The document presents a case study on implementing Overall Equipment Effectiveness (OEE) on a CNC table type boring and milling machine at a heavy machinery manufacturing industry. Initial OEE calculations found the machine's OEE to be 62%, below the world-class level of 85%. Suggestions were made to reduce changeover, break, and downtime, which improved the OEE to 75%. Further improvements could bring the OEE closer to the target world-class level.
Improving productivity for engine crank shaft machining line using tps techni...IAEME Publication
The document summarizes research on improving productivity for an engine crankshaft machining line using Toyota Production System (TPS) techniques and simulation. It analyzes the existing line configuration using time study, standard work combination tables, and Arena simulation. This identifies idle time and imbalance. A proposed configuration with 6 operators is developed using line balancing calculations. Simulation shows the proposed configuration maintains output while reducing man-hours by 14.3% and improving productivity by 16.6%, saving an estimated $312,000 annually in labor costs.
STUDIES ON AVAILABILITY AND UTILISATION OF MINING EQUIPMENT- AN OVERVIEWIAEME Publication
In any opencast mining project, the major share of initial capital investment goes towards the excavation and transportation equipment. Hence it i s very important to analyse the performance of those equipment, at regular intervals to achieve co st- effectiveness in excavation and transportation operations. In this paper, an attempt is made to calculate the percentage availability and utilisation of shovel, dumpers and dozer, employed in an opencast mine and to analyse the contributing factors to improve the overall equipment performance.
IRJET- Comparative Performance Study of Mine Trucks by Overall Equipment Effe...IRJET Journal
This document discusses measuring the effectiveness of mining equipment using Overall Equipment Effectiveness (OEE). OEE is calculated based on availability, performance, and quality to identify sources of productivity loss. It presents a method to calculate OEE for trucks used in open pit mines based on time loss classifications like scheduled maintenance, breakdowns, setups, waiting times, reduced speeds, and quality defects. Calculating OEE using a calendar time-based approach rather than loading time provides a more accurate assessment of actual equipment utilization. Regular OEE measurement can help mining operations improve productivity by reducing downtime and other inefficiencies.
Implementation of a Cellular Manufacturing Tool for Minimization of Non Value...IJERA Editor
The purpose of this study is to develop a plan for reducing lead-times and increasing profit of Centre bolt product by using value stream mapping. The Centre bolt product manufacturer is inefficient because it produces products in large batch quantities and has poor product flow as operations being departmentalized and departments are very far away from each other due to this increase in lead-times could cause a loss in the market share to its competitors. The Centre bolt product manufacturer must reduce its lead-times in order to remain competitive and continue its growth by providing quality products in a timely manner. A study will be carried out using value stream mapping to determine areas of potential improvement on the plant floor. A current state map will be developed and analyzed the areas that have potential for improvement. A future state map will then be created to suggest ways to reduce lead-times and increase profit. The map will include lean manufacturing methods to reduce wastes in the system; increasing profit and reducing lead-times. Current state and future state of manufacturing of a firm are compared and witnessed: 50 percent reduction in lead time, 4 percent reduction in processing time, 58.5 percent reduction in WIP and 22 percent reduction in manpower required to perform same amount of work.
1) The study used value stream mapping to analyze the production process of PLC controllers at PALCO in Jordan. The current state map revealed long cycle times for preparing and wiring controllers.
2) Implementing lean principles and techniques, including purchasing an automated crimping machine and adding staff, reduced the wiring preparation time by 50 minutes. This decreased the production cycle time by 30% and increased output from 2 to 4 units per day.
3) The future state map proposed merging some processes, standardizing roles, and using a supermarket pull system to further improve flow and double production rates.
DESIGN AND OPTIMIZATION OF CRITICAL PART OF A ROTARY TABLE USED IN HORIZONTAL...IAEME Publication
Growing industry demands low manufacturing cost, saving of material, low cost material, ease of transportation etc. This demand leads to use different type of material and various techniques to increase productivity.
Application of Industrial Engineering on garments industryMH RONY
Industrial engineering can be applied in the apparel industry to optimize complex processes and systems. Some key applications include line balancing to improve worker efficiency and productivity, identifying bottlenecks to improve processes, checking capacity to ensure required production needs are met, analyzing new styles and requirements, and conducting production studies to improve efficiency. The garment industry faces challenges that industrial engineering principles can help address, such as improving productivity, reducing costs, and efficiently analyzing orders.
This document summarizes key findings and recommendations from a study on improving performance and competitiveness in the apparel industry. The study analyzed production and management systems across multiple factories, identifying inefficiencies. Specific case studies found that factories carried 5-16.5% excess dead stock and labor utilization was only 59.5% due to poor line balancing, workflow, and supervision. Recommendations included eliminating dead stock through improved inventory tracking, optimizing fabric usage, establishing standard times, training supervisors, and implementing production monitoring and process improvement systems. The goal was to highlight areas where cost savings could be achieved through operational enhancements.
Improving productivity for engine crank shaft machining line using tps techni...IAEME Publication
The document summarizes research on improving productivity for an engine crankshaft machining line using Toyota Production System (TPS) techniques and simulation. It analyzes the existing line configuration using time study, standard work combination tables, and Arena simulation. This identifies idle time and imbalance. A proposed configuration with 6 operators is developed using line balancing calculations. Simulation shows the proposed configuration maintains output while reducing man-hours by 14.3% and improving productivity by 16.6%, saving an estimated $312,000 annually in labor costs.
STUDIES ON AVAILABILITY AND UTILISATION OF MINING EQUIPMENT- AN OVERVIEWIAEME Publication
In any opencast mining project, the major share of initial capital investment goes towards the excavation and transportation equipment. Hence it i s very important to analyse the performance of those equipment, at regular intervals to achieve co st- effectiveness in excavation and transportation operations. In this paper, an attempt is made to calculate the percentage availability and utilisation of shovel, dumpers and dozer, employed in an opencast mine and to analyse the contributing factors to improve the overall equipment performance.
IRJET- Comparative Performance Study of Mine Trucks by Overall Equipment Effe...IRJET Journal
This document discusses measuring the effectiveness of mining equipment using Overall Equipment Effectiveness (OEE). OEE is calculated based on availability, performance, and quality to identify sources of productivity loss. It presents a method to calculate OEE for trucks used in open pit mines based on time loss classifications like scheduled maintenance, breakdowns, setups, waiting times, reduced speeds, and quality defects. Calculating OEE using a calendar time-based approach rather than loading time provides a more accurate assessment of actual equipment utilization. Regular OEE measurement can help mining operations improve productivity by reducing downtime and other inefficiencies.
Implementation of a Cellular Manufacturing Tool for Minimization of Non Value...IJERA Editor
The purpose of this study is to develop a plan for reducing lead-times and increasing profit of Centre bolt product by using value stream mapping. The Centre bolt product manufacturer is inefficient because it produces products in large batch quantities and has poor product flow as operations being departmentalized and departments are very far away from each other due to this increase in lead-times could cause a loss in the market share to its competitors. The Centre bolt product manufacturer must reduce its lead-times in order to remain competitive and continue its growth by providing quality products in a timely manner. A study will be carried out using value stream mapping to determine areas of potential improvement on the plant floor. A current state map will be developed and analyzed the areas that have potential for improvement. A future state map will then be created to suggest ways to reduce lead-times and increase profit. The map will include lean manufacturing methods to reduce wastes in the system; increasing profit and reducing lead-times. Current state and future state of manufacturing of a firm are compared and witnessed: 50 percent reduction in lead time, 4 percent reduction in processing time, 58.5 percent reduction in WIP and 22 percent reduction in manpower required to perform same amount of work.
1) The study used value stream mapping to analyze the production process of PLC controllers at PALCO in Jordan. The current state map revealed long cycle times for preparing and wiring controllers.
2) Implementing lean principles and techniques, including purchasing an automated crimping machine and adding staff, reduced the wiring preparation time by 50 minutes. This decreased the production cycle time by 30% and increased output from 2 to 4 units per day.
3) The future state map proposed merging some processes, standardizing roles, and using a supermarket pull system to further improve flow and double production rates.
DESIGN AND OPTIMIZATION OF CRITICAL PART OF A ROTARY TABLE USED IN HORIZONTAL...IAEME Publication
Growing industry demands low manufacturing cost, saving of material, low cost material, ease of transportation etc. This demand leads to use different type of material and various techniques to increase productivity.
Application of Industrial Engineering on garments industryMH RONY
Industrial engineering can be applied in the apparel industry to optimize complex processes and systems. Some key applications include line balancing to improve worker efficiency and productivity, identifying bottlenecks to improve processes, checking capacity to ensure required production needs are met, analyzing new styles and requirements, and conducting production studies to improve efficiency. The garment industry faces challenges that industrial engineering principles can help address, such as improving productivity, reducing costs, and efficiently analyzing orders.
This document summarizes key findings and recommendations from a study on improving performance and competitiveness in the apparel industry. The study analyzed production and management systems across multiple factories, identifying inefficiencies. Specific case studies found that factories carried 5-16.5% excess dead stock and labor utilization was only 59.5% due to poor line balancing, workflow, and supervision. Recommendations included eliminating dead stock through improved inventory tracking, optimizing fabric usage, establishing standard times, training supervisors, and implementing production monitoring and process improvement systems. The goal was to highlight areas where cost savings could be achieved through operational enhancements.
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.
The document discusses production plant layout design. It describes how layout design involves analyzing material and product flows, activity relationships, space requirements and restrictions. The goals are to minimize costs and throughput times while allowing flexibility. Several layout types are described for different production situations. Systematic layout planning methods involve gathering data, analyzing flows and activities, developing relationship diagrams and space plans, generating alternative layouts, and selecting the optimal layout while considering flexibility. Material handling systems should also be designed in parallel with the layout.
IRJET- A Case Study Approach of Quality Tools in Manufacturing IndustryIRJET Journal
This document summarizes a case study on using quality tools to improve manufacturing processes at a company. The study focused on an oscillator product that was experiencing high defect rates, excess manufacturing time, and decreased productivity.
The researchers used Six Sigma's DMAIC methodology to define, measure, analyze, improve, and control the manufacturing process. In the define phase, they mapped the manufacturing process and identified issues like long cycle times, excess assembly time, and reworks. In measure, they collected time and quality data. Analysis found some operations took longer than the calculated takt time and elements had dimensional variations, leading to defects. Pareto analysis showed milling and CNC operations contributed most defects. The goal is to improve these
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.
The document describes a simulation study of a manufacturing facility with two production areas, Cell A and Cell G. Simulating the base configuration found bottlenecks in final assembly, section production station 1, and unit production stations 5. Experimenting with combining the cells reduced production. The optimal solution was found by increasing workers at specific stations and areas. Total production increased to 20,400 units at a profit of $75.3 million with the optimized resources.
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.
Design and fabrication of modular fixture for cmm inspectioneSAT Journals
Abstract This paper is on design and fabrication of modular fixture setup relative to inspection on co-ordinate Measuring Machine proposed and planned to increase the utilization of Co-ordinate Measuring Machine with respect to inspection activity by reducing setup time. The modular fixture design will hold component of different configuration, size and shape without much efforts to locate, align and clamp the components on the fixture. The modular fixture will ensure that even though the component is of different configuration will have one time design and setup configuration which will be standardized by assembly of fixture and then on fixture setup time will be less than a minute on the machine that to only if fixture is disturbed / removed from the Co-ordinate Measuring Machine table. Modular fixture will reduce setup time, hence increase opportunity to utilize the machine for useful value adding inspection purpose rather than setup activity which is noted to be non value adding activity. Along with design of modular fixture standardized method of component setup strategy is provided as work instructions to ensure components are mounted same way each time and every time whenever it is in use irrespective of time and resource.
Facilities planning - Module 1 Plant Location and Material handlingRashmi Srinivas
Plant Location: Factors influencing plant location, theories of plant location, plant layout – objectives of plant layout, principles of plant layout, types of plant layout, their merits and demerits, facilities design function: objectives.
Introduction to Material Handling: Objectives and principles of material handling, unit load concept, Basic handling equipment types, Common material handling equipment
Project Report on Maynard Operation Sequence Techniqueijtsrd
I did my 6 weeks industrial training at Maruti Suzuki India Ltd, Gurugram in the Assembly 1 Department under Production Division. The entire duration I was in the Assembly 1department. The first Week in the dept. office itself for M.O.S.T. study and techniques, then for the major part of June in Knuckle Sub Assembly Area and subsequent 4 Weeks on Line 4 and office of the department. Overall my project has been related to the standardization of man power for fluctuating production volumes of IGNIS YJC model and improvement in HPV. Majority of the time has been engaged in videography and subsequent M.O.S.T. analysis of the work stations. I have finished two projects in my tenure. Man Power Reduction was the basic principle underlying the M.O.S.T. project done. Ankur | Mr. Manish "Project Report on Maynard Operation Sequence Technique" Published in International Journal of Trend in Scientific Research and Development (ijtsrd), ISSN: 2456-6470, Volume-4 | Issue-4 , June 2020, URL: https://www.ijtsrd.com/papers/ijtsrd31411.pdf Paper Url :https://www.ijtsrd.com/engineering/mechanical-engineering/31411/project-report-on-maynard-operation-sequence-technique/ankur
Application of Taguchi method in optimization of control parameters of grindi...Carnegie Mellon University
In this study, the control parameters for grinding process are optimized for reduction in cycle time while
maintaining quality standards in a bearing manufacturing company. The Taguchi method which is a powerful tool to
design optimization for quality is used to find the optimal control parameters. An orthogonal array, the signal-to-noise
(S/N) ratio and the analysis of variance (ANOVA) are used to study the performance characteristics of grinding
process of an outer ring of a taper roller bearing. Various control parameters consisting of feed parameters, position
parameters, speed parameters were optimized and also the main parameters that affect the grinding process can be
found out. Experimental results are provided to verify the effectiveness of this approach.
Proplanner - AutoCAD Based Facility Layout Analysis & ImprovementProplanner Asia
Flow Planner is the world's leading software for facility layout analysis and improvement. Flow Planner automatically visualizes material flow and non-flow relationships within AutoCAD layouts, and provides layout statistics to support decision making (distance, cost, and time). This is also the ideal tool to automatically generate and evaluate tugger / tow-train routes.
These tools were based on the Richard Muther's Systematic Layout Planning (SLP) from 1961 and Systematic Handling Analysis (SHA) from 1969. Created by Dr. Dave Sly, Proplanner president and professor of practice at Iowa State University.
Modeling and Manufacturing of an Aerospace Component by Single Point Incremen...IRJET Journal
The document describes modeling and manufacturing an aerospace component using single point incremental forming process. It discusses modeling the component and fixture in Solidworks. A static structural analysis was performed in ANSYS to study stresses and deformations on the fixture under different forming loads. The component was then manufactured using a CNC milling machine with a hemispherical forming tool following the tool trajectories from the CAD model. Analysis of stresses, strains, and deformations helped understand how process parameters affect shape accuracy in single point incremental forming.
Effect of equipment utilisation on economics of mining project a case studyIAEME Publication
This document summarizes a research paper on the effect of equipment utilization on the economics of mining projects. Some key points:
- Poor utilization of heavy earth-moving machinery (HEMM) in open-pit mines can negatively impact production, productivity, and production costs, leading to lost revenue.
- The paper analyzes how different levels of utilization for mining shovels impacts yearly production, indirect costs per ton, direct costs per ton, and total costs per ton.
- Results show that increasing shovel utilization from 10% to 40% reduces costs per ton sharply, with little added benefit beyond 40%. Management should aim to reach at least 40% utilization.
- By increasing utilization to 40%, the cost
Case Study; Numerical Control System Retrofitting in Malaysia by Local Companyfunkseoul
1) A local Malaysian company, Ichiryu Sdn Bhd, retrofitted the numerical control (NC) system on one of the machines at an automotive manufacturing plant that was facing issues with obsolete control systems.
2) The retrofit involved replacing the old Fanuc Powermate controller with a new PLC-based NC system from Mitsubishi, along with new servo motors, HMI, and other components. This was completed for around half the cost quoted by overseas suppliers.
3) The retrofit was successful and provided benefits like lower costs, readily available local technical support, and an opportunity to develop local industry capabilities in machinery retrofitting.
Industrial engineering for apparel productionNiloy Rahman
This document provides an overview of industrial engineering for apparel production. It defines industrial engineering as applying engineering knowledge to plan, design, and control industrial operations by integrating people, materials, and energy. The objectives of the industrial engineering department are to monitor and improve production processes to increase performance and standardize manufacturing. Industrial engineers and merchandisers are key roles. Industrial engineers work to efficiently utilize tools, manage resources, and satisfy customer demands. Basic techniques used include work study, capacity study, method study, time study, and performance analysis. Cooperation between industrial engineers and merchandisers is important for the department to function properly.
Compiled By: Mr. Gokul O
Assistant Professor
Department of Mechanical Engineering
Sree Buddha College of Engineering, Pattoor
According to APJ Abdul Kalam Technological University Syllabus
Subject- Industrial Engineering
Course code- ME404
An Experimental Investigation of Capacity Utilization in Manufacturing Indus...IJMER
In the modern day competitive world, every organization demands an effective utilization of
capacity. Capacity Utilization means the maximum amount of output that can be produced in the short run of time. A lot of planning is necessary for the proper management of capacity. Capacity planning is one side of a coin and capacity management is the other. The capacity plans needs to be executed flawlessly, with unpleasant surprises avoided. A managerial problem is to match the capacity with the plans. Companies whether labour or machine intensive have a CI trend that remains fairly constant in
that particular sector. For example a company will have a monthly cumulative CI trend that could be compared with any other company trend within the same market. The present paper makes an attempt to study the most important parameter of the organization i.e capacity utilization of a company
IRJET- Productivity Improvement in Manufacturing Industry using Lean ToolsIRJET Journal
1. The document describes efforts to improve the productivity of a manufacturing assembly line through the application of lean tools and concepts like line balancing, bottleneck identification and elimination, and reduction of waste.
2. Analysis identified bottlenecks at several workstations where cycle times exceeded the takt time, including side and profile milling, bolt hole drilling, and machining operations. Travel charts and process maps also showed transportation and wait times between workstations.
3. Recommendations included reducing non-value-added activities and cycle times at bottleneck stations, implementing one-piece flow through line balancing, and applying systematic layout planning to minimize transportation and improve material flow. The goals were to increase line efficiency, throughput, and productivity while
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 - Productivity Improvement by Time Study and Motion StudyIRJET Journal
This document discusses improving productivity at a thermocole manufacturing plant through time study and motion study. It was found that delays between tasks were affecting production rates. Time study and motion study techniques from work study were used to analyze the processes. The analysis found a lack of proper time standards, uneven task distribution, inefficient space utilization, safety issues, and communication problems. After conducting time studies and setting proper time standards, production increased by 48 extra pieces per month on one machine. Implementing standards from time study and motion study analysis can effectively improve productivity by reducing delays in work processes.
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.
IRJET- Production Line Optimization using Lean Tools: A Case Study of Automot...IRJET Journal
This document summarizes a case study conducted to optimize production line productivity at an automotive parts manufacturing company in India. The production line was unable to meet increased customer demand of 1600 parts per month due to issues like lack of production planning, backtracking of materials, and high setup times. The researchers used lean tools like time studies, spaghetti diagrams, standard work combination tables, and Single Minute Exchange of Die (SMED) to address these issues. Through implementing production planning with Gantt charts, streamlining material flow with spaghetti diagrams, optimizing manpower allocation, and reducing setup times by 41-60% using SMED, they were able to increase output productivity by 32% and eliminate backtracking while reducing man
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.
The document discusses production plant layout design. It describes how layout design involves analyzing material and product flows, activity relationships, space requirements and restrictions. The goals are to minimize costs and throughput times while allowing flexibility. Several layout types are described for different production situations. Systematic layout planning methods involve gathering data, analyzing flows and activities, developing relationship diagrams and space plans, generating alternative layouts, and selecting the optimal layout while considering flexibility. Material handling systems should also be designed in parallel with the layout.
IRJET- A Case Study Approach of Quality Tools in Manufacturing IndustryIRJET Journal
This document summarizes a case study on using quality tools to improve manufacturing processes at a company. The study focused on an oscillator product that was experiencing high defect rates, excess manufacturing time, and decreased productivity.
The researchers used Six Sigma's DMAIC methodology to define, measure, analyze, improve, and control the manufacturing process. In the define phase, they mapped the manufacturing process and identified issues like long cycle times, excess assembly time, and reworks. In measure, they collected time and quality data. Analysis found some operations took longer than the calculated takt time and elements had dimensional variations, leading to defects. Pareto analysis showed milling and CNC operations contributed most defects. The goal is to improve these
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.
The document describes a simulation study of a manufacturing facility with two production areas, Cell A and Cell G. Simulating the base configuration found bottlenecks in final assembly, section production station 1, and unit production stations 5. Experimenting with combining the cells reduced production. The optimal solution was found by increasing workers at specific stations and areas. Total production increased to 20,400 units at a profit of $75.3 million with the optimized resources.
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.
Design and fabrication of modular fixture for cmm inspectioneSAT Journals
Abstract This paper is on design and fabrication of modular fixture setup relative to inspection on co-ordinate Measuring Machine proposed and planned to increase the utilization of Co-ordinate Measuring Machine with respect to inspection activity by reducing setup time. The modular fixture design will hold component of different configuration, size and shape without much efforts to locate, align and clamp the components on the fixture. The modular fixture will ensure that even though the component is of different configuration will have one time design and setup configuration which will be standardized by assembly of fixture and then on fixture setup time will be less than a minute on the machine that to only if fixture is disturbed / removed from the Co-ordinate Measuring Machine table. Modular fixture will reduce setup time, hence increase opportunity to utilize the machine for useful value adding inspection purpose rather than setup activity which is noted to be non value adding activity. Along with design of modular fixture standardized method of component setup strategy is provided as work instructions to ensure components are mounted same way each time and every time whenever it is in use irrespective of time and resource.
Facilities planning - Module 1 Plant Location and Material handlingRashmi Srinivas
Plant Location: Factors influencing plant location, theories of plant location, plant layout – objectives of plant layout, principles of plant layout, types of plant layout, their merits and demerits, facilities design function: objectives.
Introduction to Material Handling: Objectives and principles of material handling, unit load concept, Basic handling equipment types, Common material handling equipment
Project Report on Maynard Operation Sequence Techniqueijtsrd
I did my 6 weeks industrial training at Maruti Suzuki India Ltd, Gurugram in the Assembly 1 Department under Production Division. The entire duration I was in the Assembly 1department. The first Week in the dept. office itself for M.O.S.T. study and techniques, then for the major part of June in Knuckle Sub Assembly Area and subsequent 4 Weeks on Line 4 and office of the department. Overall my project has been related to the standardization of man power for fluctuating production volumes of IGNIS YJC model and improvement in HPV. Majority of the time has been engaged in videography and subsequent M.O.S.T. analysis of the work stations. I have finished two projects in my tenure. Man Power Reduction was the basic principle underlying the M.O.S.T. project done. Ankur | Mr. Manish "Project Report on Maynard Operation Sequence Technique" Published in International Journal of Trend in Scientific Research and Development (ijtsrd), ISSN: 2456-6470, Volume-4 | Issue-4 , June 2020, URL: https://www.ijtsrd.com/papers/ijtsrd31411.pdf Paper Url :https://www.ijtsrd.com/engineering/mechanical-engineering/31411/project-report-on-maynard-operation-sequence-technique/ankur
Application of Taguchi method in optimization of control parameters of grindi...Carnegie Mellon University
In this study, the control parameters for grinding process are optimized for reduction in cycle time while
maintaining quality standards in a bearing manufacturing company. The Taguchi method which is a powerful tool to
design optimization for quality is used to find the optimal control parameters. An orthogonal array, the signal-to-noise
(S/N) ratio and the analysis of variance (ANOVA) are used to study the performance characteristics of grinding
process of an outer ring of a taper roller bearing. Various control parameters consisting of feed parameters, position
parameters, speed parameters were optimized and also the main parameters that affect the grinding process can be
found out. Experimental results are provided to verify the effectiveness of this approach.
Proplanner - AutoCAD Based Facility Layout Analysis & ImprovementProplanner Asia
Flow Planner is the world's leading software for facility layout analysis and improvement. Flow Planner automatically visualizes material flow and non-flow relationships within AutoCAD layouts, and provides layout statistics to support decision making (distance, cost, and time). This is also the ideal tool to automatically generate and evaluate tugger / tow-train routes.
These tools were based on the Richard Muther's Systematic Layout Planning (SLP) from 1961 and Systematic Handling Analysis (SHA) from 1969. Created by Dr. Dave Sly, Proplanner president and professor of practice at Iowa State University.
Modeling and Manufacturing of an Aerospace Component by Single Point Incremen...IRJET Journal
The document describes modeling and manufacturing an aerospace component using single point incremental forming process. It discusses modeling the component and fixture in Solidworks. A static structural analysis was performed in ANSYS to study stresses and deformations on the fixture under different forming loads. The component was then manufactured using a CNC milling machine with a hemispherical forming tool following the tool trajectories from the CAD model. Analysis of stresses, strains, and deformations helped understand how process parameters affect shape accuracy in single point incremental forming.
Effect of equipment utilisation on economics of mining project a case studyIAEME Publication
This document summarizes a research paper on the effect of equipment utilization on the economics of mining projects. Some key points:
- Poor utilization of heavy earth-moving machinery (HEMM) in open-pit mines can negatively impact production, productivity, and production costs, leading to lost revenue.
- The paper analyzes how different levels of utilization for mining shovels impacts yearly production, indirect costs per ton, direct costs per ton, and total costs per ton.
- Results show that increasing shovel utilization from 10% to 40% reduces costs per ton sharply, with little added benefit beyond 40%. Management should aim to reach at least 40% utilization.
- By increasing utilization to 40%, the cost
Case Study; Numerical Control System Retrofitting in Malaysia by Local Companyfunkseoul
1) A local Malaysian company, Ichiryu Sdn Bhd, retrofitted the numerical control (NC) system on one of the machines at an automotive manufacturing plant that was facing issues with obsolete control systems.
2) The retrofit involved replacing the old Fanuc Powermate controller with a new PLC-based NC system from Mitsubishi, along with new servo motors, HMI, and other components. This was completed for around half the cost quoted by overseas suppliers.
3) The retrofit was successful and provided benefits like lower costs, readily available local technical support, and an opportunity to develop local industry capabilities in machinery retrofitting.
Industrial engineering for apparel productionNiloy Rahman
This document provides an overview of industrial engineering for apparel production. It defines industrial engineering as applying engineering knowledge to plan, design, and control industrial operations by integrating people, materials, and energy. The objectives of the industrial engineering department are to monitor and improve production processes to increase performance and standardize manufacturing. Industrial engineers and merchandisers are key roles. Industrial engineers work to efficiently utilize tools, manage resources, and satisfy customer demands. Basic techniques used include work study, capacity study, method study, time study, and performance analysis. Cooperation between industrial engineers and merchandisers is important for the department to function properly.
Compiled By: Mr. Gokul O
Assistant Professor
Department of Mechanical Engineering
Sree Buddha College of Engineering, Pattoor
According to APJ Abdul Kalam Technological University Syllabus
Subject- Industrial Engineering
Course code- ME404
An Experimental Investigation of Capacity Utilization in Manufacturing Indus...IJMER
In the modern day competitive world, every organization demands an effective utilization of
capacity. Capacity Utilization means the maximum amount of output that can be produced in the short run of time. A lot of planning is necessary for the proper management of capacity. Capacity planning is one side of a coin and capacity management is the other. The capacity plans needs to be executed flawlessly, with unpleasant surprises avoided. A managerial problem is to match the capacity with the plans. Companies whether labour or machine intensive have a CI trend that remains fairly constant in
that particular sector. For example a company will have a monthly cumulative CI trend that could be compared with any other company trend within the same market. The present paper makes an attempt to study the most important parameter of the organization i.e capacity utilization of a company
IRJET- Productivity Improvement in Manufacturing Industry using Lean ToolsIRJET Journal
1. The document describes efforts to improve the productivity of a manufacturing assembly line through the application of lean tools and concepts like line balancing, bottleneck identification and elimination, and reduction of waste.
2. Analysis identified bottlenecks at several workstations where cycle times exceeded the takt time, including side and profile milling, bolt hole drilling, and machining operations. Travel charts and process maps also showed transportation and wait times between workstations.
3. Recommendations included reducing non-value-added activities and cycle times at bottleneck stations, implementing one-piece flow through line balancing, and applying systematic layout planning to minimize transportation and improve material flow. The goals were to increase line efficiency, throughput, and productivity while
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 - Productivity Improvement by Time Study and Motion StudyIRJET Journal
This document discusses improving productivity at a thermocole manufacturing plant through time study and motion study. It was found that delays between tasks were affecting production rates. Time study and motion study techniques from work study were used to analyze the processes. The analysis found a lack of proper time standards, uneven task distribution, inefficient space utilization, safety issues, and communication problems. After conducting time studies and setting proper time standards, production increased by 48 extra pieces per month on one machine. Implementing standards from time study and motion study analysis can effectively improve productivity by reducing delays in work processes.
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.
IRJET- Production Line Optimization using Lean Tools: A Case Study of Automot...IRJET Journal
This document summarizes a case study conducted to optimize production line productivity at an automotive parts manufacturing company in India. The production line was unable to meet increased customer demand of 1600 parts per month due to issues like lack of production planning, backtracking of materials, and high setup times. The researchers used lean tools like time studies, spaghetti diagrams, standard work combination tables, and Single Minute Exchange of Die (SMED) to address these issues. Through implementing production planning with Gantt charts, streamlining material flow with spaghetti diagrams, optimizing manpower allocation, and reducing setup times by 41-60% using SMED, they were able to increase output productivity by 32% and eliminate backtracking while reducing man
International Journal of Engineering Research and DevelopmentIJERD Editor
Electrical, Electronics and Computer Engineering,
Information Engineering and Technology,
Mechanical, Industrial and Manufacturing Engineering,
Automation and Mechatronics Engineering,
Material and Chemical Engineering,
Civil and Architecture Engineering,
Biotechnology and Bio Engineering,
Environmental Engineering,
Petroleum and Mining Engineering,
Marine and Agriculture engineering,
Aerospace Engineering.
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.
Overall equipment effectiveness of critical machines in manufacturing industriesIAEME Publication
This document summarizes a study that assessed the overall equipment effectiveness (OEE) of critical machines in two large manufacturing industries - a tire industry and an automobile industry. The study selected two critical machines from each industry and collected data on their performance over one year to calculate OEE values. OEE considers availability, performance and quality to measure actual equipment effectiveness. The results were statistically analyzed to identify how major losses like downtime and defects influence OEE and where improvements could be targeted.
The document provides a report on analyzing and optimizing the manufacturing system of a client company called KCP technologies Private Ltd. Key points:
- The company manufactures screw pump rotors in a batch production process using 3 CNC workstations.
- Cycle times for the two main products were recorded to calculate production rates. Motion studies were conducted to optimize workstation layouts and reduce travel times.
- The current number of workstations was found to be optimal. Modifications like rearranging tools saved an estimated 1 minute per part produced.
- Further analyses included machine cluster possibilities and quality assurance processes to improve the system.
The document provides a report on analyzing and optimizing the manufacturing system of a client company called KCP technologies Private Ltd. Key points:
- The company manufactures screw pump rotors in a batch production process using 3 CNC workstations.
- Cycle times for the two main products were recorded to calculate production rates. Motion studies were conducted to optimize workstation layouts and reduce travel times.
- The current number of workstations was found to be optimal. Modifications like rearranging tools saved an estimated 1 minute per part produced.
- Further analyses included machine cluster possibilities and quality assurance processes to improve the system.
This report analyzes and optimizes the manufacturing system of a client that produces screw pump rotors. Key points:
1) The factory currently has 3 CNC workstations and produces rotors in batch production. Cycle times were recorded to calculate production rates.
2) The optimum number of workstations was calculated to be 2.97, matching the current 3 workstations. Motion studies were conducted to reduce repositioning times.
3) Implementation of layout changes reduced average cycle times, increasing production rates. Machine clustering allowed one worker to manage multiple machines.
4) Cost analyses showed the optimized system with clustering lowered production costs per unit compared to the present situation. Further automation of material handling was recommended
Capacity utilization for product mix using operation based time standard eval...eSAT Journals
Abstract In this paper, a systematic and quantitative view is presented for the application of time study in woodworking furniture industry. The study is done in panel conversion plant on five CNC machines for various operations. For the calculation of cycle time, machining time calculator is developed and the operation research technique of mathematical programming is used for the capacity calculation of product mix. This makes manager to make faster decision in outsourcing problem and to improve the financial performance of the company. Keywords - Capacity utilization, cycle time, linear programming, manufacturing, time study
Capacity utilization for product mix using operation based time standard eval...eSAT Publishing House
This document describes a study conducted at a woodworking furniture company to determine optimal capacity utilization and product mix. Time studies were performed on five CNC machines to calculate cycle times for different operations and products. A software tool called the Machining Time Calculator was developed to streamline cycle time calculations for new products. Linear programming was used to formulate a mathematical model to maximize profit based on production capacity constraints, material costs, selling prices, and market demand for five products. The optimal solution was to manufacture specified quantities of four products internally and outsource the remainder to maximize total throughput.
IRJET- Efficiency Enhancement by Reducing Production and Machining TimeIRJET Journal
This document summarizes a study on improving efficiency in a manufacturing process by reducing production time and machining time. It discusses using lean manufacturing techniques like value stream mapping, work standardization, and line balancing in a CNC machining cell that produces housings for gearboxes. Value stream mapping was used to analyze the current process and identify opportunities for improvement. Process times were analyzed using time studies and video analysis to standardize work and reduce non-value added activities. Line balancing was also implemented to better distribute the workload between operators and reduce idle time. The results showed reductions in lead time and improvements in overall equipment effectiveness.
OVERALL EQUIPMENT EFFECTIVENESS OF CRITICAL MACHINES IN MANUFACTURING INDUSTR...IAEME Publication
Overall Equipment Effectiveness (OEE) is a measure used in Total Productive Maintenance (TPM), a maintenance program which involves a newly defined concept for maintaining plants and equipment, to calculate the percentage of actual effectiveness of the equipment, taking into consideration the availability of the equipment, the performance rate when running and the quality rate of the manufactured product measured over a period of time (days, weeks or months). The equipment criticality is decided by considering how and how much the equipment affects the production volume and quality.
The document discusses improving productivity in the assembly line of an automobile industry. It analyzes time and motion studies conducted at Tata Motors in Lucknow, India to assess the assembly of accelerator pedals. The study found that total time taken was originally 124 seconds with 73.2 meters of worker motion. By implementing improvements like using a trolley and changing the layout, total time was reduced to 51 seconds and motion was reduced to 32 meters. This represented a 58.3% decrease in time and 56.3% decrease in worker motion. The analysis demonstrated that time and motion studies can effectively identify opportunities to streamline assembly processes and improve productivity.
“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.
IRJET- Improvement of Availability and Maintainability through Actions based ...IRJET Journal
This document summarizes a case study on improving the availability and maintainability of critical machines at a steel plant through root cause analysis of failures and implementing corrective countermeasures. Data was collected on breakdowns of a housing less mill stand machine and slitting machine before and after implementing countermeasures. Root cause analysis found the main issues for the slitting machine were fire cracks in the reel and improper adjustment. Corrective actions like improved cooling and adjustments increased availability from 94.89% to 97.72%, MTBF from 59 to 82.81 hours, and decreased MTTR from 3.17 to 1.93 hours, demonstrating the effectiveness of the countermeasures at improving performance.
IRJET-Production of Hybrid Aluminium Matrix Composite with Welding Slag and F...IRJET Journal
This document describes the design and fabrication of a multi-purpose tooling machine. The machine allows five operations - drilling, shaping, cutting, buffing, and grinding - to be performed simultaneously using a single machine. This is more efficient than separate machines for each operation as it saves space, time, and costs for industries. The machine uses a belt drive system connected to pulleys and bevel gears to transfer power from an electric motor to shafts that drive the various tools. A scotch yoke mechanism is also used to convert rotational motion to reciprocating motion for shaping. The machine aims to improve productivity while reducing production costs for industries.
Study of Fabrication of Multipurpose Tooling MachineIRJET Journal
This document describes the design and fabrication of a multi-purpose tooling machine. The machine allows five operations - drilling, shaping, cutting, buffing, and grinding - to be performed simultaneously using a single machine. This is more efficient than separate machines for each operation as it saves space, time, and costs for industries. The machine uses a belt drive system connected to pulleys and bevel gears to transfer power from an electric motor to shafts that drive the various tools. A scotch yoke mechanism is also used to convert rotational motion to reciprocating motion for shaping. The machine aims to improve productivity while reducing production costs for industries.
Business Mathematics is a course that teaches mathematical concepts and techniques used in business. It covers topics such as financial calculations, statistics, probability, and modeling to solve business problems. The goal is to provide students with the quantitative skills needed to analyze business situations and make informed financial decisions.
This document discusses sources and forms of long-term financing. It describes the money and capital markets, including short-term and long-term securities. The main sources of intermediate and long-term debt are term loans and bonds. Bonds can take various forms such as mortgage bonds, debentures, convertible bonds, and floating rate bonds. Preferred stock and common stock are also discussed, along with factors that influence dividend policy.
The document discusses several theories of capital structure:
1) Net income approach assumes capitalization rates are constant as debt increases, making 100% debt optimal.
2) Net operating income approach finds no optimal structure as equity rates adjust to keep overall rates constant.
3) Traditional approach finds an optimal structure where costs initially fall then rise with more debt.
4) MM theory initially argues capital structure is irrelevant without taxes but debt provides tax shields with taxes.
5) Trade-off theory balances tax shields against costs of financial distress and agency, finding an optimal balance.
This document provides an overview of budgeting and the budgeting process. It defines key terms like budgets, the master budget, and different types of budgets such as operational budgets, the cash budget, and capital budgets. It explains the purposes of budgeting like planning, allocating resources, and evaluating performance. The document also describes how to develop specific budgets such as the sales budget, production budget, materials budget, and cash budget. It provides examples of how to calculate figures for these various budgets.
This document discusses dividend theory and policy. It explains that in the absence of dividends, corporate earnings accrue to shareholders as retained earnings that are automatically reinvested in the firm. However, when dividends are declared, those funds leave the firm permanently. The document then outlines several factors that determine a firm's dividend policy, including dividend payout ratio, stability of dividends, legal restrictions, and owners' considerations. It provides examples and explanations of different types of dividend payments, including cash dividends, stock dividends, stock splits, and share repurchases.
This document discusses plate cutting errors that can occur in fabrication shops and their potential causes and remedies. It presents a case study of a fabrication shop that analyzed errors occurring during CNC oxy-fuel/plasma cutting of steel plates. Through observations and discussions with operators, the study identified 27 common errors, such as edge fusion, chain of molten beads, and undulating cut surfaces. For each error, possible causes were determined, such as torch feed speed being too low or high, clearance between the nozzle and plate being too small or large, and nozzle issues. Remedies for the causes are provided to minimize errors, rework and improve productivity during plate cutting.
The document summarizes key aspects of the Mines Act of 1952 in India. It discusses:
- The Act is administered by the Ministry of Labour and Employment and aims to ensure health, safety and welfare of mine workers.
- It prescribes duties of mine owners regarding management, health, safety, working hours, wages and more. Compliance is overseen by the Directorate General of Mines Safety.
- The Act covers definitions, appointments of inspectors and medical officers, requirements around drinking water, sanitation, medical facilities, accident reporting, hours of work, leaves, and powers to create regulations. Non-compliance is punishable by fines or imprisonment.
- Various forms are also prescribed
Generative AI Use cases applications solutions and implementation.pdfmahaffeycheryld
Generative AI solutions encompass a range of capabilities from content creation to complex problem-solving across industries. Implementing generative AI involves identifying specific business needs, developing tailored AI models using techniques like GANs and VAEs, and integrating these models into existing workflows. Data quality and continuous model refinement are crucial for effective implementation. Businesses must also consider ethical implications and ensure transparency in AI decision-making. Generative AI's implementation aims to enhance efficiency, creativity, and innovation by leveraging autonomous generation and sophisticated learning algorithms to meet diverse business challenges.
https://www.leewayhertz.com/generative-ai-use-cases-and-applications/
Digital Twins Computer Networking Paper Presentation.pptxaryanpankaj78
A Digital Twin in computer networking is a virtual representation of a physical network, used to simulate, analyze, and optimize network performance and reliability. It leverages real-time data to enhance network management, predict issues, and improve decision-making processes.
Open Channel Flow: fluid flow with a free surfaceIndrajeet sahu
Open Channel Flow: This topic focuses on fluid flow with a free surface, such as in rivers, canals, and drainage ditches. Key concepts include the classification of flow types (steady vs. unsteady, uniform vs. non-uniform), hydraulic radius, flow resistance, Manning's equation, critical flow conditions, and energy and momentum principles. It also covers flow measurement techniques, gradually varied flow analysis, and the design of open channels. Understanding these principles is vital for effective water resource management and engineering applications.
Null Bangalore | Pentesters Approach to AWS IAMDivyanshu
#Abstract:
- Learn more about the real-world methods for auditing AWS IAM (Identity and Access Management) as a pentester. So let us proceed with a brief discussion of IAM as well as some typical misconfigurations and their potential exploits in order to reinforce the understanding of IAM security best practices.
- Gain actionable insights into AWS IAM policies and roles, using hands on approach.
#Prerequisites:
- Basic understanding of AWS services and architecture
- Familiarity with cloud security concepts
- Experience using the AWS Management Console or AWS CLI.
- For hands on lab create account on [killercoda.com](https://killercoda.com/cloudsecurity-scenario/)
# Scenario Covered:
- Basics of IAM in AWS
- Implementing IAM Policies with Least Privilege to Manage S3 Bucket
- Objective: Create an S3 bucket with least privilege IAM policy and validate access.
- Steps:
- Create S3 bucket.
- Attach least privilege policy to IAM user.
- Validate access.
- Exploiting IAM PassRole Misconfiguration
-Allows a user to pass a specific IAM role to an AWS service (ec2), typically used for service access delegation. Then exploit PassRole Misconfiguration granting unauthorized access to sensitive resources.
- Objective: Demonstrate how a PassRole misconfiguration can grant unauthorized access.
- Steps:
- Allow user to pass IAM role to EC2.
- Exploit misconfiguration for unauthorized access.
- Access sensitive resources.
- Exploiting IAM AssumeRole Misconfiguration with Overly Permissive Role
- An overly permissive IAM role configuration can lead to privilege escalation by creating a role with administrative privileges and allow a user to assume this role.
- Objective: Show how overly permissive IAM roles can lead to privilege escalation.
- Steps:
- Create role with administrative privileges.
- Allow user to assume the role.
- Perform administrative actions.
- Differentiation between PassRole vs AssumeRole
Try at [killercoda.com](https://killercoda.com/cloudsecurity-scenario/)
DEEP LEARNING FOR SMART GRID INTRUSION DETECTION: A HYBRID CNN-LSTM-BASED MODELijaia
As digital technology becomes more deeply embedded in power systems, protecting the communication
networks of Smart Grids (SG) has emerged as a critical concern. Distributed Network Protocol 3 (DNP3)
represents a multi-tiered application layer protocol extensively utilized in Supervisory Control and Data
Acquisition (SCADA)-based smart grids to facilitate real-time data gathering and control functionalities.
Robust Intrusion Detection Systems (IDS) are necessary for early threat detection and mitigation because
of the interconnection of these networks, which makes them vulnerable to a variety of cyberattacks. To
solve this issue, this paper develops a hybrid Deep Learning (DL) model specifically designed for intrusion
detection in smart grids. The proposed approach is a combination of the Convolutional Neural Network
(CNN) and the Long-Short-Term Memory algorithms (LSTM). We employed a recent intrusion detection
dataset (DNP3), which focuses on unauthorized commands and Denial of Service (DoS) cyberattacks, to
train and test our model. The results of our experiments show that our CNN-LSTM method is much better
at finding smart grid intrusions than other deep learning algorithms used for classification. In addition,
our proposed approach improves accuracy, precision, recall, and F1 score, achieving a high detection
accuracy rate of 99.50%.
Tools & Techniques for Commissioning and Maintaining PV Systems W-Animations ...Transcat
Join us for this solutions-based webinar on the tools and techniques for commissioning and maintaining PV Systems. In this session, we'll review the process of building and maintaining a solar array, starting with installation and commissioning, then reviewing operations and maintenance of the system. This course will review insulation resistance testing, I-V curve testing, earth-bond continuity, ground resistance testing, performance tests, visual inspections, ground and arc fault testing procedures, and power quality analysis.
Fluke Solar Application Specialist Will White is presenting on this engaging topic:
Will has worked in the renewable energy industry since 2005, first as an installer for a small east coast solar integrator before adding sales, design, and project management to his skillset. In 2022, Will joined Fluke as a solar application specialist, where he supports their renewable energy testing equipment like IV-curve tracers, electrical meters, and thermal imaging cameras. Experienced in wind power, solar thermal, energy storage, and all scales of PV, Will has primarily focused on residential and small commercial systems. He is passionate about implementing high-quality, code-compliant installation techniques.
Blood finder application project report (1).pdfKamal Acharya
Blood Finder is an emergency time app where a user can search for the blood banks as
well as the registered blood donors around Mumbai. This application also provide an
opportunity for the user of this application to become a registered donor for this user have
to enroll for the donor request from the application itself. If the admin wish to make user
a registered donor, with some of the formalities with the organization it can be done.
Specialization of this application is that the user will not have to register on sign-in for
searching the blood banks and blood donors it can be just done by installing the
application to the mobile.
The purpose of making this application is to save the user’s time for searching blood of
needed blood group during the time of the emergency.
This is an android application developed in Java and XML with the connectivity of
SQLite database. This application will provide most of basic functionality required for an
emergency time application. All the details of Blood banks and Blood donors are stored
in the database i.e. SQLite.
This application allowed the user to get all the information regarding blood banks and
blood donors such as Name, Number, Address, Blood Group, rather than searching it on
the different websites and wasting the precious time. This application is effective and
user friendly.
1. IOSR Journal of Mechanical and Civil Engineering (IOSR-JMCE)
e-ISSN: 2278-1684,p-ISSN: 2320-334X, Volume 12, Issue 5 Ver. V (Sep. - Oct. 2015), PP 63-70
www.iosrjournals.org
DOI: 10.9790/1684-12556370 www.iosrjournals.org 63 | Page
A Case Study of Implementation of Overall Equipment
Effectiveness on CNC Table type boring & milling machine of a
Heavy Machinery Manufacturing Industry
Vijay Lahri1
, Dr. Pramod Pathak2
1
(M.Tech scholar, Industrial Engineering and Management, Department of Management Studies, Indian School
of Mines, Dhanbad, Jharkhand, India)
2
(Head of department, Department of Management Studies, Indian School of Mines, Dhanbad, Jharkhand,
India)
Abstract: This Case Study Examines the Overall Equipment Effectiveness (OEE) of CNC Table Type Boring
and Milling Machine. I.e. (Juaristi) of a Heavy machinery manufacturing Industry. This OEE Tool is a route
map to boost the effectiveness of manufacturing process and Equipment. (I.e. loading time, job setting,
machining, machine utilization etc) Present situation and all time raises question for any company is how they
can optimise the performance of their existing machines and equipment. The answer is OEE which extracts all
the reason for delay of the job. OEE not just only measures Inefficiency but also categorises those into 3
categories for better understanding of manufacturing procedure. In this case study we carried out OEE on CNC
Table type boring & milling machine to find out the bottleneck and hidden losses. After carrying out OEE we
see that productivity is improved up to a significant percentage.
Keywords: OEE, Juaristi, Availability, Downtime, Productivity.
I. Introduction
In this Journal case study is carried out on CNC Table Type Boring & Milling machine (i.e. Juaristi) of
a Heavy Machinery Manufacturing Industry. In today’s Era Company survival depends on their timely
production with effective machinery Equipment and quality product. Companies have undergone significant
changes day by day so it is necessary to conduct continues study of the existing machinery system. So that
company can identify that their system is working on full captive load or not. To answer this OEE tool is used.
OEE is a productivity improvement tool developed by Seiichi Nkajima in the 1960’s to identify how effectively
machines are being utilised. OEE is a performance indicator and their result is categorised into three different
parameters i.e. Availability, Performance and Quality.
Fig- (1.1) CNC table type boring & milling machine specification
OEE is a tool for benchmarking with world class OEE and then optimizing the efficiency of machine.
OEE conveys how well our manufacturing facilities are performed relative to its full load capacity during the
planned production time.
2. A Case Study of Implementation of Overall Equipment Effectiveness on CNC Table type boring…
DOI: 10.9790/1684-12556370 www.iosrjournals.org 64 | Page
1.1- Classification of OEE factors:
OEE is classified into three metrics:-
Availability
Performance
Quality
Availability: -This metric describes how actually the machine is available for production. Availability accounts
with down time losses. Down time are those events which can be stop planned production for a particular time.
For e.g.:- machine is stop due to overheating, tool not available, voltage trip suddenly, coolant supply stopped
due to technical fault , job change over time.
Availability = Actual operating time
Planned production time
It accounts the first two of the 6 big losses i.e. breakdown and setup/adjustment time.
Performance: - It accounts for speed losses. Performance metric tells how fast and effectively the operator
carries out the job as soon as possible within the budget hours. It identifies and focuses on those factors which
cause delay in production and speed reductions some of the causes are (Improper casting, miss fed, operator
Inefficiency, and machine vibrations.)
Performance = Budgeted allotted time
Actual completion time
Quality: - Quality metric accounts for quality losses i.e. good product among all fabricated product. In this case
study we consider rework time as one of a parameter for quality. After completion of job due to machine and
operator Inefficiency rework is carried out for dimensional accuracy of the job. This quality metric shows how
well the operator carried out the process for producing a job. This metric shows quality of machine as well as
operator skill to run the machine effectively. Quality losses are due to scrap, rework, incorrect, dimension,
incorrect sequence of operation, in process damage.
Quality= Actual time to turn out job
Actual time + Rework time
Over all Equipment Effectiveness (OEE):-
OEE is the product of these three metrics i.e. Availability, Performance, Quality.
OEE = Availability × Performance × Quality
1.2- Six Big losses:
Losses are those activities which consume input and resources without giving any valuable output in
terms of monetary value. So for that Seiichi Nakajima categorises these losses in six frameworks.
Losses which are identified in this case study are shown below.
DOWNTIME
PLANTPRODUCTIONTIME (8HOURSSHIFT)
PLANTPRODUCTIONTIME (8HOURSSHIFT)
PLANNEDPRODUCTIONTIME
PLANNEDPRODUCTIONTIME
ACTUALOPERATINGTIME
SHEDULEDOWNTIME
3. A Case Study of Implementation of Overall Equipment Effectiveness on CNC Table type boring…
DOI: 10.9790/1684-12556370 www.iosrjournals.org 65 | Page
S.No Big Losses Reasons for losses Category
1- Breakdown - Machine failure
- Tool breakage
- Machine program hang
- Electric power trip
- Unplanned maintenance
- General breakdown
- Heavy vibration occurs due to uneven
casting
- Tool unavailability
Downtime losses
2- Set-up and adjustment - Operator unavailability
- Crane unavailability
- Fixture are not up to mark
- Helper inefficient
Downtime losses
3- Small stops - Obstructed product flow
- Drill jams
- Component jam
- Coolant stop
- Misfed
- Housekeeping of machine
- Frequent dimension check due to lack of
confidence and documentation.
Speed losses
4- Reduced speed - Low grade of tool used
- Low maintenance of equipment
- Operator procrastinates job
- Level of machine operator training
Speed losses
5- Production start-up reject - Casted/fabricated job damage during
setup
Quality
6- Production reject - In process damage
- Scrap
- Rework
- In correct dimension due to wrong
program
Quality
Table: 1.2.1- Losses identified during case study
II. Methodology
This case study is carried out at Heavy Machinery Manufacturing Industry situated near Raipur,
Chhattisgarh. Methodology which is adopted for the study is direct observation of machines. Here both primary
as well as secondary data is being gathered for the case analysis.
After several visits and direct observation of machines and analysing previous machine utilisation
record problem is identified that machine is not working up to its full load production capacity. So management
wants to implement productivity improvement tool. So for this brief literature study is carried out and finally
OEE tool is selected to carry out the study. Previous machine utilisation records and dispatch hour records are
used as secondary data while for primary data direct observation of “Bottom Balancer frame” which is a sub
part of EOT (Electrical Over travel crane) is selected. This sub part is machined on CNC Table type Boring and
milling machine. The budgeted hour given by planning department is 30 hours for completion of job and this
data is being carefully analysed according to the literature. And finally the result is obtained in terms of OEE
percentage.
Fig- Bottom Balancer frame
4. A Case Study of Implementation of Overall Equipment Effectiveness on CNC Table type boring…
DOI: 10.9790/1684-12556370 www.iosrjournals.org 66 | Page
This case study is carried out step by step these steps are shown below in flow diagram.
Fig: 2.1- Process flow diagram
III. Analysis And Result
Data is being collected manually by continuous observation from 5-10-2015 morning 6am to 6-10-
2015 night. i.e. (40 hours, 5-Shift) data is being gathered in excel format after this collected data is being
analysed. According to OEE tool method a calculation excel sheet is prepared after finding present OEE
situation of machine. Bottlenecks are identified and recommended suggestions are implemented. And then
again data being gather in same manner and analysis is carried out and we find that over all Equipment
Effectiveness (OEE) of CNC Table type boring and milling machine is increased upto a certain level of
percentage.
5. A Case Study of Implementation of Overall Equipment Effectiveness on CNC Table type boring…
DOI: 10.9790/1684-12556370 www.iosrjournals.org 67 | Page
1.3- Excel format for data collection:
1.4- Present OEE Calculation:
S.No Shift
Job
setting
Date & Shift
duration
Down
time
Down time reason
Budget
Hrs
Actual
Hrs
Remark
1-
A & BFirst
5/10/15 ( 6am-
10pm)
16 hrs shift
120 min
15 min
45 min
120 min No load
15 min more due to crowd in
canteen
Tool insert unavailable
Issue of tool insert
from store is a
time consuming
process which
increase down time
C First
5/10/15 (10pm-
6am)
8 hrs
30 min Insert not available
Store Department
takes much time to
issue new inserts.
2-
A First
6/10/15 (6am-
2pm)
8 hrs
60 min Operator not available
working on other
machine
B Second
6/10/15 (2pm-
6pm)
8 hrs
15 min More time in tea break
Here 1 Hrs more
for Rework due to
some unfinished
drill and bore end
surfaces.
OVERALL EQUIPMENT EFFECTIVENESS (OEE)
MACHINE:- JUARISTI JOB MATERIAL :- Mild steel (E-350) Grade NO OFSHIFT :- 5 Shifts
DRG. NO:- 11001.89.20.220 JOB TITLE:- BottomBalancer Frame
Project No- Cp3/140185-001
Job unload than rotate setting adjustment
Drill 26 mm dia complete
Bore 45^+.02 finish complete
Job completed and rework is carried out.
TOOL INSERT MATERIAL :- Carbide Insert used
OBSERBER NAME:- VIJAYLAHRI
TOTAL BUDGETTED HRS:- 30 HRs
Operation details
Job load at 8:00 am
Job setting time-8:00am to 9:20 am
Program making and tool preparation 20 min
Bore of 140 dia 4-NOS Rough cut, Bore of 160 dia Rough
Bore of 160 mm dia complete
Bore of 140 mm dia finish cut complete 4-NOS
Bore facing 6-NOS complete
Groove 146*15 width 3 NOSboth side
Groove 164*10 width 2 Nos both side
Drill 17.5*16 , Tap M20*30 deep completed
30 39
Job Title : Bottom balancer frame
Machine :
Date :
4 Breaks@ 15 60 Minute
0 Breaks@ 60 0 Minute
285 Minute 0 Minute
120 Minute 60 Minute
60 Minute 120 Minute
2280 Minute
2400 Minute
2340 Minute
1800 Minute
1875 Minute
OEE OEE %
0.8224 82.23%
0.7692 76.92%
0.975 97.50%
0.6168 62%
Quality: Actual Min/(Rework Min + Actual Min)
OEECNC Table type Boring and Milling machine
5-10-2015 to 6-10-2015
Actual operating time:
Overall OEE: Availability × Performance × Quality
Shift Duration : 8 Hrs shift (6am-2pm , 2pm-10pm , 10pm-6am )
Minute per Shift
Meal Break : MIN EACH
Down Time: Sheduled maintenace:
Shift length : 480
OEE CALCULATIONS
OEE FACTORS CALCULATION
Availabilty: Actual Operating time/planned production time
Performance: Budget time/ actual completion time of job
OEE DATA
Number of shifts: 5
OVERALL EQUIPMENT EFFECTIVENESS WORKSHEET
Change Over Time : House keeping of m/c
Short Breaks: MIN EACH
Rework Time duration:
Planned Production Time:
Operating time :
Actual completion time :
Budgeted time for job :
Total time
62%
World class OEE
Actual operating time = Planned production time- Total down time
Planned production time = Plant operating time - Planned down time
Plant operating time = Shift length × No of shift
Total Down Time = Down time + Change over time
My OEE
FORMULA
WORLD CLAS S OEE
Overall OEE: 85%
82.23%
76.92%
quality: 99.90%
Availabilty: 90%
Performance: 95%
OEE Factors:
97.50%
6. A Case Study of Implementation of Overall Equipment Effectiveness on CNC Table type boring…
DOI: 10.9790/1684-12556370 www.iosrjournals.org 68 | Page
Fig: 3.2.1- Present OEE of CNC Machine
Fig: 3.2.2- World class OEE and Present OEE
1.5- Finding and Suggestions:
After the analysis of present situation we found that CNC Table type Boring and milling machine is
working much below the world class OEE i.e. 65% OEE compare to 85% world class OEE so there is a scope of
improvement.
After carefully analysis and discussion with shop floor Incharge and management we find some
feasible suggestions for improvement of OEE. These suggestions are based on the visual recorded data in excel
sheet.
These suggestions are as follows:-
1- During observation we found that housekeeping of machine is carried out during machining hours
which accounts for 60 minute delay. So if housekeeping of machine is carried out during lunch time
and in break time then delay can be reduced to 50 minute compare to previous 60 minute delay.
2- During observation we found that time taken to distribute snacks takes 30 minute. And time allotted for
short break is 15 minute only. So every day 15 minute extra time is taken by operator which causes job
delay this can be reduced by increasing canteen staff during short breaks.
3- During observation Tool and Tool insert unavailability is a huge problem it usually takes huge time to
find the tools from
0
0.2
0.4
0.6
0.8
1
EFFECTIVENESS
PRESENT OEE
7. A Case Study of Implementation of Overall Equipment Effectiveness on CNC Table type boring…
DOI: 10.9790/1684-12556370 www.iosrjournals.org 69 | Page
Other machines so during this period machine is ideal. We can reduce this delay if company deployed
experience manpower in Tool crib room so he will ensure the availability of Tool and Tool insert for
all machines. This will largely reduce the unplanned down time. Approximately 60 minute for this
machine during the machining of bottom balancer frame.
4- Planning department must ensure the provision of operation process sheet (OPS) so the operator will
easily understand the sequence of operation. And drawing should be provided before the job load. So
operator can study and make program for that particular job in their ideal time. This step reduces 60
minute delay for the bottom balancer frame during the study of Juaristi CNC machine i.e. CNC table
type boring & milling machine.
5- During observation we found that at the time of loading and job setting proper arrangement of clams
and fixture is not their prior to the job loading. And helper is not enough trained. This increased the job
setting and loading time so there must be prior arrangement of fixture clams and other necessary items
prior to the job loading.
1.6- Improved OEE Calculation sheet:
1.7- Result:
After implementation of suggestions it is found that Overall Equipment Effectiveness of CNC Table
type boring & milling machine i.e. Juaristi is increased from 62% to 75%. But still it is below the world class
OEE it means there is further scope of improvement of machine utilization. Here following comparative graph
are shown below between present, Improved and world class OEE.
Fig: 3.5.1- Comparative chart for present, improved and world class OEE
Job Title :
Machine :
Date :
4 Breaks@ 15 60 Minute
0 Breaks@ 60 0 Minute
205 Minute 0 Minute
65 Minute 10 Minute
30 Minute 70 Minute
2330 Minute
2400 Minute
2100 Minute
1800 Minute
2060 Minute
OEE OEE %
0.8841 88.41%
0.8571 85.71%
0.9859 98.59%
0.7471 75%
OVERALL EQUIPMENT EFFECTIVENES S WORKS HEET
OEE
Bottom balancer frame
CNC Table type Boring and M illing machine
7-10-2015 to 8-10-2015
S hift Duration : 8 Hrs shift (6am-2pm , 2pm-10pm , 10pm-6am )
S hift length : 480 MINUTE PER S HIFT
OEE DATA
Number of shifts: 5
S hort Breaks: MIN EACH
Meal Break : MIN EACH
Down Time: S heduled maintenace:-
Change Over Time : House keeping of m/c
Rework Time duration: Total time
OEE CALCULATIONS
OEE FACTORS CALCULATION
Availabilty: Actual Operating time/planned production time
Planned Production Time:
Operating time :
Actual completion time :
Budgeted time for job :
Actual operating time:
Performance: Budget time/ actual completion time of job
Quality: Actual M in/(Rework M in + Actual M in)
Overall OEE: Availability × Performance × Quality
8. A Case Study of Implementation of Overall Equipment Effectiveness on CNC Table type boring…
DOI: 10.9790/1684-12556370 www.iosrjournals.org 70 | Page
PRESENT IMPROVED WORLD
CLASS
Availability 0.82 0.88 0.90
Performance 0.76 0.85 0.95
Quality 0.97 0.98 0.99
OEE 0.62 0.75 0.85
IV. Conclusion
At last I conclude that Juaristi i.e. CNC Table type boring and milling machine was continuously
running before the case study but company production schedule delayed for every time. So after implementation
of Overall Equipment Effectiveness (OEE) cycle time for machining of Bottom Balancer frame decreased from
39 hours to 35 hours. Saving of 4 hours it means by using OEE performance and productivity is improved up to
a certain level. As we know that measurement of performance is important, because it identifies current
performance gaps between current and desired performance and provides indication of progress towards closing
the gap. So by using OEE we can reduce this gap up to a certain level.
Acknowledgement
The author acknowledges the support received from Dr. Pramod Pathak, HOD, Department of
Management studies, Indian School Of Mines Dhanbad. And Mr. Shyam Sundar Mishra, Assistant manager,
Heavy machinery manufacturing Industry for their valuable suggestion and guidance during the case study.
References
[1]. http://www.juaristi.com/en/menu,company-video/menu,history/
[2]. Taylor fits- Gibbon, C (1990) “Performance indicator “, BERA Dialogues (2), ISBN 978-1-85359-092-4
[3]. Overall Equipment Effectiveness: A powerful Production/Maintenance Tool for increased productivity/profits. TS192.H3632001,
Page 25-42, 1-17.
[4]. Prokopenko, J, (1987), Productivity management, A practical Handbook, International Labour Office, ISBN: 92-2-105901-4.
[5]. Wauters, F –Mathot, J OEE White Paper (online) Zurych (Switzerland): ABB ltd, June 2002 (cit,2005-12-16) PDF Format available
at : <URL: http://library.abb.com//overallequipment effectivenesspdf>
[6]. Anonymous, the complete guide to simple OEE, Website: http://www.exor-rd.com,
[7]. Anonymous, OEE Pocket Guide, Website: http://www.vorne.com.
[8]. Hemant Singh Rajput, Pratesh Jaswal, A total productive maintenance approach to improve overall equipment effectiveness,
International journals of modern engineering research, Vol 2 Issue 6 pp 4383-4386.
[9]. Krawjeski, L.J. and Ritz man, L.P. (2002), “Operations Management: Strategy and Analysis”, 6th ed., Prentice-Hall, Upper Saddle
River, NJ.
[10]. Robert C. Hansen, 2001, Overall Equipment Effectiveness: A powerful Production/Maintenance tool for increased profit, first
edition, Industries press, Inc.
AUTHOR BIBLOGRAPHY
Mr. Vijay Lahri
He has completed his Graduation from Government Engineering College, Jhansi, U.P, India in 2012. At present
he is M.Tech Scholar of Industrial Engineering and Management in Department of Management Studies, Indian
School Of Mines, Dhanbad, Jharkhand, India.
Vijay.lahri07@gmail.com
Professor Pramod Pathak Professor, HOD, Department of Management Studies Indian School
of Mines Dhanbad-826004. India.
pathak.p.ms@ismdhanbad.ac.in