is one of the main
issues in reverse logistic and green supply chain to reduce production cost and environmental problem.
The aim of this research is to minimize the total inventory cost by determining the optimal cycle time and
the optimal number of production setups. The convexity of the inventory model is derived by using
mathematical software. The result is illustrated with numerical example for the model. The effects of the
problem parameters upon the optimal solution are examined numerically. This model can be applied to
optimizing the total inventory cost for the business enterprises where production rate and demand rate are
time dependent and salvage value is incorporated to the deteriorated items.
Manufacturing Lead Time Reduction in Monoblock (SWJ) Pump Industry [irjet-v4 ...PERUMALSAMY M
Manufacturing lead time is the time required to produce product from its raw materials to final product.A company has to fulfill its customer needs to sustain in this competitive world. Lean has served the manufacturing sector with speed and quality. This project aims at lead time reduction in pump manufacturing company. Value Stream Map(VSM) served as an initiative for identifying bottlenecks process and waste in the manufacturing line; current state map is drawn by the observation made on the shop floor. The takt time is calculated for the demand to find out the bottleneck operations. After identifying the bottleneck operations line balancing is done. The Work In Process (WIP) inventory is reduced by balancing the workstation. Future state map is developed in the perspective of reduction of lead time and to match the takt time with bottleneck process. After line balancing implementation, the lead time for assembly of the SWJ pump is reduced 32 percent and work in process inventory is reduced 25 percent.
Manufacturing Lead Time Reduction in Monoblock (SWJ) Pump IndustryIRJET Journal
This document discusses reducing manufacturing lead time in a pump manufacturing company through lean manufacturing techniques. It begins with an introduction to lean manufacturing and value stream mapping. A current state value stream map is created to identify bottlenecks and waste in the production process. A time study is conducted to calculate takt time. Line balancing is then performed to match process times to takt time and reduce work in process inventory. The key findings are that after implementing line balancing, the lead time for pump assembly was reduced by 32% and work in process inventory was reduced by 25%.
Estimation of Manufacturing Costs in the Early Stages of Product Development ...IJMER
The document summarizes a research paper about estimating manufacturing costs in the early stages of product development. It describes a software prototype developed by the author that uses the Lucas method to calculate cost estimates. The Lucas method takes a simple part with known costs and applies factors to estimate costs. The software allows comparing costs for different materials, manufacturing methods, and lot sizes. The results generated by the software were compared to other cost estimation methods and found to work surprisingly well in the early design stages when details are unclear. The software provides a simple way for designers to consider manufacturing costs early in the design process.
Solving Multi-level, Multi-product and Multi-period Lot Sizing and Scheduling...Editor IJCATR
In this paper, a new model of capacitated lot sizing and scheduling in a permutation flow shop is developed. In this model
demand can be totally backlogged. Setups can be carryover and are sequence-dependent. It is well-known from literatures that
capacitated lot sizing problem in permutation flow shop systems are NP-hard. This means the model is solved in polynomial time and
metaheuristics algorithms are capable of solving these problems within reasonable computing load. Metaheuristic algorithms find more
applications in recent researches. On this concern this paper proposes two evolutionary algorithms, one of the most popular namely,
Genetic Algorithm (GA) and one of the most powerful population base algorithms namely, Imperialist Competitive Algorithm (ICA).
The proposed algorithms are calibrate by Taguchi method and be compared against a presented lower bound. Some numerical
examples are solved by both the algorithms and the lower bound. The quality of solution obtained by the proposed algorithm showed
superiority of ICA to GA.
The Performance Analysis of a Fettling Shop Using SimulationIOSR Journals
Fettling shop is the product finishing shop of casting products.After the knockout, the casting is taken
to the fettling shop for doing the fettling work. The fettling process includes cutting, shot blasting, grinding and
painting. In all these process the sand and extra metal on the castings are removed. The project titled „The
performance analysis of a fettling shop using simulation‟ is based on a fettling shop of a casting industry. The
main aim of the project is the performance analysis of the fettling shop. This project is a simulation based
project and is done using a simulation tool called arena. The main concepts related with the performance
analysis are Bottleneck analysis, Productivity analysis and System improvement analysis.
IRJET- Value Engineering: Better Way of Implementing Conventional MethodsIRJET Journal
This document discusses value engineering and its application in various fields. It begins with an introduction to value engineering, defining it as a creative, organized effort to analyze projects to achieve essential functions cost-effectively. It then provides examples of value engineering being used in waste management, residual value analysis of vehicles, and machine-based optimization. The document concludes that value engineering can reduce production costs through techniques like reducing cycle times, optimizing materials and weights, and improving product life cycles and sustainable development.
This document presents a mathematical model for analyzing a generic single channel, multi-phase production line. The model aims to minimize system costs by reducing idle machine times and work-in-process inventory levels between machines. The model accounts for machine cycle times and calculates the times at which products enter and exit each machine in the production line. It assumes deterministic arrival rates and develops equations to determine the optimal level of service to minimize the total expected costs of providing service and of waiting for service.
Abstract: The case study discuss about production process in Better Castings Company. Consider for a moment what it takes to produce a product in manufacturing industry that has to produce different products at various times. Major, there are the logistics of scheduling and raw material handling. Then, add the human labour factor affecting both quality and efficiency. The production process in the company is similar to the other production process of companies where the raw material transfer from foundry to store, store to the lathe machining for parting material, from lathe machining to the CNC (computer numerical control) machines where the first operation and the second operation are carried out to obtain the final design of the ring joint gaskets. After the final machining the obtained product is carried to the quality control where the visual inspection, dimensional inspection, Quality of product & the specifications of the product are checked depending on the customer requirement. While machining product the tolerance in tool fit will affect the dimensions of product. Due to that product can’t reach its specification limit given by customer. So company losing its machining time in the form of reworks and rejections, man power and production. This is common problem in many small scale manufacturing industries. In order of considering all these process a single change in production process leads better quality and efficiency production of company. The paper shows a solution to reduce machining time and man power in order to increase production of a company.
Keyword: CNC (computer numerical controlled machines), better castings, job, Q.C (quality control), Q.A (quality assurance), ring joint gasket, O.D (outer diameter), Quality inspection.
Abstract: The case study discuss about production process in Better Castings Company. Consider for a moment what it takes to produce a product in manufacturing industry that has to produce different products at various times. Major, there are the logistics of scheduling and raw material handling. Then, add the human labour factor affecting both quality and efficiency. The production process in the company is similar to the other production process of companies where the raw material transfer from foundry to store, store to the lathe machining for parting material, from lathe machining to the CNC (computer numerical control) machines where the first operation and the second operation are carried out to obtain the final design of the ring joint gaskets. After the final machining the obtained product is carried to the quality control where the visual inspection, dimensional inspection, Quality of product & the specifications of the product are checked depending on the customer requirement. While machining product the tolerance in tool fit will affect the dimensions of product. Due to that product can’t reach its specification limit given by customer. So company losing its machining time in the form of reworks and rejections, man power and production. This is common problem in many small scale manufacturing industries. In order of considering all these process a single change in production process leads better quality and efficiency production of company. The paper shows a solution to reduce machining time and man power in order to increase production of a company.
Keyword: CNC (computer numerical controlled machines), better castings, job, Q.C (quality control), Q.A (quality assurance), ring joint gasket, O.D (outer diameter), Quality inspection.
Reducing Manufacturing Cost through Value Stream MappingEditor IJCATR
To survive in today's competitive world, companies require low costs and high customer service levels. As such,
companies pay more effort to reduce their manufacturing cost. Value stream mapping CVSM) technique has been used on a broad
scale in big companies such as toyato and boeing. This paper considers the implementation of value stream mapping technique in
manufacturing technical spring by railway spring manufacturing company. It focuses on product family, current state map and the
future state map. The aim is to identify waste in the form of non value added activities and processes and than removing them to
improve the performance of the company. Current state map is prepared to describe the existing position and various problem
areas. Future state map is prepared to show the proposed improvement action plans. The achievements of value stream mapping
implementation are reduction in manufacturing cost. It was found that even a small company make significant improvements by
adopting VSM technology. It was concluded that if we adopt the VSM technique the company could reduce the manufacturing
cost from 62.5Cr to 61.88Cr
Abstract: The case study discuss about production process in Better Castings Company. Consider for a moment what it takes to produce a product in manufacturing industry that has to produce different products at various times. Major, there are the logistics of scheduling and raw material handling. Then, add the human labour factor affecting both quality and efficiency. The production process in the company is similar to the other production process of companies where the raw material transfer from foundry to store, store to the lathe machining for parting material, from lathe machining to the CNC (computer numerical control) machines where the first operation and the second operation are carried out to obtain the final design of the ring joint gaskets. After the final machining the obtained product is carried to the quality control where the visual inspection, dimensional inspection, Quality of product & the specifications of the product are checked depending on the customer requirement. While machining product the tolerance in tool fit will affect the dimensions of product. Due to that product can’t reach its specification limit given by customer. So company losing its machining time in the form of reworks and rejections, man power and production. This is common problem in many small scale manufacturing industries. In order of considering all these process a single change in production process leads better quality and efficiency production of company. The paper shows a solution to reduce machining time and man power in order to increase production of a company.
“Development of automatic feeder system in cellular manufacturing to improve ...IRJET Journal
This document summarizes a study on developing an automatic feeder system for a machine shop to improve productivity. The study aims to automate the loading and unloading of workpieces on turning machines to improve safety, quality and reduce costs. It analyzes implementing a vibratory bowl feeder and cellular manufacturing approach. The document discusses the current issues with manual operations, downtime reduction and compares productivity before and after installing the automatic feeder system.
1) The document discusses allocation of equipment in a multi-stage manufacturing process where multiple equipment are used at each stage to minimize wait times between stages.
2) It presents a linear model to estimate the effects of main equipment and interactions between adjacent stages on final product quality. Fractional factorial designs are used to analyze the model with multiple factors of mixed levels.
3) As an example, a six-stage process with two two-level and three three-level factors is examined. A resolution III fractional factorial design is constructed by taking the product of two-level and three-level fractional designs to estimate all main and two-way interaction effects between adjacent stages.
Design and Analysis of Chute System to obtain World Class OEEijsrd.com
A large investment in a piece of capital machinery and, in theory, it could run 24 hour a day for seven days a week at its optimum Speed. If it did this you gain the maximum value from the investment. In reality there is number of element that can affect the value gained from the investment. So that fully utilization of equipment can be done. Hence for fully utilization of any equipment any firm must have to calculate OEE. This paper represents the methodology applied in increasing the OEE of an Organization by exchanging the feed mechanism from a conveyor to a Chute system.
Cosa hanno in comune un mattoncino Lego e la backdoor XZ?Speck&Tech
ABSTRACT: A prima vista, un mattoncino Lego e la backdoor XZ potrebbero avere in comune il fatto di essere entrambi blocchi di costruzione, o dipendenze di progetti creativi e software. La realtà è che un mattoncino Lego e il caso della backdoor XZ hanno molto di più di tutto ciò in comune.
Partecipate alla presentazione per immergervi in una storia di interoperabilità, standard e formati aperti, per poi discutere del ruolo importante che i contributori hanno in una comunità open source sostenibile.
BIO: Sostenitrice del software libero e dei formati standard e aperti. È stata un membro attivo dei progetti Fedora e openSUSE e ha co-fondato l'Associazione LibreItalia dove è stata coinvolta in diversi eventi, migrazioni e formazione relativi a LibreOffice. In precedenza ha lavorato a migrazioni e corsi di formazione su LibreOffice per diverse amministrazioni pubbliche e privati. Da gennaio 2020 lavora in SUSE come Software Release Engineer per Uyuni e SUSE Manager e quando non segue la sua passione per i computer e per Geeko coltiva la sua curiosità per l'astronomia (da cui deriva il suo nickname deneb_alpha).
Programming Foundation Models with DSPy - Meetup SlidesZilliz
Prompting language models is hard, while programming language models is easy. In this talk, I will discuss the state-of-the-art framework DSPy for programming foundation models with its powerful optimizers and runtime constraint system.
Building Production Ready Search Pipelines with Spark and MilvusZilliz
Spark is the widely used ETL tool for processing, indexing and ingesting data to serving stack for search. Milvus is the production-ready open-source vector database. In this talk we will show how to use Spark to process unstructured data to extract vector representations, and push the vectors to Milvus vector database for search serving.
GraphSummit Singapore | The Art of the Possible with Graph - Q2 2024Neo4j
Neha Bajwa, Vice President of Product Marketing, Neo4j
Join us as we explore breakthrough innovations enabled by interconnected data and AI. Discover firsthand how organizations use relationships in data to uncover contextual insights and solve our most pressing challenges – from optimizing supply chains, detecting fraud, and improving customer experiences to accelerating drug discoveries.
Communications Mining Series - Zero to Hero - Session 1DianaGray10
This session provides introduction to UiPath Communication Mining, importance and platform overview. You will acquire a good understand of the phases in Communication Mining as we go over the platform with you. Topics covered:
• Communication Mining Overview
• Why is it important?
• How can it help today’s business and the benefits
• Phases in Communication Mining
• Demo on Platform overview
• Q/A
Essentials of Automations: The Art of Triggers and Actions in FMESafe Software
In this second installment of our Essentials of Automations webinar series, we’ll explore the landscape of triggers and actions, guiding you through the nuances of authoring and adapting workspaces for seamless automations. Gain an understanding of the full spectrum of triggers and actions available in FME, empowering you to enhance your workspaces for efficient automation.
We’ll kick things off by showcasing the most commonly used event-based triggers, introducing you to various automation workflows like manual triggers, schedules, directory watchers, and more. Plus, see how these elements play out in real scenarios.
Whether you’re tweaking your current setup or building from the ground up, this session will arm you with the tools and insights needed to transform your FME usage into a powerhouse of productivity. Join us to discover effective strategies that simplify complex processes, enhancing your productivity and transforming your data management practices with FME. Let’s turn complexity into clarity and make your workspaces work wonders!
Why You Should Replace Windows 11 with Nitrux Linux 3.5.0 for enhanced perfor...SOFTTECHHUB
The choice of an operating system plays a pivotal role in shaping our computing experience. For decades, Microsoft's Windows has dominated the market, offering a familiar and widely adopted platform for personal and professional use. However, as technological advancements continue to push the boundaries of innovation, alternative operating systems have emerged, challenging the status quo and offering users a fresh perspective on computing.
One such alternative that has garnered significant attention and acclaim is Nitrux Linux 3.5.0, a sleek, powerful, and user-friendly Linux distribution that promises to redefine the way we interact with our devices. With its focus on performance, security, and customization, Nitrux Linux presents a compelling case for those seeking to break free from the constraints of proprietary software and embrace the freedom and flexibility of open-source computing.
Infrastructure Challenges in Scaling RAG with Custom AI modelsZilliz
Building Retrieval-Augmented Generation (RAG) systems with open-source and custom AI models is a complex task. This talk explores the challenges in productionizing RAG systems, including retrieval performance, response synthesis, and evaluation. We’ll discuss how to leverage open-source models like text embeddings, language models, and custom fine-tuned models to enhance RAG performance. Additionally, we’ll cover how BentoML can help orchestrate and scale these AI components efficiently, ensuring seamless deployment and management of RAG systems in the cloud.
Let's Integrate MuleSoft RPA, COMPOSER, APM with AWS IDP along with Slackshyamraj55
Discover the seamless integration of RPA (Robotic Process Automation), COMPOSER, and APM with AWS IDP enhanced with Slack notifications. Explore how these technologies converge to streamline workflows, optimize performance, and ensure secure access, all while leveraging the power of AWS IDP and real-time communication via Slack notifications.
“An Outlook of the Ongoing and Future Relationship between Blockchain Technologies and Process-aware Information Systems.” Invited talk at the joint workshop on Blockchain for Information Systems (BC4IS) and Blockchain for Trusted Data Sharing (B4TDS), co-located with with the 36th International Conference on Advanced Information Systems Engineering (CAiSE), 3 June 2024, Limassol, Cyprus.
In the rapidly evolving landscape of technologies, XML continues to play a vital role in structuring, storing, and transporting data across diverse systems. The recent advancements in artificial intelligence (AI) present new methodologies for enhancing XML development workflows, introducing efficiency, automation, and intelligent capabilities. This presentation will outline the scope and perspective of utilizing AI in XML development. The potential benefits and the possible pitfalls will be highlighted, providing a balanced view of the subject.
We will explore the capabilities of AI in understanding XML markup languages and autonomously creating structured XML content. Additionally, we will examine the capacity of AI to enrich plain text with appropriate XML markup. Practical examples and methodological guidelines will be provided to elucidate how AI can be effectively prompted to interpret and generate accurate XML markup.
Further emphasis will be placed on the role of AI in developing XSLT, or schemas such as XSD and Schematron. We will address the techniques and strategies adopted to create prompts for generating code, explaining code, or refactoring the code, and the results achieved.
The discussion will extend to how AI can be used to transform XML content. In particular, the focus will be on the use of AI XPath extension functions in XSLT, Schematron, Schematron Quick Fixes, or for XML content refactoring.
The presentation aims to deliver a comprehensive overview of AI usage in XML development, providing attendees with the necessary knowledge to make informed decisions. Whether you’re at the early stages of adopting AI or considering integrating it in advanced XML development, this presentation will cover all levels of expertise.
By highlighting the potential advantages and challenges of integrating AI with XML development tools and languages, the presentation seeks to inspire thoughtful conversation around the future of XML development. We’ll not only delve into the technical aspects of AI-powered XML development but also discuss practical implications and possible future directions.
Best 20 SEO Techniques To Improve Website Visibility In SERPPixlogix Infotech
Boost your website's visibility with proven SEO techniques! Our latest blog dives into essential strategies to enhance your online presence, increase traffic, and rank higher on search engines. From keyword optimization to quality content creation, learn how to make your site stand out in the crowded digital landscape. Discover actionable tips and expert insights to elevate your SEO game.
HCL Notes and Domino License Cost Reduction in the World of DLAUpanagenda
Webinar Recording: https://www.panagenda.com/webinars/hcl-notes-and-domino-license-cost-reduction-in-the-world-of-dlau/
The introduction of DLAU and the CCB & CCX licensing model caused quite a stir in the HCL community. As a Notes and Domino customer, you may have faced challenges with unexpected user counts and license costs. You probably have questions on how this new licensing approach works and how to benefit from it. Most importantly, you likely have budget constraints and want to save money where possible. Don’t worry, we can help with all of this!
We’ll show you how to fix common misconfigurations that cause higher-than-expected user counts, and how to identify accounts which you can deactivate to save money. There are also frequent patterns that can cause unnecessary cost, like using a person document instead of a mail-in for shared mailboxes. We’ll provide examples and solutions for those as well. And naturally we’ll explain the new licensing model.
Join HCL Ambassador Marc Thomas in this webinar with a special guest appearance from Franz Walder. It will give you the tools and know-how to stay on top of what is going on with Domino licensing. You will be able lower your cost through an optimized configuration and keep it low going forward.
These topics will be covered
- Reducing license cost by finding and fixing misconfigurations and superfluous accounts
- How do CCB and CCX licenses really work?
- Understanding the DLAU tool and how to best utilize it
- Tips for common problem areas, like team mailboxes, functional/test users, etc
- Practical examples and best practices to implement right away
HCL Notes and Domino License Cost Reduction in the World of DLAU
Ac04606177183
1. M. Ullah&C.W. Kang Int. Journal of Engineering Research and Applications www.ijera.com
ISSN : 2248-9622, Vol. 4, Issue 6( Version 6), June 2014, pp.177-183
Quality Costs (IRR) Impact on Lot Size Considering Work in
Process Inventory
Misbah Ullaha
, Chang W. Kangb*
a-b
Department of Industrial and Management Engineering, ERICA Campus, Hanyang University, Ansan,
Republic of Korea
Abstract
Economic order quantity model and production quantity model assume that production processes are error
free. However, variations exist in processes which result in imperfection particularly in high machining
environments. Processes variations result in nonconformities that increase quality costs in the form of
rework, rejects and quality control techniques implementations to ensure quality product delivery. This
paper is an attempt towards development of inventory model which incorporate inspection, rework, and
rejection (IRR) quality costs in optimum lot size calculation focusing work in process inventory.
Mathematical model is derived for optimum lot size based on minimum average cost function using
analytical approach. This new developed model (GTOQIRR) assume an imperfect production environment.
Numerical examples are used to visualize the significant effect of quality cost in the proposed model in
comparison to the previously developed models. The proposed model is highly recommendable for quality
based high machining manufacturing environments considering work in process inventories.
Keywords: WIP inventory; EOQ model; quality cost; lot size; GTOQ model.
I. Introduction
During past few decades, significant attention has
been given to the area of inventory management
because of its prime importance for most
manufacturing organizations. Organizations use
economic order quantity (EOQ) and production order
quantity (POQ) models since 1913 to calculate
optimum inventory lot size considering holding and
setup costs. Researchers extended these models to
more generic and practical situations of everyday life.
However these two basic models are based on an
unrealistic assumption that perfect products are
produced every time. A number of factors affect
manufacturing processes which include machine
failure, changes in raw material supplier, tool wear
and tear, outside conditions etc. especially where
machining time is large relatively. Therefore the
phenomena of rework, reject and inspection is
common in industries like machine tool industries,
aerospace industries and glass industries etc. High
machining environments, rework, rejects and
inspection compel to introduce quality costs incurred
during these process and its ultimate impact on
inventory lot size.
Rosenblatt and Lee [1] developed EOQ model for
imperfect manufacturing environments with
conclusion that lot size reduces as imperfection is
increased. Later Sarker et al. [2] extended EOQ model
to a multistage manufacturing environment with
imperfection in processes. The developed model
assumed that rework operation is performed at the end
of each cycle and at the end of N cycle. Further
extension of such models can be realized in research
articles published in the last decade [3-12].They
realized that the impact of imperfection on inventory
lot size in addition to the importance of inspection in
real world manufacturing environments. Combined
effect of inspection with imperfections was
emphasized in few papers such as ([13] and [18]).
Furthermore, ([14], [15], [16], [17] and [19])
developed models for optimum lot size by considering
other important aspects of the real world
manufacturing systems. Researchers mainly focused
raw materials and finish goods inventories in
calculation of optimum lot size calculation. However,
the third type of inventory, work in process, in
combination with quality cost has been relatively
ignored in previous literature.
Today, industries put their efforts to reduce their
inventories cost either in the form of raw materials,
finish goods or work in process. Boucher [20]
introduced the concept of work in process inventory in
group technology based manufacturing environment
for calculation of optimum lot size. The model was
named as group technology order quantity (GTOQ)
model. Barzoki et al. [21] extended GTOQ model for
imperfect production environments under the title of
group technology order quantity model with rework
(GTOQR). Their model considered 100%
qualification of rework products. Numerical examples
were used for model comparison against previous
models. These models are recommended for group
technology work environment where machining time
and lot size are relatively large. However, increase
RESEARCH ARTICLE OPEN ACCESS
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machining time and higher demand rate significantly
contribute towards quality costs in processes. Higher
machining rate and large machining time results in
increased quality costs due to high tool wear and tear,
process failure etc. Increased quality costs are in the
form of rework, rejects and inspection that affect total
cost for optimum lot size calculation. This paper is an
attempt towards calculation of quality costs impact on
the optimal lot size considering imperfection in
processes. This paper incorporate quality costs due to
inspection, rework and rejection (IRR) in total cost
calculation. Inclusion of quality costs in inventory
models and its impact on lot size is lacking in previous
papers incorporating work in process inventories. The
remaining sections are listed as follow;
Section 2 explains problem statement with
assumptions and notations. In section 3, the problem is
modeled based on modeling for relevant costs
associated with this problem. Section 4 comprises
comparison of models based on numerical
computations. Conclusion is presented in the last
section.
II. Problem statement
We consider a single discrete manufacturing
setup. A machining station is followed by an
inspection process with three buffer stations in the
manufacturing workshop. Buffer stations are used for
work in process inventories i.e. raw material
(unprocessed items, waiting for operations), good
quality products and poor quality products (rejected
items).
A lot of material (Q) arrives in the workshop
processed on machining station in each cycle. Lot (Q)
is released for inspection to declare products as either
good quality products or poor quality products. As
the process is imperfect so three kinds of products are
produced during the whole cycle time.
The process produces, 𝑄𝑄𝑄𝑄10, percent of parts as poor
quality products, 𝑄𝑄𝑄𝑄1𝑟𝑟, percent of parts as reworked
and the remaining 𝑄𝑄�1 − (𝑝𝑝10 + 𝑝𝑝1𝑟𝑟)� as good
quality products in the first phase of the lot Q as
shown in Figure 1.
During the next phase 2, the rework items 𝑄𝑄𝑄𝑄1𝑟𝑟=
Q(𝑝𝑝20 + 𝑝𝑝21) are reprocessed and re-inspected.
𝑄𝑄𝑝𝑝21percent of products are good quality products
and, 𝑄𝑄𝑄𝑄20, percent of products are poor quality in the
phase 2 as shown in Figure 2. We assume that no
rework is needed after that. At the end of the cycle,
the following conclusion is drawn regarding the lot
size Q.
Good quality products produced,𝑄𝑄𝑝𝑝1 = 𝑄𝑄�1 −
(𝑝𝑝10 + 𝑝𝑝20)�
Poor quality products produced,𝑄𝑄𝑝𝑝0 = 𝑄𝑄(𝑝𝑝10 + 𝑝𝑝20)
Products that are rework able after phase 1,
𝑄𝑄𝑃𝑃1𝑟𝑟 = 𝑄𝑄(𝑝𝑝20 + 𝑝𝑝21)
Therefore, our objective is to develop an
economic order quantity model for an imperfect
manufacturing environment taking quality costs into
consideration with work in process inventory.
Figure 1. Processing of lot size Q during phase 1
Figure 2. Processing of rework products in phase 2.
2.1. Notations
𝑑𝑑 customer demand
𝑄𝑄 lot size processed per unit cycle
𝑀𝑀𝑐𝑐 raw material cost per unit
𝑃𝑃𝑐𝑐 purchasing cost per unit of time
𝑆𝑆𝑐𝑐 setup cost per unit of time ($/unit of time)
Process
Q
i
Q(1-(p10+p1r))
Rejected: Q(p10)
Rework: Qp1r
Inspection
Process
QP1r units
Q(p21)
Rejected:Q(p20)
Rework: 0
Inspection
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𝑄𝑄𝑐𝑐 cost of quality per unit of time ($/unit of time)
𝐶𝐶𝑖𝑖 inspection cost
𝑅𝑅𝑅𝑅𝑐𝑐 rework cost
𝑅𝑅𝑅𝑅𝑐𝑐 rejection cost
𝑊𝑊𝑊𝑊𝑊𝑊𝑐𝑐 work in process holding cost
𝐼𝐼 𝐼𝐼𝑐𝑐 inventory holding cost
𝑇𝑇𝑐𝑐 total cost
𝑡𝑡𝑠𝑠 setup time
𝑡𝑡 𝑚𝑚1 machining time in phase 1. (unit time per unit
product)
𝑡𝑡 𝑚𝑚𝑚𝑚 machining time per unit for rework products
𝑝𝑝10 proportion of poor quality products in phase 1
𝑝𝑝11 proportion of good quality products in phase 1
𝑝𝑝21 proportion of good quality products in phase 2
𝑝𝑝20 proportion of poor quality products in phase 2
𝑝𝑝1𝑟𝑟 proportion of rework able products in phase 1
𝑝𝑝0 proportion of poor quality products at the end of
cycle
𝑝𝑝1 proportion of good quality products at the end of
cycle
𝑡𝑡𝑐𝑐 cycle time
𝑡𝑡𝑝𝑝 total processing time
𝑡𝑡 average manufacturing time for each product item
𝐺𝐺 average storage inventory
𝑊𝑊 average monetary value of the WIP inventory ($)
𝑖𝑖 inventory holding cost per unit of time ($/unit of
time)
𝑐𝑐 average unit value of each product (unit of money
($) per unit)
𝑘𝑘 rate charged per unit of cell production time
including all overheads, moving cost,
loading/unloading cost etc. (unit of money ($) per
unit of time)
2.2 Assumptions
Shortages are not allowed
Demand is known and pre-determined.
Inspection is performed of all lot and
rework able products.
Poor quality products are produced during
the rework operation.
Rework operation is done one time only.
No stoppage is allowed during the
manufacturing of one lot.
All parameters including demand and production rate,
setup times etc. are constants and deterministic.
III. Modeling
Modeling of the problem is based on cycle time
calculation in terms of demand rate and lot size Q in
addition to the imperfection in the production
processes.
As the objective of almost every manufacturing
setup is to meet customer demand rate (d) therefore
lot size (Q) is defined keeping customer demand in
mind. Processes undergoing imperfection results in
poor quality products at the end of each cycle.
Therefore we can have following relation for the
above mentioned scenario
𝑄𝑄(1 − 𝑝𝑝0) = 𝑑𝑑𝑡𝑡𝑐𝑐
𝑡𝑡𝑐𝑐=
𝑄𝑄(1−𝑝𝑝0)
𝑑𝑑
(1)
The total processing time ( 𝑡𝑡𝑝𝑝 ) of a product
having lot size Q comprises of setup time,
manufacturing time, inspection time per unit product
(𝑡𝑡𝑖𝑖), rework time and re-inspection time.
𝑡𝑡𝑝𝑝= total processing time
𝑡𝑡𝑝𝑝= 𝑡𝑡𝑠𝑠 + 𝑄𝑄𝑡𝑡 𝑚𝑚1 + 𝑡𝑡𝑖𝑖 𝑄𝑄 + 𝑄𝑄𝑡𝑡 𝑚𝑚1 𝑝𝑝1𝑟𝑟 + 𝑡𝑡𝑖𝑖 𝑄𝑄𝑝𝑝1𝑟𝑟 (2)
Therefore average processing time is given by
𝑡𝑡 =
𝑡𝑡𝑝𝑝
𝑄𝑄
𝑡𝑡 =
𝑡𝑡𝑠𝑠 + 𝑄𝑄𝑡𝑡 𝑚𝑚1 + 𝑡𝑡𝑖𝑖 𝑄𝑄 + 𝑄𝑄𝑡𝑡 𝑚𝑚1 𝑝𝑝1𝑟𝑟 + 𝑡𝑡𝑖𝑖 𝑄𝑄𝑝𝑝1𝑟𝑟
𝑄𝑄
If 𝑘𝑘 is the average cost of production per unit of
time then the average cost added to each product unit
during its manufacturing is 𝑣𝑣 given by
𝑣𝑣 = 𝑘𝑘𝑡𝑡 = 𝑘𝑘 �
𝑡𝑡𝑠𝑠+𝑄𝑄𝑡𝑡 𝑚𝑚1 +𝑡𝑡𝑖𝑖 𝑄𝑄+𝑄𝑄𝑡𝑡 𝑚𝑚1 𝑝𝑝1𝑟𝑟+𝑡𝑡𝑖𝑖 𝑄𝑄𝑝𝑝1𝑟𝑟
𝑄𝑄
�
We assume that 𝑀𝑀𝑐𝑐 be the material cost per unit of
product, then the average total cost added to each
product unit is given by
𝑐𝑐= 𝑀𝑀𝑐𝑐 + 𝑘𝑘 �
𝑡𝑡𝑠𝑠+𝑄𝑄𝑡𝑡 𝑚𝑚1 +𝑡𝑡𝑖𝑖 𝑄𝑄+𝑄𝑄𝑡𝑡 𝑚𝑚1 𝑝𝑝1𝑟𝑟+𝑡𝑡𝑖𝑖 𝑄𝑄𝑝𝑝1𝑟𝑟
𝑄𝑄
� (3)
3.1 Cost calculation
As we know that most of the inventory models
are based on the cost minimization, therefore we are
interested to calculate associated costs with this
model. Quality costs, inventory holding cost, setup
cost and material purchasing cost are the main
components of total cost calculation. All these costs
are calculated keeping imperfection in processes
under consideration.
3.1.1 Quality cost (IRR)
Quality costs considered in this paper are mainly
associated with imperfection in processes. These
imperfection results in products failure either in the
form of rework or rejected products. Similarly,
quality control techniques including inspection exists
within the manufacturing setup which also results in
quality cost. Other kinds of quality cost related to
appraisal and prevention has been neglected.
Therefore, quality costs considered in this model are
(a) Quality costs due to products inspection (𝐶𝐶𝑖𝑖). (b)
Quality costs due to rework (𝐶𝐶𝑟𝑟𝑟𝑟), (c) Quality costs
due to rejection (𝐶𝐶𝑟𝑟𝑟𝑟).
Therefore quality cost (𝐶𝐶𝑞𝑞) is given by
𝑄𝑄𝑐𝑐 = 𝐶𝐶𝐶𝐶+ 𝑅𝑅𝑅𝑅𝑐𝑐 + 𝑅𝑅𝑅𝑅𝑐𝑐 (4)
These costs are modeled as follow
a) Quality costs due to inspection
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Inspection is performed for all manufactured and
reworked products. 100% inspection of lot is carried
out when it is manufactured. Similarly reworked
products are also passed through the inspection
process. The inspection cost 𝐶𝐶𝐶𝐶 per unit of cycle time
is given by
𝐶𝐶𝐶𝐶 =
𝐼𝐼𝑐𝑐 𝑄𝑄
𝑡𝑡𝑐𝑐
+
(𝑝𝑝1𝑟𝑟)𝑄𝑄𝐼𝐼𝑐𝑐
𝑡𝑡𝑐𝑐
𝐶𝐶𝐶𝐶 =
𝐼𝐼𝑐𝑐 𝑑𝑑
(1 − 𝑝𝑝0)
+
𝐼𝐼𝑐𝑐 𝑑𝑑(𝑝𝑝1𝑟𝑟)
(1 − 𝑝𝑝0)
𝐶𝐶𝐶𝐶 = �
𝐼𝐼𝑐𝑐 𝑑𝑑
1−𝑝𝑝0
� (1 + 𝑝𝑝1𝑟𝑟) (5)
b) Quality costs due to rework
Let 𝑝𝑝1𝑟𝑟 is the percentage of rework product in a lot
size Q in a complete cycle and c be the value added to
the products in the manufacturing process. Then the
quality cost per unit time for rework items is given by
𝑅𝑅𝑅𝑅𝑐𝑐 = �
𝑛𝑛𝑝𝑝1𝑟𝑟 𝑄𝑄
𝑡𝑡𝑐𝑐
� 𝑐𝑐 (6)
where n is the no. of times rework operation is
performed.
c) Quality costs due to rejection
Let 𝑝𝑝0 is the percentage of rejected product in a lot
size Q in a complete cycle and 𝑐𝑐 be the value added
to the products in the manufacturing process. Then
the quality cost per unit time for rejected products is
given by
𝑅𝑅𝑅𝑅𝑐𝑐= �
𝑝𝑝0 𝑄𝑄
𝑡𝑡𝑐𝑐
� 𝑐𝑐 (7)
Therefore, Equation (4) becomes,
𝑄𝑄𝑐𝑐= �
𝐼𝐼𝑐𝑐 𝑑𝑑
1−𝑝𝑝0
� (1 + 𝑝𝑝1𝑟𝑟) + �
𝑛𝑛𝑝𝑝1𝑟𝑟 𝑄𝑄
𝑡𝑡𝑐𝑐
� 𝑐𝑐 + �
𝑝𝑝0 𝑄𝑄
𝑡𝑡𝑐𝑐
� 𝑐𝑐
𝑄𝑄𝑐𝑐= �
𝐼𝐼𝑐𝑐 𝑑𝑑
1−𝑃𝑃𝑏𝑏
� (1 + 𝑝𝑝1𝑟𝑟) + �
𝑐𝑐𝑐𝑐
1−𝑝𝑝0
� (𝑛𝑛𝑛𝑛1𝑟𝑟 + 𝑝𝑝0) (8)
3.1.2 Inventory holding cost
Silver et al. [22] introduced following
relationship for calculation of inventory holding cost
per unit of time.
𝐼𝐼 𝐼𝐼𝑐𝑐= 𝑖𝑖𝑖𝑖𝑖𝑖, (9)
Here 𝐺𝐺 = average inventory over each cycle by the
cycle period.
𝑐𝑐 = average unit monetary value for each item.
𝑖𝑖 = carrying charge.
The average holding inventory (𝐺𝐺) per unit cycle time
is given as
𝐺𝐺 =
1
2
𝑄𝑄(1−𝑝𝑝0)𝑡𝑡𝑐𝑐
𝑡𝑡𝑐𝑐
=
1
2
𝑄𝑄(1 − 𝑝𝑝0) (10)
Given Equations (3) and (10), the inventory holding
cost per unit of time will be
𝐼𝐼 𝐼𝐼𝑐𝑐=
1
2
𝑖𝑖 ��𝑀𝑀𝑐𝑐 +
𝑘𝑘 �
𝑡𝑡𝑠𝑠+𝑄𝑄𝑡𝑡 𝑚𝑚1 +𝑡𝑡𝑖𝑖 𝑄𝑄+𝑄𝑄𝑡𝑡 𝑚𝑚1 𝑝𝑝1𝑟𝑟+𝑡𝑡𝑖𝑖 𝑄𝑄𝑝𝑝1𝑟𝑟
𝑄𝑄
�� 𝑄𝑄(1 − 𝑝𝑝0)� (11)
3.1.3 Work in process cost
Based on the same concepts as [21] and [22], the
work in process inventory holding cost is calculated
by:
𝑊𝑊𝑊𝑊𝑊𝑊𝑐𝑐 = 𝑖𝑖𝑊𝑊, (12)
where 𝑖𝑖 = it is the carrying charge per unit of time
𝑊𝑊 = average work in process inventory
𝑊𝑊can be computed by summation of following types
of inventories in the workshop.
(a). The unprocessed product item waiting for
operation on machine versus manufacturing time 𝑡𝑡𝑝𝑝
during each cycle. (b). Good quality products
inventory over time. (c). Rejected parts inventory
over time.
Hence the average value of the total work in process
inventory will be equal to
𝑊𝑊 = �
1/2𝑄𝑄𝑡𝑡 𝑝𝑝
𝑡𝑡𝑐𝑐
� 𝑀𝑀𝑐𝑐 + �
1
2
𝑄𝑄( 1−𝑝𝑝0)𝑡𝑡 𝑝𝑝
𝑡𝑡𝑐𝑐
� 𝑐𝑐 + �
1
2
𝑄𝑄𝑝𝑝0 𝑡𝑡 𝑝𝑝
𝑡𝑡𝑐𝑐
� 𝑐𝑐
𝑊𝑊 =
1
2
𝑄𝑄𝑡𝑡 𝑝𝑝
𝑡𝑡𝑐𝑐
(𝑀𝑀𝑐𝑐 + (1 − 𝑝𝑝0)𝑐𝑐 + 𝑝𝑝0 𝑐𝑐)
𝑊𝑊 =
1
2
�
𝑑𝑑
1−𝑝𝑝0
� (𝑡𝑡𝑠𝑠 + 𝑄𝑄𝑡𝑡 𝑚𝑚1 + 𝑡𝑡𝑖𝑖 𝑄𝑄 + 𝑄𝑄𝑡𝑡 𝑚𝑚1 𝑝𝑝1𝑟𝑟 + 𝑡𝑡𝑖𝑖 𝑄𝑄𝑝𝑝1𝑟𝑟)(𝑀𝑀𝑐𝑐 + 𝑐𝑐)
Given Equation (3), the average value of total work in process inventory will be
𝑊𝑊=
1
2
�
𝑑𝑑
1−𝑝𝑝0
� �2𝑀𝑀𝑐𝑐 +
𝑘𝑘𝑡𝑡𝑠𝑠
𝑄𝑄
+ 𝑘𝑘𝑡𝑡 𝑚𝑚1 + 𝑘𝑘𝑡𝑡 𝑚𝑚1 𝑝𝑝1𝑟𝑟+𝑡𝑡𝑖𝑖 𝑘𝑘 + 𝑡𝑡𝑖𝑖 𝑘𝑘𝑝𝑝1𝑟𝑟 � (𝑡𝑡𝑠𝑠 + 𝑄𝑄𝑡𝑡 𝑚𝑚1 + 𝑡𝑡𝑖𝑖 𝑄𝑄 + 𝑄𝑄𝑡𝑡 𝑚𝑚1 𝑝𝑝1𝑟𝑟 + 𝑡𝑡𝑖𝑖 𝑄𝑄𝑝𝑝1𝑟𝑟) (13)
Therefore given Equations (12) and (13), the average carrying charge of the work in process inventory will be
𝑊𝑊𝑊𝑊𝑊𝑊𝑐𝑐 =
1
2
�
𝑑𝑑𝑑𝑑
1−𝑝𝑝0
� �2𝑀𝑀𝑐𝑐 +
𝑘𝑘𝑡𝑡𝑠𝑠
𝑄𝑄
+ 𝑘𝑘𝑡𝑡 𝑚𝑚1 + 𝑘𝑘𝑡𝑡 𝑚𝑚1 𝑝𝑝1𝑟𝑟+𝑡𝑡𝑖𝑖 𝑘𝑘 + 𝑡𝑡𝑖𝑖 𝑘𝑘𝑝𝑝1𝑟𝑟 � (𝑡𝑡𝑠𝑠 + 𝑄𝑄𝑡𝑡 𝑚𝑚1 + 𝑡𝑡𝑖𝑖 𝑄𝑄 + 𝑄𝑄𝑡𝑡 𝑚𝑚1 𝑝𝑝1𝑟𝑟 + 𝑡𝑡𝑖𝑖 𝑄𝑄𝑝𝑝1𝑟𝑟) (14)
3.1.4Material Cost
Material cost per unit of cycle time (𝑃𝑃𝑐𝑐) is given by the following equation
𝑃𝑃𝑐𝑐 = 𝑀𝑀𝑐𝑐 𝑄𝑄 𝑡𝑡𝑐𝑐⁄
We can write in terms of demand(𝑑𝑑) is
𝑃𝑃𝑐𝑐 =
𝑀𝑀𝑐𝑐 𝑑𝑑
(1−𝑝𝑝0)
(15)
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3.1.5Setup cost
Machines and inspection setup take place only once during whole lot manufacturing. We assume that no extra
setup is required for rework operations.
It can be modeled as follow
𝑆𝑆𝑐𝑐 =
𝐴𝐴
𝑡𝑡𝑐𝑐
=
𝐴𝐴𝐴𝐴
𝑄𝑄(1−𝑝𝑝0)
(16)
Where A is the setup cost. It is a product of set up time per cycle (𝑡𝑡𝑠𝑠) and the rate charged by the production
cycle (𝑘𝑘).
3.2 Total cost per unit of time
The total cost per unit of time are given by the following equation:
𝑇𝑇𝑐𝑐=𝑄𝑄𝑐𝑐 + 𝐼𝐼 𝐼𝐼𝑐𝑐+ 𝑊𝑊𝑊𝑊𝑊𝑊𝑐𝑐 + 𝑃𝑃𝑐𝑐 + 𝑆𝑆𝑐𝑐 (17)
Given equations (4), (5), (10), (13), and (16) in Eq. (17)
𝑇𝑇𝑐𝑐= �
𝐼𝐼𝑐𝑐 𝑑𝑑
1−𝑃𝑃𝑏𝑏
� (1 + 𝑝𝑝1𝑟𝑟) + �
𝑐𝑐𝑐𝑐
1−𝑝𝑝0
� (𝑛𝑛𝑛𝑛1𝑟𝑟 + 𝑝𝑝0) +
1
2
𝑖𝑖 ��𝑀𝑀𝑐𝑐 + 𝑘𝑘 �
𝑡𝑡𝑠𝑠+𝑄𝑄𝑡𝑡 𝑚𝑚1 +𝑡𝑡𝑖𝑖 𝑄𝑄+𝑄𝑄𝑡𝑡 𝑚𝑚1 𝑝𝑝1𝑟𝑟+𝑡𝑡𝑖𝑖 𝑄𝑄𝑝𝑝1𝑟𝑟
𝑄𝑄
�� 𝑄𝑄(1 − 𝑝𝑝0)�
+
1
2
�
𝑑𝑑𝑑𝑑
1−𝑝𝑝0
� �2𝑀𝑀𝑐𝑐 +
𝑘𝑘𝑡𝑡𝑠𝑠
𝑄𝑄
+ 𝑘𝑘𝑡𝑡 𝑚𝑚1 + 𝑘𝑘𝑡𝑡 𝑚𝑚1 𝑝𝑝1𝑟𝑟+𝑡𝑡𝑖𝑖 𝑘𝑘 + 𝑡𝑡𝑖𝑖 𝑘𝑘𝑝𝑝1𝑟𝑟 � (𝑡𝑡𝑠𝑠 + 𝑄𝑄𝑡𝑡 𝑚𝑚1 + 𝑡𝑡𝑖𝑖 𝑄𝑄 + 𝑄𝑄𝑡𝑡 𝑚𝑚1 𝑝𝑝1𝑟𝑟 + 𝑡𝑡𝑖𝑖 𝑄𝑄𝑝𝑝1𝑟𝑟)+
𝑀𝑀𝑐𝑐 𝑑𝑑
(1−𝑝𝑝0)
+
𝐴𝐴𝐴𝐴
𝑄𝑄(1−𝑝𝑝0)
(18)
3.3 Optimum lot size
Equation (18) gives average cost function considering quality cost. Optimum lot size can be calculated based on
average cost minimization. Therefore by taking 1st
derivative of the function w.r.t. Q and equating to 0 i.e.
𝑑𝑑𝑇𝑇𝑐𝑐
𝑑𝑑𝑑𝑑
= 0
and sufficient condition that the equation must hold and satisfy for optimum lot size calculation is given by
𝑑𝑑2 𝑇𝑇𝑐𝑐
𝑑𝑑𝑄𝑄2 > 0
Hence the optimum lot size is given by
GTOQIRR = (19)
�
2𝐴𝐴 𝑑𝑑 + 𝑖𝑖𝑑𝑑𝑑𝑑(𝑡𝑡𝑠𝑠)2 + 2 𝑘𝑘𝑡𝑡𝑠𝑠 𝑑𝑑(𝑛𝑛𝑛𝑛1𝑟𝑟 + 𝑝𝑝0)
𝑖𝑖(1 − 𝑝𝑝0)2�(𝑀𝑀𝑐𝑐 + 𝑘𝑘𝑡𝑡 𝑚𝑚1 + 𝑡𝑡𝑖𝑖 𝑘𝑘) + (𝑘𝑘𝑡𝑡 𝑚𝑚𝑟𝑟 + 𝑡𝑡𝑖𝑖 𝑘𝑘)𝑝𝑝1𝑟𝑟� + 𝑑𝑑𝑖𝑖 ��(𝑡𝑡 𝑚𝑚1 + 𝑡𝑡 𝑚𝑚𝑟𝑟 𝑝𝑝1𝑟𝑟)(2𝑀𝑀𝑐𝑐 + 𝑘𝑘𝑡𝑡 𝑚𝑚1 + 𝑘𝑘𝑡𝑡 𝑚𝑚𝑟𝑟 𝑝𝑝1𝑟𝑟)� + (𝑡𝑡𝑖𝑖(1 + 𝑝𝑝1 𝑟𝑟)(2𝑀𝑀𝑐𝑐 + 𝑡𝑡𝑖𝑖 𝑘𝑘 + 2𝑘𝑘𝑡𝑡 𝑚𝑚1 + 2𝑘𝑘𝑡𝑡 𝑚𝑚𝑚𝑚 𝑝𝑝1𝑟𝑟 + 𝑡𝑡𝑖𝑖 𝑘𝑘𝑝𝑝1𝑟𝑟)�
The addition of the term “2 𝑘𝑘𝑡𝑡𝑠𝑠 𝑑𝑑(𝑛𝑛𝑛𝑛1𝑟𝑟 + 𝑝𝑝0) ” represents the quality cost (IRR) impact on the optimum lot size.
Where ‘n’ represents the no. of times rework operation is performed.𝑝𝑝1𝑟𝑟 represents the proportion of rework
components produced during the process and 𝑝𝑝0 represnest the rejected products during the production process.
It can be observed that increased in imperfection, number of rework operations increased quality costs and
optimal lot size.
IV. Results
The proposed model is compared with the most well-known EOQ model and GTOQ model developed by
Boucher [20]. Five different cases data is taken from a US tool manufacturing company, initially introduced by
Boucher [20]. Few assumptions were made regarding data calculation e.g. percentage of rejects 𝑝𝑝0 = 20%, the
percentage of rework 𝑝𝑝1𝑟𝑟= 5%,𝑡𝑡 𝑚𝑚𝑚𝑚= 5% of actual machining time 𝑡𝑡 𝑚𝑚1 and k= 3000 ($/year) in all five cases. It
is assumed that rework operation is performed only once.
Table 1. Optimum lot size using GTOQ, EOQ and proposed model. (assume, 𝑖𝑖 = 35%
Case
No.
𝑡𝑡𝑖𝑖(min/
unit)
A ($/unit)
d(units
/year)
𝑀𝑀𝑐𝑐
(USD/ unit)
𝑡𝑡𝑠𝑠*(min/
setup)
𝑡𝑡 𝑚𝑚1* (min/
unit)
EOQ GTOQ
GTOQ
IRR
1 20 14.349 77 5.63 574 100 28 26 34
2 20 12.75 233 1.57 510 32 85 81 96
3 20 12.951 580 1.42 518 87 109 87 98
4 20 14.349 1877 1.64 574 67 216 135 139
5 20 17.274 5361 1.12 691 41 497 255 233
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It can be observed that the response of all three models is different to all cases. Response of the proposed
model is significant in comparison to the previous developed model (EOQ and GTOQ) as imperfection and
quality costs are taken into consideration.
The impact of quality cost (IRR) has also been highlighted in the table 2 below. We assume 𝑖𝑖 = 35 %, 𝑀𝑀𝑐𝑐 =
1($/unit), d = 14000 (units/year), 𝑘𝑘 = 7000 ($/year), 𝑡𝑡𝑠𝑠= 0.0017(years/unit), 𝑡𝑡 𝑚𝑚1= 0.12 (mints/unit), 𝑡𝑡 𝑚𝑚𝑚𝑚= 5%
(𝑚𝑚1), A =11.9 ($/unit).It can be observed that as imperfection in processes increase, quality costs shoots up and
optimal lot size is increased. This impact of imperfection on quality cost and optimum lot size has also been
shown in Fig.3. Quality costs are almost negligible when there processes are perfect and goes on increasing as
imperfection in the form of rework and rejected products increases.
Table 2.Impact of imperfection on quality cost in inventory model.
Case No. 𝑝𝑝𝑏𝑏(%) 𝑝𝑝1𝑟𝑟(%) GTOQIRR Setup cost WIP cost Finish goods cost Quality cost (IRR)
1 0 0 943 176.63 17.81 471.61 0.01
2 5 5 1037 169.05 20.01 492.76 1511.78
3 10 10 1139 162.57 22.59 512.40 3189.48
4 15 15 1248 157.00 25.64 530.57 5062.92
5 20 20 1368 152.22 29.28 547.23 7169.20
6 25 25 1499 148.14 33.67 562.29 9555.25
Fig. 3 Change in optimal lot size and quality cost (IRR) with change in Imperfection
V. Conclusion
The importance of quality in manufacturing
setups cannot be neglected in general and particularly
in environments where machining work is large
relatively. Boucher [20] realized in his model that
GTOQ is good for high machining environments.
This increased machining ultimately impact quality
costs as well. Impact of quality costs on lot size has
not been considered till now while developing such
models for work in process inventories. Different
inventory models are developed during last few
decades to solve the real world problems and
optimize the lot size as per actual scenarios. However
work in process based inventory model are lacking
the component of quality costs in their previously
developed models especially when the imperfection
and high machining rate of processes are considered.
This paper is an attempt towards the development of
such model for imperfect process considering IRR
quality cost component. The proposed model is of
significance for manufacturing environments having
concentration on quality costs. It is more generalized
and incorporate all aspects of the previously
developed models. This research can be further
extended by estimating the effect of shortages and
machine breakdowns on lot size focusing work in
process inventory.
VI. Acknowledgment:
The author would like to express his gratitude to
all anonymous editors and referees for their valuable
comments.
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