This document discusses utilizing value stream mapping to optimize production lead times for heavy duty earth-moving vehicles. It presents a case study of applying lean tools like value stream mapping, kaizen, kanban, and production leveling to reduce waste and lead times in the production of dummy axles at an automobile manufacturing plant in India. Currently, the plant produces 247 dummy axles per day but wants to increase production to 270 axles per day without additional capital costs. It aims to reduce the manufacturing lead time from 60 to 45 minutes and reduce in-process inventory levels and non-value added time through this lean improvement project.
The International Journal of Engineering & Science is aimed at providing a platform for researchers, engineers, scientists, or educators to publish their original research results, to exchange new ideas, to disseminate information in innovative designs, engineering experiences and technological skills. It is also the Journal's objective to promote engineering and technology education. All papers submitted to the Journal will be blind peer-reviewed. Only original articles will be published.
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.
The International Journal of Engineering & Science is aimed at providing a platform for researchers, engineers, scientists, or educators to publish their original research results, to exchange new ideas, to disseminate information in innovative designs, engineering experiences and technological skills. It is also the Journal's objective to promote engineering and technology education. All papers submitted to the Journal will be blind peer-reviewed. Only original articles will be published.
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.
The Impact of Lean Production on the Cycle Time: A Case Study of a Welding As...ijsrd.com
The growing global competition is forcing the organisations to reduce the cost for increasing the profit. Lean manufacturing is a powerful tool for attaining this. The history of lean manufacturing starts from the craft production of 1900's. It is evolved through the contributions of F.W. Taylor, Henry Ford, Eiji Toyoda & Taiichi Ohno. The main concept of the lean manufacturing is the reduction in cost by eliminating waste. However, not all lean implementations have produced such results. In this study, a critical examination of lean manufacturing implementation experience at the welding department of a medium size industry located in Kerala, India. . Cycle time reduction is an important way by eliminating or reducing non-value-added activities. To reduce the overall cycle time of manufacturing, the cycle time of each sub-assembly needs to be reduced. Reducing cycle time will have a significant impact on a company's bottom line when implemented. The outcome of this study leads to substantial reduction in cycle time, reduced defects, better utilization of human resource and machines, and reduced cost of maintenance. It has been proved and validated by an empirical relation. The cause and effect diagram is used for analysing the cycle time reduction. The Quality control chart is also used. The improved return on investment (ROI) and reduction in cycle time shows the feasibility. The data for this study were obtained through interviews, Questionnaire survey and archival sources.
Methods and Techniques to Improve the Design of Cell Phones Using Quality Fun...Prathamesh Mohite
With the advancement of technology the world is becoming increasingly interconnected, both
economically and socially. Over the years there has been a significant increase in the percentage of people
accessing the internet and using a mobile phone. The quality of mobile services and the smartphones is
ultimately judged on the basis of one key factor that is, customer satisfaction. This is particularly true in case of
third or fourth generation connectivity. For this purpose we make use of QFD to acquire and analyse the
voice of customer (VOC) and then transform it into product requirements and quality assurance measures
throughout the design, build, test, commercialisation and even product retirement process. In this paper we
have presented an example to illustrate the use of QFD in the process of designing a smartphone based on
customer reviews and their requirements.
Supply Chain Management Assignment on Lean manufacturing wit real life Exampl...Yamini Kahaliya
This document is on Lean manufacturing with real life example of Jaguar company.
this is short assignment.
it includes -
1. Meaning of Lean manufacturing system
2. Objective of Lean manufacturing system
3. Principles of lean manufacturing system
4. Types of waste in traditional production system
5. Tools & Techniques of Lean manufacturing system
6. Case study on Jaguar -
7. Introduction of Company
8. Case study
9. Conclusion
10. Bibliography
LAYOUT DESIGN AND RANKING THE FACILITY DESIGN OF CREAM MANUFACTURING PLANT BY...Majid Babaie, MBA, PMP
Layout problems are found in a variety of production systems. Normally layout problems are related to facilitate
place (e.g., machinery, parts, etc.) in a factory. These facilities are heavily influenced by the performance of the system as well as having an effect on system performance. Several studies have been conducted related to facility design. When facilities design software or the design factory offered several final designs to the director, selecting an option for the manager will be difficult. This paper presents an approach based on Multi-Criteria Decision Method by which a director can be selected the best option of several designs. Purpose of review discussed the facility's manufacturing plant creams.
First the units and then the required facilities for each unit are introduced. Then with the engineers and designers with
software factory began layout design facility at the plant and finally, four projects were presented. Then fuzzy TOPSIS methods to rank were proposed projects.
A STUDY OF ENQUIRY RESPONSE LEAD TIME AND CAPACITY UTILIZATION AT PEEKAY STEE...Muhammed Anaz PK
Analyzed the Existing Enquiry Response System and found its Problems and reasons for delay in getting quotation from Clients and Suggestions are Submitted with the Operational Manager. also studied the Capacity utilization at the Machine Shop, a section where final Boring, Drilling, Phasing took place under Production Department. Worker, Machine and Helper Utilization are Calculated based on the Time data.
Decisions Optimization Related to the Production Within Refining and Petroche...ijtsrd
The paper underlines the use of quantitative analyses and mathematical models to optimize the decision within companies from oil and gas industry. It will be presented a case study from a refinery that use RPMS Refinery and Petrochemical Modeling System software for optimizing LPG blends. Catalin Popescu "Decisions Optimization Related to the Production Within Refining and Petrochemical Industry" Published in International Journal of Trend in Scientific Research and Development (ijtsrd), ISSN: 2456-6470, Volume-3 | Issue-1 , December 2018, URL: http://www.ijtsrd.com/papers/ijtsrd20189.pdf
http://www.ijtsrd.com/management/operations-management/20189/decisions-optimization-related-to-the-production-within-refining-and-petrochemical-industry/catalin-popescu
Six Sigma DMADV Approach for Conceptual Design Synthesis of Car DashboardJayesh Sarode
The main goals of Six Sigma need to incorporate
these specific expected outcomes for the program, and
typically fall within the key areas like Quality, Variability,
Productivity. Without attacking quality issues in any process,
all other improvement efforts will certainly come up short. For
doing that Six Sigma implementation can differ widely
between organizations, depending on their individual goals
and operational strategies.
In this project I have successfully applied many design
processes related with six sigma like Identify Customer CTQs/
Customer Survey, develop a Fishbone Diagram, Input
Requirement Checklist, Quality Function Deployment, Design
Concepts (Competitive assessments (Benchmarking), Tradeoff
Analysis, Engineering Analysis - Develop System & Subsystem
Models, Error Proofing and Fixing, Validation, etc.
The aim is to achieve the essential function at the lowest
overall cost while maintaining customers’ optimum value
assurance. In this project I try to develop a such dashboard
design which follow a plastic design guideline, and analyze
and discuss the results to Obtain valid conclusions which
follows a design Standards. Plastic part dashboard is designed
by following Plastic trim design guidelines as well as DFM
(Design for manufacturing) and DFA (Design for Assembly)
guidelines. This project intends to explore the adoption of Six
sigma as a value creation tool. This project presents the basics
of Six sigma and its different phases that can be implemented
to a dashboard for its optimization.
The Impact of Lean Production on the Cycle Time: A Case Study of a Welding As...ijsrd.com
The growing global competition is forcing the organisations to reduce the cost for increasing the profit. Lean manufacturing is a powerful tool for attaining this. The history of lean manufacturing starts from the craft production of 1900's. It is evolved through the contributions of F.W. Taylor, Henry Ford, Eiji Toyoda & Taiichi Ohno. The main concept of the lean manufacturing is the reduction in cost by eliminating waste. However, not all lean implementations have produced such results. In this study, a critical examination of lean manufacturing implementation experience at the welding department of a medium size industry located in Kerala, India. . Cycle time reduction is an important way by eliminating or reducing non-value-added activities. To reduce the overall cycle time of manufacturing, the cycle time of each sub-assembly needs to be reduced. Reducing cycle time will have a significant impact on a company's bottom line when implemented. The outcome of this study leads to substantial reduction in cycle time, reduced defects, better utilization of human resource and machines, and reduced cost of maintenance. It has been proved and validated by an empirical relation. The cause and effect diagram is used for analysing the cycle time reduction. The Quality control chart is also used. The improved return on investment (ROI) and reduction in cycle time shows the feasibility. The data for this study were obtained through interviews, Questionnaire survey and archival sources.
Methods and Techniques to Improve the Design of Cell Phones Using Quality Fun...Prathamesh Mohite
With the advancement of technology the world is becoming increasingly interconnected, both
economically and socially. Over the years there has been a significant increase in the percentage of people
accessing the internet and using a mobile phone. The quality of mobile services and the smartphones is
ultimately judged on the basis of one key factor that is, customer satisfaction. This is particularly true in case of
third or fourth generation connectivity. For this purpose we make use of QFD to acquire and analyse the
voice of customer (VOC) and then transform it into product requirements and quality assurance measures
throughout the design, build, test, commercialisation and even product retirement process. In this paper we
have presented an example to illustrate the use of QFD in the process of designing a smartphone based on
customer reviews and their requirements.
Supply Chain Management Assignment on Lean manufacturing wit real life Exampl...Yamini Kahaliya
This document is on Lean manufacturing with real life example of Jaguar company.
this is short assignment.
it includes -
1. Meaning of Lean manufacturing system
2. Objective of Lean manufacturing system
3. Principles of lean manufacturing system
4. Types of waste in traditional production system
5. Tools & Techniques of Lean manufacturing system
6. Case study on Jaguar -
7. Introduction of Company
8. Case study
9. Conclusion
10. Bibliography
LAYOUT DESIGN AND RANKING THE FACILITY DESIGN OF CREAM MANUFACTURING PLANT BY...Majid Babaie, MBA, PMP
Layout problems are found in a variety of production systems. Normally layout problems are related to facilitate
place (e.g., machinery, parts, etc.) in a factory. These facilities are heavily influenced by the performance of the system as well as having an effect on system performance. Several studies have been conducted related to facility design. When facilities design software or the design factory offered several final designs to the director, selecting an option for the manager will be difficult. This paper presents an approach based on Multi-Criteria Decision Method by which a director can be selected the best option of several designs. Purpose of review discussed the facility's manufacturing plant creams.
First the units and then the required facilities for each unit are introduced. Then with the engineers and designers with
software factory began layout design facility at the plant and finally, four projects were presented. Then fuzzy TOPSIS methods to rank were proposed projects.
A STUDY OF ENQUIRY RESPONSE LEAD TIME AND CAPACITY UTILIZATION AT PEEKAY STEE...Muhammed Anaz PK
Analyzed the Existing Enquiry Response System and found its Problems and reasons for delay in getting quotation from Clients and Suggestions are Submitted with the Operational Manager. also studied the Capacity utilization at the Machine Shop, a section where final Boring, Drilling, Phasing took place under Production Department. Worker, Machine and Helper Utilization are Calculated based on the Time data.
Decisions Optimization Related to the Production Within Refining and Petroche...ijtsrd
The paper underlines the use of quantitative analyses and mathematical models to optimize the decision within companies from oil and gas industry. It will be presented a case study from a refinery that use RPMS Refinery and Petrochemical Modeling System software for optimizing LPG blends. Catalin Popescu "Decisions Optimization Related to the Production Within Refining and Petrochemical Industry" Published in International Journal of Trend in Scientific Research and Development (ijtsrd), ISSN: 2456-6470, Volume-3 | Issue-1 , December 2018, URL: http://www.ijtsrd.com/papers/ijtsrd20189.pdf
http://www.ijtsrd.com/management/operations-management/20189/decisions-optimization-related-to-the-production-within-refining-and-petrochemical-industry/catalin-popescu
Six Sigma DMADV Approach for Conceptual Design Synthesis of Car DashboardJayesh Sarode
The main goals of Six Sigma need to incorporate
these specific expected outcomes for the program, and
typically fall within the key areas like Quality, Variability,
Productivity. Without attacking quality issues in any process,
all other improvement efforts will certainly come up short. For
doing that Six Sigma implementation can differ widely
between organizations, depending on their individual goals
and operational strategies.
In this project I have successfully applied many design
processes related with six sigma like Identify Customer CTQs/
Customer Survey, develop a Fishbone Diagram, Input
Requirement Checklist, Quality Function Deployment, Design
Concepts (Competitive assessments (Benchmarking), Tradeoff
Analysis, Engineering Analysis - Develop System & Subsystem
Models, Error Proofing and Fixing, Validation, etc.
The aim is to achieve the essential function at the lowest
overall cost while maintaining customers’ optimum value
assurance. In this project I try to develop a such dashboard
design which follow a plastic design guideline, and analyze
and discuss the results to Obtain valid conclusions which
follows a design Standards. Plastic part dashboard is designed
by following Plastic trim design guidelines as well as DFM
(Design for manufacturing) and DFA (Design for Assembly)
guidelines. This project intends to explore the adoption of Six
sigma as a value creation tool. This project presents the basics
of Six sigma and its different phases that can be implemented
to a dashboard for its optimization.
Improvement of Productivity Using Value Stream Mappingijsrd.com
one of the most appropriate ways to emerge the productivity for the particular area is through Lean Manufacturing. Value stream mapping is that lean manufacturing tool which helps to improve the productivity for the area through its detailed mapping. It is the visualize tool which describes the current state map followed by lean techniques resulting into the final state map that aiming at reduction of the non-value added activities throughout its phase. This paper illustrates the review of VSM techniques and its benefits in machining industry. The purpose of this paper is to highlight the effective utilization of the VSM tools for process and productivity improvements.
Development of new products is extremely essential for the success and smooth running of every industry. Companies have to constantly inject innovations and design efforts to make the design processes easy and to attract consumers in a constantly in a evolving and highly competitive market with best quality . Keeping ahead of the competition by bringing new and exciting products to market fast, and at the necessary level of quality, presents a major engineering challenge. A new casting bracket in place of old stamping brackets in snowmobile chassis development process is described, which introduces advanced FEM and Optimization technology into the concept development phase. Detailed predictions of interacting parts in a mechanism assembly are made possible through use of value engineering based process and material selection and advanced simulation technology. Design optimization is then employed using the modeling as a virtual testing ground for design variants. The approach provides clear design direction and helps to improve performance and reduce the unnecessary welding efforts of bracket manufacturing. Design is an intelligent activity that begins with design requirements and ends with a product description. Using Altair Optistruct was able to significantly reduce design time by sub modeling with structural optimization. The resultant casting bracket design showed superior performance characteristics. And finely the manufacturer had to put less efforts in stamping and part welding , which reduced the manufacturing time and cost also.
The International Journal of Engineering & Science is aimed at providing a platform for researchers, engineers, scientists, or educators to publish their original research results, to exchange new ideas, to disseminate information in innovative designs, engineering experiences and technological skills. It is also the Journal's objective to promote engineering and technology education. All papers submitted to the Journal will be blind peer-reviewed. Only original articles will be published.
The Art of the Pitch: WordPress Relationships and SalesLaura Byrne
Clients don’t know what they don’t know. What web solutions are right for them? How does WordPress come into the picture? How do you make sure you understand scope and timeline? What do you do if sometime changes?
All these questions and more will be explored as we talk about matching clients’ needs with what your agency offers without pulling teeth or pulling your hair out. Practical tips, and strategies for successful relationship building that leads to closing the deal.
Securing your Kubernetes cluster_ a step-by-step guide to success !KatiaHIMEUR1
Today, after several years of existence, an extremely active community and an ultra-dynamic ecosystem, Kubernetes has established itself as the de facto standard in container orchestration. Thanks to a wide range of managed services, it has never been so easy to set up a ready-to-use Kubernetes cluster.
However, this ease of use means that the subject of security in Kubernetes is often left for later, or even neglected. This exposes companies to significant risks.
In this talk, I'll show you step-by-step how to secure your Kubernetes cluster for greater peace of mind and reliability.
Dev Dives: Train smarter, not harder – active learning and UiPath LLMs for do...UiPathCommunity
💥 Speed, accuracy, and scaling – discover the superpowers of GenAI in action with UiPath Document Understanding and Communications Mining™:
See how to accelerate model training and optimize model performance with active learning
Learn about the latest enhancements to out-of-the-box document processing – with little to no training required
Get an exclusive demo of the new family of UiPath LLMs – GenAI models specialized for processing different types of documents and messages
This is a hands-on session specifically designed for automation developers and AI enthusiasts seeking to enhance their knowledge in leveraging the latest intelligent document processing capabilities offered by UiPath.
Speakers:
👨🏫 Andras Palfi, Senior Product Manager, UiPath
👩🏫 Lenka Dulovicova, Product Program Manager, UiPath
A tale of scale & speed: How the US Navy is enabling software delivery from l...sonjaschweigert1
Rapid and secure feature delivery is a goal across every application team and every branch of the DoD. The Navy’s DevSecOps platform, Party Barge, has achieved:
- Reduction in onboarding time from 5 weeks to 1 day
- Improved developer experience and productivity through actionable findings and reduction of false positives
- Maintenance of superior security standards and inherent policy enforcement with Authorization to Operate (ATO)
Development teams can ship efficiently and ensure applications are cyber ready for Navy Authorizing Officials (AOs). In this webinar, Sigma Defense and Anchore will give attendees a look behind the scenes and demo secure pipeline automation and security artifacts that speed up application ATO and time to production.
We will cover:
- How to remove silos in DevSecOps
- How to build efficient development pipeline roles and component templates
- How to deliver security artifacts that matter for ATO’s (SBOMs, vulnerability reports, and policy evidence)
- How to streamline operations with automated policy checks on container images
Essentials of Automations: Optimizing FME Workflows with ParametersSafe Software
Are you looking to streamline your workflows and boost your projects’ efficiency? Do you find yourself searching for ways to add flexibility and control over your FME workflows? If so, you’re in the right place.
Join us for an insightful dive into the world of FME parameters, a critical element in optimizing workflow efficiency. This webinar marks the beginning of our three-part “Essentials of Automation” series. This first webinar is designed to equip you with the knowledge and skills to utilize parameters effectively: enhancing the flexibility, maintainability, and user control of your FME projects.
Here’s what you’ll gain:
- Essentials of FME Parameters: Understand the pivotal role of parameters, including Reader/Writer, Transformer, User, and FME Flow categories. Discover how they are the key to unlocking automation and optimization within your workflows.
- Practical Applications in FME Form: Delve into key user parameter types including choice, connections, and file URLs. Allow users to control how a workflow runs, making your workflows more reusable. Learn to import values and deliver the best user experience for your workflows while enhancing accuracy.
- Optimization Strategies in FME Flow: Explore the creation and strategic deployment of parameters in FME Flow, including the use of deployment and geometry parameters, to maximize workflow efficiency.
- Pro Tips for Success: Gain insights on parameterizing connections and leveraging new features like Conditional Visibility for clarity and simplicity.
We’ll wrap up with a glimpse into future webinars, followed by a Q&A session to address your specific questions surrounding this topic.
Don’t miss this opportunity to elevate your FME expertise and drive your projects to new heights of efficiency.
Elevating Tactical DDD Patterns Through Object CalisthenicsDorra BARTAGUIZ
After immersing yourself in the blue book and its red counterpart, attending DDD-focused conferences, and applying tactical patterns, you're left with a crucial question: How do I ensure my design is effective? Tactical patterns within Domain-Driven Design (DDD) serve as guiding principles for creating clear and manageable domain models. However, achieving success with these patterns requires additional guidance. Interestingly, we've observed that a set of constraints initially designed for training purposes remarkably aligns with effective pattern implementation, offering a more ‘mechanical’ approach. Let's explore together how Object Calisthenics can elevate the design of your tactical DDD patterns, offering concrete help for those venturing into DDD for the first time!
Smart TV Buyer Insights Survey 2024 by 91mobiles.pdf91mobiles
91mobiles recently conducted a Smart TV Buyer Insights Survey in which we asked over 3,000 respondents about the TV they own, aspects they look at on a new TV, and their TV buying preferences.
Generative AI Deep Dive: Advancing from Proof of Concept to ProductionAggregage
Join Maher Hanafi, VP of Engineering at Betterworks, in this new session where he'll share a practical framework to transform Gen AI prototypes into impactful products! He'll delve into the complexities of data collection and management, model selection and optimization, and ensuring security, scalability, and responsible use.
Welocme to ViralQR, your best QR code generator.ViralQR
Welcome to ViralQR, your best QR code generator available on the market!
At ViralQR, we design static and dynamic QR codes. Our mission is to make business operations easier and customer engagement more powerful through the use of QR technology. Be it a small-scale business or a huge enterprise, our easy-to-use platform provides multiple choices that can be tailored according to your company's branding and marketing strategies.
Our Vision
We are here to make the process of creating QR codes easy and smooth, thus enhancing customer interaction and making business more fluid. We very strongly believe in the ability of QR codes to change the world for businesses in their interaction with customers and are set on making that technology accessible and usable far and wide.
Our Achievements
Ever since its inception, we have successfully served many clients by offering QR codes in their marketing, service delivery, and collection of feedback across various industries. Our platform has been recognized for its ease of use and amazing features, which helped a business to make QR codes.
Our Services
At ViralQR, here is a comprehensive suite of services that caters to your very needs:
Static QR Codes: Create free static QR codes. These QR codes are able to store significant information such as URLs, vCards, plain text, emails and SMS, Wi-Fi credentials, and Bitcoin addresses.
Dynamic QR codes: These also have all the advanced features but are subscription-based. They can directly link to PDF files, images, micro-landing pages, social accounts, review forms, business pages, and applications. In addition, they can be branded with CTAs, frames, patterns, colors, and logos to enhance your branding.
Pricing and Packages
Additionally, there is a 14-day free offer to ViralQR, which is an exceptional opportunity for new users to take a feel of this platform. One can easily subscribe from there and experience the full dynamic of using QR codes. The subscription plans are not only meant for business; they are priced very flexibly so that literally every business could afford to benefit from our service.
Why choose us?
ViralQR will provide services for marketing, advertising, catering, retail, and the like. The QR codes can be posted on fliers, packaging, merchandise, and banners, as well as to substitute for cash and cards in a restaurant or coffee shop. With QR codes integrated into your business, improve customer engagement and streamline operations.
Comprehensive Analytics
Subscribers of ViralQR receive detailed analytics and tracking tools in light of having a view of the core values of QR code performance. Our analytics dashboard shows aggregate views and unique views, as well as detailed information about each impression, including time, device, browser, and estimated location by city and country.
So, thank you for choosing ViralQR; we have an offer of nothing but the best in terms of QR code services to meet business diversity!
State of ICS and IoT Cyber Threat Landscape Report 2024 previewPrayukth K V
The IoT and OT threat landscape report has been prepared by the Threat Research Team at Sectrio using data from Sectrio, cyber threat intelligence farming facilities spread across over 85 cities around the world. In addition, Sectrio also runs AI-based advanced threat and payload engagement facilities that serve as sinks to attract and engage sophisticated threat actors, and newer malware including new variants and latent threats that are at an earlier stage of development.
The latest edition of the OT/ICS and IoT security Threat Landscape Report 2024 also covers:
State of global ICS asset and network exposure
Sectoral targets and attacks as well as the cost of ransom
Global APT activity, AI usage, actor and tactic profiles, and implications
Rise in volumes of AI-powered cyberattacks
Major cyber events in 2024
Malware and malicious payload trends
Cyberattack types and targets
Vulnerability exploit attempts on CVEs
Attacks on counties – USA
Expansion of bot farms – how, where, and why
In-depth analysis of the cyber threat landscape across North America, South America, Europe, APAC, and the Middle East
Why are attacks on smart factories rising?
Cyber risk predictions
Axis of attacks – Europe
Systemic attacks in the Middle East
Download the full report from here:
https://sectrio.com/resources/ot-threat-landscape-reports/sectrio-releases-ot-ics-and-iot-security-threat-landscape-report-2024/
State of ICS and IoT Cyber Threat Landscape Report 2024 preview
D04942231
1. IOSR Journal of Engineering (IOSRJEN) www.iosrjen.org
ISSN (e): 2250-3021, ISSN (p): 2278-8719
Vol. 04, Issue 09 (September. 2014), ||V4|| PP 22-31
International organization of Scientific Research 22 | P a g e
Utilizing Value Stream Mapping for Scheduled Optimization of Heavy Duty Earth-moving Vehicles Suman Kumar Suman1 Prakash Kumar2 1Research Scholar, Production Engineering, B.I.T Sindri, Dhanbad, Jharkhand, India 2Assistant Professor, Production Engineering, B. I. T. Sindri, Dhanbad, Jharkhand India Abstract: Growth of business world these days created higher market competition, because the existing industrial market become more global and have penetrated the inter-states boundary. In this global competitive scenario every company claimed to own the excellence and competitiveness so that, probability to win the competition is greater. Their ultimate goal is to satisfy the customer with the exact product, quantity, and quality in the shortest lead-time. It can only be achieve if the company is able to create and implement effective and efficient processes in each of its line of their business. For this, Lean tools are used to focus on the continuous improvement of a company towards reduction of various wastes like inventory, transportation, waiting, motion, cost factory space, correction etc. It is a systematic approach for eliminating waste in every area of business, including customer relations, product design, process layout, manufacturing sequence/operation and supplier networks. The system includes a wide range of tools and technique that aims at reducing inventory and production lead- time and to enhance the value added time and thus optimize the whole maintenance schedule. In this paper, an attempt has made to reduce the production lead- time (Dummy axle of heavy vehicles) of an automobile industry through value stream mapping. The result shows reduction in waste and system responsiveness according to the changing customers‟ needs through value stream mapping, a lean tool. Key Words: Kaizen, Kanban, Lean manufacturing, Lead time, Pull Production, Value Stream Mapping. Lean manufacturing is based on findings efficiencies and removing wasteful steps that don‟t add value to the end product. Lean Manufacturing is widely recognized as a mechanism for ensuring improvement in the manufacturing processes. The goal of lean manufacturing is to reduce the wastes in terms of human effort, inventory, time to market and manufacturing space and become highly responsive to customer demand while producing world class quality products in most efficient and economic manner (Liker, 1998).(Todd 2000) and Shigeo Shingo (1992) strongly advocated the elimination of waste and put forth the idea, „don‟t accept waste as unavoidable‟. The basis of lean manufacturing is the elimination of waste. 1.1 Main Kinds of Waste in Lean Manufacturing: (i) Over-production (ii) Defects (iii) Inventory (iv) Transportation (v) Waiting (vi) Motion (vii) Correction (viii) Over-processing (ix) Knowledge Disconnection. II. LEAN TOOLS USED IN THIS STUDY 2.1 Kaizen- is a Japanese word for the philosophy that defines management‟s role in continuously encouraging and implementing small improvements involving everyone. It is the process of continuous improvement in small increments that make the process more efficient, effective, under control and adaptable. 2.2 Kanban- “Kanban” is a pull-based material replenishment system that uses visual signals, such as color- coded cards, to signal to upstream workstations when inputs are required by the downstream workstation. 2.3 Production Leveling - also known as production smoothing, aims to distribute production volumes and product mix evenly over time so as to minimize peaks and valleys in the workload. 2.4 Pull Production – In Pull system the production will flow from downstream to upstream as opposed to the traditional manufacturing concept. JIT is also about minimization of raw material, work in process and smooth flow of operations.
2.5 VSM- It provides various tools for data collection and analysis, in order to identify the waste occurring at different stages of manufacturing process and their impact on the overall production system. Minimization of the waste is the main objective of the lean philosophy. The role of value stream mapping is very important in the identification and subsequently reduction of waste. Value stream mapping is prescribed as part of the lean production portfoliooftoolsandhasbeenappliedinavarietyofindustries.VSM is useful in a situation like, product complexity (leading to differences in processing and set-up times across product variants),
2. Utilizing Value Stream Mapping for Scheduled Optimization of Heavy Duty Earth-moving Vehicles
International organization of Scientific Research 23 | P a g e
parallel processing steps and/or different number of shifts used across a production line. III. CASE STUDY OF A HEAVY DUTY EARTHMOVING VEHICLES (HDEMV) The case study was conducted for HDEMV in an automobile industry located in eastern part of India which was a job shop industry. There were problems related with the wastes. In this study it was confined with two major parameters: manufacturing lead time and in-process inventory. The study was conducted keeping in view of the value stream mapping of a specific product line AB of dummy axle. A dummy axle is located immediately in front of a drive axle and it is known as pusher axle. Material used in axle production is SAE Grade 41xx steel or SAE Grade 10xx steel, according to the product. SAE Grade 41xx steel has commonly known as chrome-molybdenum steel. SAE Grade 10xx steel is also known as Carbon steel. In designed features of a dummy axle, the wheels on a lazy axle only come into contact with ground when the load is significant, thus saving unnecessary tyre wear. A dummy axle, also called dead axle, is not a part of driver train but is instead free floating. Many heavy weight vehicles use dead axles for strictly load-bearing purposes. Company is also producing trailer axles, LCV front axles, tractor axle and various other axles in this unit. It has a staggering capacity to manufacture 2, 00,000 axles/year. Axles are one of the most significant products Manufactured by the Company. The monthly demand of axles is 7500 units. Time available per shift is different because break time is varying for every shift. Total number of shifts is three. Total time available for production is 1320 minute (3 shifts).
3.1 Problem Identification
In this industry two types of axle are manufacturing (i) Live axle (ii) dummy axle (dead axle).The industry was facing increased pressure both externally and internally, to improve the performance of a specific product line AB (dummy axle).These challenges are summarized in this table. Table-1:
Externally focused challenges
Internally focused challenges
1. Increased no of suppliers for this product creating more choices for the customer. 2. Ability of competitors to meet customer requirements at a lower and better service. 3. Poor delivery performance and repeated missed delivery dates.
1. Lack of definition of standard AB product line. 2. Lack of clear and consistent process for scheduling and rescheduling work. 3. Discrepancy between quoted and actual lead times increases the pressure to reduce lead time.
3.2 Objective of the Paper The main aim of this Paper is to develop strategies for elimination of operational inefficiencies and various wastes hidden in the Company by using lean manufacturing techniques like value stream mapping. In this Paper our aim is to reduce the Production lead time of dummy axle to meet the customer demand. The objective is to systematically demonstrate how lean manufacturing tools when used appropriately can help the industry to eliminate waste, have better product quality & better overall financial and operational procedures. The expectations for improvement set for the (dummy axle) AB product line include: 1. Production of 270 axles/day, based on perceived market need (current production throughput is 247 axles/day) that means, to increase the production of AB product line without incurring additional capital expense. 2. Reduction in manufacturing lead-time from 60 minutes to 45 minutes. 3. Reduction in the in – process inventories and non-value added time. 4. To enhance the service quality and on – time delivery date. 5. To enhance the system responsiveness. 3.3 Background of Problem Our aim is to offer a logically feasible and scientifically proven decision support system to select value stream mapping tools for detail analysis of waste while implementing lean manufacturing paradigm in an automobile company. Identification of the wastes having more negative impact on the organization and subsequently the selection of detailed value stream mapping tools are view a complex multi-criteria decision making problem.
3. Utilizing Value Stream Mapping for Scheduled Optimization of Heavy Duty Earth-moving Vehicles
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3.4 Current State Map Key features: Help in visualizing the flows, Help identifying waste, Pull together the lean thinking principles, Help in deciding who should be in the implementation teams, Show relationships between information and physical flows and Create buy-in from the senior team undertaking the big picture mapping. The company produces several products such as Axle, Propeller Shaft, motor, Transmission Components, Aluminum Castings etc. The focus of this value stream mapping is one product family, i.e. axle family. The customizations that occur inside a standard product family do not leads to significant differences in processing time and set-up time of other part families. Cycle times of different processing steps for different axle family are shown in Table-2. Table -2
Axle Family
Axle Family (2515DA)
Axle Family (3118DA)
Axle Family (T. Axle)
Processing stage
A (Minute)
B (Minute)
C (Minute)
Final inspection
8
8
8
Dressing and Deburring
6
7
6
Fab. Chamber, Bkt Weld
10
8
9
Machining 4
26
25
24
Z Bracket , Base plate & Assy.
5
4
5
Machining 3
7
8
8
Straightening
6
5
4
Painting
5
7
6
Shot blasting
6
5
5
SS, Flange assy. & weld
15
14
16
Lumps turning
8
9
9
Friction Welding
7
7
8
End Facing/milling
8
6
7
Machining 2
8
9
9
Machining 1
14
14
13
Shearing
5
5
7
3.5 Future state map Based on the outcome of the current state map, defects, waiting time, and different inventory, are identified as the three major wastes affecting the performance of the industry under study. In this section, the wastes concerning with inventory, overproduction and waiting are taken into account. Analytical treatment is also included by taking into account takt time, pitch, Heijunka box etc. Improvements in the existing process have been identified and accordingly future state map has been developed. The future state map is developed by answering eight questions in a straight forward manner, using approach prescribed by Rother and Shook (1999). Some questions must be answered for developing future state map. All these questions have different strategies and its applications. Based on Rother and shook‟s approach the first five topics are related to basic issues for construction of future state map. The next two topics deal with technical implementation details such as the detail of control system (heijunka box). They help in defining non-mapping details such as production mix, order release time, etc. Finally, the last topic of the section is related to the definition of effort or actions needed (kaizen) to migrate from the current state to the future state. 3.5.1 Takt time Takt Time = Available working time per day/Customer demand per day Takt Time= (22 hrs. x 60 min//h) / 247 motors =
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5.5 min/Axle (approx.) 3.5.2 Production finished goods supermarket A supermarket is nothing more than a buffer area for storage of the products that are ready to be shipped and is located at the end of the production line. 3.5.3 Pull system supermarket Sixteen additional pull system supermarkets are needed to create a continuous flow at complete dummy axle assembly depending on up- time, changeover time and percentage defects at different processing stages. Average cycle time (taking into consideration number of resources available) of different processing stages for different axle family are found. On the basis of average cycle time we calculate the average daily and monthly demand (42, 163, 42 for axle part family A, B, C respectively). The next step is to calculate lot size, trigger point and number of kanban for different supermarkets. 3.5.4 Formulae for change-over, lot size & number of kanban: di= Defect rate, Cri= average cycle time per piece Dd = Daily demand of product in piece T = Time available per shift X Number of shifts per day Required run time for product in minutes, Ri = (1+di/100) X Cri X Dd Net available time for set-up and changeover, Ts = T- Σ Ri Average Down time(Including set up and Changeover time) = Total working hours X Down time No of changeover per day= Total time available for changeover (Minutes)/ Average changeover time for every product. Total run time per day= 440 minutes X 3=1320 minutes, Required run time per day= average cycle time /day X average demand/day (for product A+B+C) =385 minutes; Time available for change over = net available time – avg. d/t. =738 minutes (approx.); Number of changeovers per day =time available for changeover / change over time= 82.034 = 82 changeovers per day. (Ref. Table No. 5) Calculation of batch factor: Batch factor= Number of product family / Number of changeover per day = 0.037Setting up a lot size for production: By multiplying batch factor* demand / day(Lot size = Numbers of kanban) =3 pieces (0+3+0) Establish a trigger point for reorder: Trigger point= Total lead time to replenish / takt time By exercising all the four steps, we can determine the time available for changeover/cycle time per day, average lot size for production and trigger point for reorder of 16 pull system supermarkets in a whole value stream. Calculation of trigger point for reorder is only necessary for some supermarkets because changeover time is more &company needs a triangle kanban. In other supermarket changeover time are less, so calculation of trigger point for reorder is not necessary and simple withdrawal kanbans are used. Inventory levels at various supermarkets : By proceeding the same way in all the supermarkets we can calculate required run time / day, time required / day, to meet average demand, net time available for set-ups and change- over, average down time, desired number of change-over / day ,batch factors, lot size and number of kanban or ,inventory levels at various supermarkets. Tables No5.0 provides details of lot size, number of Kanbans, total lead-time, takt time, and trigger point for reorder to the supermarkets ahead of every processing stage and is calculated on the basis of aforementioned equations. Similarly, we can calculate lot size, number of Kanbans, total lead- time, takt time, and trigger point for reorder from one supermarket to the other supermarket. 3.5.5 Continuous flow Whenever the supermarkets are at their full capacity then the respective processing stage switched to make other product types. To stop overproduction at any workstation in the value stream, only one processing stage in the supplier to customer value stream needs to be scheduled. The processing stage is called the pacemaker process, because this point sets the pace of production for all the upstream process together. 3.5.6 Production at the pacemaker process / Production leveling
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The basis for addressing Pacemaker process is to distribute the production of the three axes part families uniformly over the production line at the pace maker process. To determine the production sequence, level the product mix in a given pitch interval and produce the three different products at constant rate. The relationship used is: qir =(r-0.5) (Q / Ddi) Here Q= Total no of product demand in one day Ddi = Demand quantity of A, B, C product r = 1, 2, 3………n Table-3 Production sequence for smooth production
Product(i)
Unit(r)
qir
qir(Sorted)
Product(i) Sorted
A
1
2.940
0.757
B
A
2
8.821
2.273
B
A
3
14.702
2.940
A
A
4
20.33
2.940
C
A
5
26.46
3.788
B
A
6
32.34
5.303
B
A
7
38.226
6.8190
B
A
8
44.107
8.821
A
3.5.7 Pitch for pacemaker process Depending upon the sequence determined by the production leveling, one should release and withdraw (the “pitch”) the increment of production from the pacemaker process? The pitch is the basic time unit of the production schedule for a axle family. Table-4 Number of pitches for every product
Product
Time interval per pitch
A
1305/42 = 31 Minute
B
1305/54 = 24 Minute
C
1305/42 = 31 minute
3.5.8 Process Improvements: To realize future state map, it is essential for the company to incorporate improvements in the material and information flow as envisioned after intensive analysis of various processes. Whatever is the value of takt time, pitch, kanban control and production leveling etc. discussed in the steps to formulate future state map, it may not lead to the improvements in production unless specific efforts are directed to improve the processes by involving specific set of lean tools. Lot size, trigger point and no of kanban for supermarket between z bracket, base plate weld & Machining 4. Table No 5
Part
Average demand per day (pieces)
Average Cycle time per piece (min)
Average change- over time (min)
Average scrap rate
Down time
Required run time per day (min)
A
42
1.625
9
7%
15%
68.25
B
163
1.5625
9
7%
15%
254.687
C
42
1.500
9
7%
15%
63.00
385.937
Net time available for setup and change over (min.)
934.063
Average down time (not including setup and changeover) min.
195.75
Time available for change over (min.)
738.313
Desired number of changeover per day
82.034
Batch Factor = number of parts/ desired no of changeovers per day
0.036
Products
Lot size
No. of Kanban ( Containers)
Total Lead Time(min)
A
2
2
18
B
6
6
25
C
2
2
18
First container time
=
3 minutes
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Fig. 1 Product flow diagram of HDEMV Part
7. Utilizing Value Stream Mapping for Scheduled Optimization of Heavy Duty Earth-moving Vehicles
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Fig. 2 Current State Map for Process Scheduling
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Machining1 contains these processes (i) Pressing of half (ii) Beveling and Plasma Cutting (iii) Sub assembly of half Machining 2 contains (i) Root weld (ii) Linear Weld (iii) Filler weld Assembly & weld contains (i) flange assembly and No punching (ii) SS bottom and top assembly (iii) Flange welding(iv) SS bottom and top weld Machining 3 contains (i) CNC turning (ii) SS top milling Machining 4 contains (i) Z bracket milling (ii) Flange Drilling (iii) SS top drilling (iv) CNC grinding (v) Notch Milling & plate drilling Fig. 3 Future State Map for Scheduled Optimization IV. RESULTS & DISCUSSION OF CASE STUDY Three wastes identified as vital wastes after analysis i.e. inventory, overproduction and waiting. These wastes must been addressed through value stream mapping (developed in the future state map). The axle manufacturing company must adapt to a change to have a flexible production system. Sixteen pull system super markets have suggested at different stages. The lot size and the number of kanban requirements at each super market are calculated. Triangular kanbans are utilized for replenishment of three super markets which are located after the processing stage (Machining1, SS Flange assembly & Weld and Machining 4) having higher set up time and requiring higher inventory level.
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This means that only when the inventory level reaches the trigger point, a triangular kanban will be send to the succeeding stage to produce the whole lot of the product according to the lot size. The same cycle keeps on repeating for different products within a day according to the production sequence (B-B-A-C-B) and number of pitches per day. The whole production system runs on the principle of pull system of manufacturing and the products are manufactured only when they are required by the application of pull system, a drastic reduction in the in-process inventory, and elimination of waste related to over production is anticipated. The inventory lead- time falls from 60minutes to 34minutes. Therefore, reduction of in-process inventory by 43% has estimated by implementation of the future state map. 4.1 Future scope: Future studies should integrate the approach with economic measures to express both value-added and non- value-added costs sustained through the process. The primary goal is to develop simulation model for balance throughput, WIP and production lead-time and also integrate simulation model through value stream mapping. Simulation makes not only testing ideas easier, cheaper and quicker, but also gives immediate assessment of proposed changes to the system. Different objectives, such as cost minimization, machine availability maximization, should explore to examine the performance of the simulation model. Secondly, a more substantiate simulation model should be constructed to incorporate more practical issues by relaxing some assumptions. Simulation models have to be developed by observing the actual processing times of activities in the process and then characterizing their variation by statistical distributions. V. CONCLUSION The main aim of this paper is to develop the various strategies to minimize the wastes that existed in the AB product line in form of operational in-efficiencies, in process inventory and manufacturing lead-time. It has observed that wastes occur in different layer at different processing stages and to overcome this, continuous improvement is necessary, this will not only lead to waste minimization but also enable the company to survive and prosper in a competitive environment of continuous and unpredictable change. Value stream mapping (VSM) has proven not only to be universal but also to be universally successful at improving results. When applied appropriately for scheduled optimization, VSM is a well- understood and well-tested technique upon which simulation models has to be build. REFERENCES Journal Papers:
[1] Abbett, D., & Payne.V., Gulfstream Value stream tour, 1999 Lean Summit (Atlanta, GA, Lean Enterprise Institute).
[2] Hines, P, and Rich N, 1997, The seven value stream mapping tools, international Journal of Operation and Production Management, 17(1), 46-64.
[3] Hines P, Rich N, Bicheno J, Brunt D, Taylore D, 1998, Value stream Management, International Journal of Logistic Management, 9 (1), 25-42.
[4] Prakash Kumar, R.K Srivastava (2014), Implementing Lean and Agile Manufacturing System in Electric Motor Assembly Industry for Sustainable Environment, in an International Journal, Manufacturing Technology & Research, (Jan –June 2014).
[5] Rother, M., and Shook, J., 1999, Learning to See: Value stream mapping to add value and eliminate muda (1.2 edition; Brookline, MA: The Lean Enterprise Institute Inc.)
[6] Yusuf, Y.Y. and Adeleye, E.O. (2002), “A comparative study of lean and agile manufacturing with a related survey of current practices in the UK”, International Journal of Production Research, Vol. 40 No. 17, pp. 4545-62.
Books:
[7] Black, J., 1991, The Design of factory with a future (McGraw-Hill, New York).
[8] Liker, J., 2004, The Toyota Way: 14 Management Principles from the World’s Greatest Manufacturer, McGraw-Hill, New York, NY.
[9] M. Kitno, Toyota production systems: One-by-one configuration, Lean Manuf. Conf., University of Kentucky, May 14-16, 1997, pp.: 1-8.
[10] Monden, Y., 1998, Toyota Production System –An Integrated Approach to Just- in-time(3rd Edition; Norcross, Georgia: Engineering and Management Press).
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Thesis:
[11] Prakash Kumar “Development of Strategies for minimization of Wastes in manufacturing industry through Lean Techniques” BIT Sindri, Dhanbad, 2009.
Proceedings Papers:
[12] Bergmiller, G.G., and McCright, P.R., 2009, “Parallel Models for Lean and Green Operations,” Proceedings of the 2009 Industrial Engineering Research Conference, Miami, FL, May 2009.
[13] Gary G. Bergmiller & Paul R. McCright ,A Zero Waste Management Strategy to Reduce the Cost of Alternative Energy :Proceeding of 2009 Industrial Engineering & Research Conference.
[14] Prakash Kumar, Srivastava.R.K “Role of Lean Manufacturing in Quality Engineering System” in National Workshop on “Technological Excellence of 21st Century-The Road Ahead” from 8th – 9th Feb. 2008 at B.I.T. Sindri. Pg.141-152.