The document presents a model for operating and maintenance of modern printing machines. It analyzes data on unexpected breakdowns collected over 17 years from 65 printing machines at a large Hungarian printing plant. The key findings are:
1) Unexpected breakdowns accounted for 46% of maintenance events and caused over 105,000 hours of downtime.
2) The average downtime per breakdown was 1.8 hours and the average repair time was 2.24 hours.
3) The machines operated on average 2,883 hours per year.
4) Average downtimes and repair times have slightly decreased over time, showing an improvement in maintenance efficiency. However, fundamental maintenance characteristics are determined by machine structures and technologies.
Implementation of lean document production in the printing industrSudhendu Rai
Abstract: A previous Interfaces (Edelman Finalist) paper [12] described the LDP Lean Document Production toolkit and work process based on operations research techniques that demonstrated significant improvements in the productivity of small to mid-sized print shops. In this paper, the extensions of the methodology to improve productivity of very large print shops are described. The printing industry is segmented into four quadrants based on resource utilization and job variability. Job variability in one of the industry segments is extremely high and is characterized by fat-tail distributions. This paper describes the extensions required to handle the applications of LDP Lean Document Production to this market segment.
International Journal of Business and Management Invention (IJBMI)inventionjournals
International Journal of Business and Management Invention (IJBMI) is an international journal intended for professionals and researchers in all fields of Business and Management. IJBMI publishes research articles and reviews within the whole field Business and Management, new teaching methods, assessment, validation and the impact of new technologies and it will continue to provide information on the latest trends and developments in this ever-expanding subject. The publications of papers are selected through double peer reviewed to ensure originality, relevance, and readability. The articles published in our journal can be accessed online
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.
This document discusses facility layout, including the meaning and objectives of good layout. It describes factors that influence layout such as material handling costs, safety, and efficiency. The principles of an ideal layout are described as well as the importance of layout. Different types of layouts are covered including product, process, cellular manufacturing and combined layouts. Revision of existing layouts is discussed. The document concludes with a case study on a McDonald's kitchen layout.
This document discusses operations management concepts including production systems, types of processes, and process performance metrics. It defines a production system as having inputs, resources, a production process, and outputs. Process analysis involves process flowcharting to diagram a process and understanding cycle time, utilization, and other metrics. The document outlines common process types like make-to-order and make-to-stock and defines key metrics for evaluating process performance.
This document discusses different types of production systems. It defines production as manufacturing, mining or growing goods for trade by employing processes to transform inputs like ideas, raw materials and components into finished goods. A production system is described as an arrangement of interdependent activities and processes designed to achieve some objective. Key types of production systems discussed include intermittent, job, batch, flow/continuous, project, process and assembly line production. Intermittent production is not uniform and produces different products in small volumes based on customer orders. Continuous production constantly produces standardized goods in large volumes based on demand forecasts.
Production planning and control are important managerial functions concerned with determining production facilities, layout, and rates to produce desired products. Production planning considers routing and layout, while production control monitors execution against plans and takes corrective actions. There are three types of production systems: intermittent, continuous, and batch. Intermittent production produces goods in small batches based on customer orders and is flexible. Continuous production constantly produces standardized goods on a large scale based on demand forecasts. Batch production divides production into lots that must be completed before starting the next batch.
Implementation of lean document production in the printing industrSudhendu Rai
Abstract: A previous Interfaces (Edelman Finalist) paper [12] described the LDP Lean Document Production toolkit and work process based on operations research techniques that demonstrated significant improvements in the productivity of small to mid-sized print shops. In this paper, the extensions of the methodology to improve productivity of very large print shops are described. The printing industry is segmented into four quadrants based on resource utilization and job variability. Job variability in one of the industry segments is extremely high and is characterized by fat-tail distributions. This paper describes the extensions required to handle the applications of LDP Lean Document Production to this market segment.
International Journal of Business and Management Invention (IJBMI)inventionjournals
International Journal of Business and Management Invention (IJBMI) is an international journal intended for professionals and researchers in all fields of Business and Management. IJBMI publishes research articles and reviews within the whole field Business and Management, new teaching methods, assessment, validation and the impact of new technologies and it will continue to provide information on the latest trends and developments in this ever-expanding subject. The publications of papers are selected through double peer reviewed to ensure originality, relevance, and readability. The articles published in our journal can be accessed online
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.
This document discusses facility layout, including the meaning and objectives of good layout. It describes factors that influence layout such as material handling costs, safety, and efficiency. The principles of an ideal layout are described as well as the importance of layout. Different types of layouts are covered including product, process, cellular manufacturing and combined layouts. Revision of existing layouts is discussed. The document concludes with a case study on a McDonald's kitchen layout.
This document discusses operations management concepts including production systems, types of processes, and process performance metrics. It defines a production system as having inputs, resources, a production process, and outputs. Process analysis involves process flowcharting to diagram a process and understanding cycle time, utilization, and other metrics. The document outlines common process types like make-to-order and make-to-stock and defines key metrics for evaluating process performance.
This document discusses different types of production systems. It defines production as manufacturing, mining or growing goods for trade by employing processes to transform inputs like ideas, raw materials and components into finished goods. A production system is described as an arrangement of interdependent activities and processes designed to achieve some objective. Key types of production systems discussed include intermittent, job, batch, flow/continuous, project, process and assembly line production. Intermittent production is not uniform and produces different products in small volumes based on customer orders. Continuous production constantly produces standardized goods in large volumes based on demand forecasts.
Production planning and control are important managerial functions concerned with determining production facilities, layout, and rates to produce desired products. Production planning considers routing and layout, while production control monitors execution against plans and takes corrective actions. There are three types of production systems: intermittent, continuous, and batch. Intermittent production produces goods in small batches based on customer orders and is flexible. Continuous production constantly produces standardized goods on a large scale based on demand forecasts. Batch production divides production into lots that must be completed before starting the next batch.
Material and capacity requirements planning (mrp and crp) part 2Dr. Mahmoud Al-Naimi
Lectures on Production Planning and Control for B.Sc. Students - Industrial Engineering Branch -Department of Production Engineering and Metallurgy- University of Technology - Baghdad -Iraq
1. The document discusses computer integrated manufacturing (CIM) and automation strategies. It provides an introduction to automation, describing the types of automation as fixed, programmable, and flexible.
2. The reasons for automation include increasing productivity and reducing costs. Automation strategies aim to improve flexibility, material handling, inspection, and integrate operations through computer systems.
3. Production systems are classified as job shop, batch, or mass production based on factors like volume, variety, and workflow. CIM fully integrates all functions of a manufacturing company using computer systems.
Om lect 04_a(r0-aug08)_facility location & layout_mms_siesvideoaakash15
This document discusses factors to consider when selecting a location and designing the layout for a manufacturing plant. It outlines key steps in the plant location process, including selecting a country, region, locality, and exact site based on availability of resources. The document then covers different types of plant layouts like process, product, and cellular layouts and considerations for each. It also discusses factors that influence layout design like the type of product, workers, and machinery used. The overall goal of location and layout selection is to allow for efficient material and information flow at the lowest possible cost.
International Journal of Engineering Research and Applications (IJERA) aims to cover the latest outstanding developments in the field of all Engineering Technologies & science.
International Journal of Engineering Research and Applications (IJERA) is a team of researchers not publication services or private publications running the journals for monetary benefits, we are association of scientists and academia who focus only on supporting authors who want to publish their work. The articles published in our journal can be accessed online, all the articles will be archived for real time access.
Our journal system primarily aims to bring out the research talent and the works done by sciaentists, academia, engineers, practitioners, scholars, post graduate students of engineering and science. This journal aims to cover the scientific research in a broader sense and not publishing a niche area of research facilitating researchers from various verticals to publish their papers. It is also aimed to provide a platform for the researchers to publish in a shorter of time, enabling them to continue further All articles published are freely available to scientific researchers in the Government agencies,educators and the general public. We are taking serious efforts to promote our journal across the globe in various ways, we are sure that our journal will act as a scientific platform for all researchers to publish their works online.
This document provides an overview of computer-aided manufacturing resource planning, including material resource planning (MRP), manufacturing resource planning (MRP II), capacity resource planning (CRP), and enterprise resource planning (ERP). It describes MRP as a computational technique that converts a master schedule for end products into a detailed schedule for raw materials and components. It also outlines the key concepts and inputs used in MRP, including independent/dependent demand, lumpy demand, manufacturing lead times, and common use items. The document then provides brief descriptions of MRP II, CRP, and ERP systems.
Case Study for Plant Layout :: A modern analysisSarang Bhutada
The document summarizes an approach to developing an optimal layout for a manufacturing plant. It considers factors like the load and distance between operation centers, uses a stratified random sample to evaluate the requirements, and applies Schneider's method and a load distance matrix to transform the existing layout. The new layout improved efficiency and reduced material handling costs. It also discusses alternative layout approaches, including using a hybrid process-assembly line layout to reduce production time.
The document provides an overview of computer integrated manufacturing (CIM) systems, including:
- CIM encompasses the entire range of product development and manufacturing activities carried out with dedicated software. It uses a common database and communication technologies to integrate functions.
- CIM reduces the human component of manufacturing to relieve the process of slow, expensive and error-prone aspects. It takes a holistic, methodological approach to improve performance.
- CIM hardware includes manufacturing equipment, computers, peripheral devices. CIM software includes programs for management, design, production control, and other functions.
- The nine major elements of a CIM system are marketing, product design, planning, purchasing, manufacturing engineering,
Plant layout refers to the physical arrangement of equipment, machines, tools, and furniture in a manufacturing facility. The goal is to optimize material flow from raw materials to finished goods with the lowest costs and least amount of handling. There are four main types of layouts: product layout arranges machines in a straight line based on production steps; process layout groups similar machines together; combined layout uses aspects of both; and fixed position layout keeps products stationary while workers and machines move between positions. The optimal layout depends on factors like production volume and product standardization.
This document outlines the course objectives, outcomes, modules, and content for a Computer Aided Design and Manufacturing course. The key points are:
- The course aims to teach students about concepts of computer-integrated manufacturing systems including CAD, CAM, automation, and modern trends like additive manufacturing and Industry 4.0.
- The content covers topics like CAD software, geometric modeling, computer-aided process planning, CNC machine tools, and numerical problems involving geometric transformations.
- The course objectives are for students to understand CAD/CAM applications, automated manufacturing systems, computer applications in design and manufacturing, and modern manufacturing trends leading to smart factories.
An Ontology for Learning Services on the Shop FloorCarsten Ullrich
An ontology expresses a common understanding of a domain that serves as a basis of communication between people or systems, and enables knowledge sharing, reuse of domain knowledge, reasoning and thus problem solving. In Technology-Enhanced Learning, especially in Intelligent Tutoring Systems and Adaptive Learning Environments, ontologies serve as the basis of adaptivity and personalization. For mathematics learning and similarly structured domains, ontologies and their usage for adaptive learning are well understood and established. This contribution presents an ontology for the industrial shop floor (the area of a factory where operatives assemble products) and illustrates its usage in several learning services.
Plant location refers to establishing an industry at a particular place. There are two types: localization/centralization concentrates similar industries in one area, while delocalization/decentralization spreads them out. Key factors in choosing a location include availability of resources like materials, labor, transportation; market access; and operating costs. Methods for evaluating potential sites include comparative cost charts, which assess total costs, and dimensional analysis, which assigns weights to qualitative factors.
Rules for Adaptive Learning and Assistance on the Shop FloorCarsten Ullrich
Today’s shop floor, the area of a factory where operatives assemble products, is a complex and demanding work environment. The employed and produced technology becomes ever more complex, and employees are responsible for an increasing amount of tasks. As a consequence, the employee is under constant pressure to solve problems occurring on the shop floor as fast as possible, and simultaneously to improve his work-related knowledge, skills, and capabilities.
This paper gives an account how adaptive technology can support the employee on the shop floor in these respects. It describes the organizational requirements to take into consideration and describes a set of rules that support the employee in problem solving and knowledge acquisition.
It gives the complete information about plant layout- objectives of plant layout-factors affecting plant layout- types of plant layouts-advantages and disadvantages of those layouts-methods of designing plant layout-computerised algorithms to design plant layout-geometric modelling of plant layout-soft wares available to design plant layouts-advantages of using soft wares for the preparation of plant layouts.
IRJET- A Review of Data Mining and its Methods Used in Manufacturing and How ...IRJET Journal
This document provides a review of data mining methods used in manufacturing and how warehousing impacts manufacturing. It discusses how data mining techniques can be applied to extract patterns from manufacturing data to improve quality, optimize processes, and predict demands. Common data mining methods used include decision trees, neural networks, clustering, and regression. The document also examines the role of warehousing in managing inventory and supporting efficient manufacturing operations. Issues like demand variability, labor costs, and inventory inaccuracies are discussed. Automating warehouse processes through technologies like RFID is presented as a way to improve performance.
The presentation content Introduction
Objective, Factors affecting layout, Scope of facility of layout, Type of facility of layout and Process designing
Prerequisites for Developing a Facility Layout
Level of plants, Technique for designing a facility layout, Case study with example
6. process selection and facility layoutSudipta Saha
The document discusses process selection and facility layout. It describes different types of processes - job shop, batch, repetitive, continuous flow, and project - and factors like volume, variety, and flexibility that determine which type is suitable. It also covers automation levels from fixed to programmable to flexible. Facility layout depends on the process and aims to optimize efficiency, flow, and safety. Product and process layouts are introduced.
The document provides an introduction to production and operations management. It defines production, production management, and operations management. It explains why operations management is studied and discusses the historical development of the field from Adam Smith to Frederick Taylor. It also outlines different types of production systems such as flow, intermittent, mass production, and job/batch production. Finally, it discusses the role and importance of operations strategy and criteria for evaluating production and operations management systems.
This document presents a mathematical model for analyzing a generic single channel, multi-phase production line. The model aims to minimize system costs by reducing idle machine times and work-in-process inventory levels between machines. The model accounts for machine cycle times and calculates the times at which products enter and exit each machine in the production line. It assumes deterministic arrival rates and develops equations to determine the optimal level of service to minimize the total expected costs of providing service and of waiting for service.
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.
Material and capacity requirements planning (mrp and crp) part 2Dr. Mahmoud Al-Naimi
Lectures on Production Planning and Control for B.Sc. Students - Industrial Engineering Branch -Department of Production Engineering and Metallurgy- University of Technology - Baghdad -Iraq
1. The document discusses computer integrated manufacturing (CIM) and automation strategies. It provides an introduction to automation, describing the types of automation as fixed, programmable, and flexible.
2. The reasons for automation include increasing productivity and reducing costs. Automation strategies aim to improve flexibility, material handling, inspection, and integrate operations through computer systems.
3. Production systems are classified as job shop, batch, or mass production based on factors like volume, variety, and workflow. CIM fully integrates all functions of a manufacturing company using computer systems.
Om lect 04_a(r0-aug08)_facility location & layout_mms_siesvideoaakash15
This document discusses factors to consider when selecting a location and designing the layout for a manufacturing plant. It outlines key steps in the plant location process, including selecting a country, region, locality, and exact site based on availability of resources. The document then covers different types of plant layouts like process, product, and cellular layouts and considerations for each. It also discusses factors that influence layout design like the type of product, workers, and machinery used. The overall goal of location and layout selection is to allow for efficient material and information flow at the lowest possible cost.
International Journal of Engineering Research and Applications (IJERA) aims to cover the latest outstanding developments in the field of all Engineering Technologies & science.
International Journal of Engineering Research and Applications (IJERA) is a team of researchers not publication services or private publications running the journals for monetary benefits, we are association of scientists and academia who focus only on supporting authors who want to publish their work. The articles published in our journal can be accessed online, all the articles will be archived for real time access.
Our journal system primarily aims to bring out the research talent and the works done by sciaentists, academia, engineers, practitioners, scholars, post graduate students of engineering and science. This journal aims to cover the scientific research in a broader sense and not publishing a niche area of research facilitating researchers from various verticals to publish their papers. It is also aimed to provide a platform for the researchers to publish in a shorter of time, enabling them to continue further All articles published are freely available to scientific researchers in the Government agencies,educators and the general public. We are taking serious efforts to promote our journal across the globe in various ways, we are sure that our journal will act as a scientific platform for all researchers to publish their works online.
This document provides an overview of computer-aided manufacturing resource planning, including material resource planning (MRP), manufacturing resource planning (MRP II), capacity resource planning (CRP), and enterprise resource planning (ERP). It describes MRP as a computational technique that converts a master schedule for end products into a detailed schedule for raw materials and components. It also outlines the key concepts and inputs used in MRP, including independent/dependent demand, lumpy demand, manufacturing lead times, and common use items. The document then provides brief descriptions of MRP II, CRP, and ERP systems.
Case Study for Plant Layout :: A modern analysisSarang Bhutada
The document summarizes an approach to developing an optimal layout for a manufacturing plant. It considers factors like the load and distance between operation centers, uses a stratified random sample to evaluate the requirements, and applies Schneider's method and a load distance matrix to transform the existing layout. The new layout improved efficiency and reduced material handling costs. It also discusses alternative layout approaches, including using a hybrid process-assembly line layout to reduce production time.
The document provides an overview of computer integrated manufacturing (CIM) systems, including:
- CIM encompasses the entire range of product development and manufacturing activities carried out with dedicated software. It uses a common database and communication technologies to integrate functions.
- CIM reduces the human component of manufacturing to relieve the process of slow, expensive and error-prone aspects. It takes a holistic, methodological approach to improve performance.
- CIM hardware includes manufacturing equipment, computers, peripheral devices. CIM software includes programs for management, design, production control, and other functions.
- The nine major elements of a CIM system are marketing, product design, planning, purchasing, manufacturing engineering,
Plant layout refers to the physical arrangement of equipment, machines, tools, and furniture in a manufacturing facility. The goal is to optimize material flow from raw materials to finished goods with the lowest costs and least amount of handling. There are four main types of layouts: product layout arranges machines in a straight line based on production steps; process layout groups similar machines together; combined layout uses aspects of both; and fixed position layout keeps products stationary while workers and machines move between positions. The optimal layout depends on factors like production volume and product standardization.
This document outlines the course objectives, outcomes, modules, and content for a Computer Aided Design and Manufacturing course. The key points are:
- The course aims to teach students about concepts of computer-integrated manufacturing systems including CAD, CAM, automation, and modern trends like additive manufacturing and Industry 4.0.
- The content covers topics like CAD software, geometric modeling, computer-aided process planning, CNC machine tools, and numerical problems involving geometric transformations.
- The course objectives are for students to understand CAD/CAM applications, automated manufacturing systems, computer applications in design and manufacturing, and modern manufacturing trends leading to smart factories.
An Ontology for Learning Services on the Shop FloorCarsten Ullrich
An ontology expresses a common understanding of a domain that serves as a basis of communication between people or systems, and enables knowledge sharing, reuse of domain knowledge, reasoning and thus problem solving. In Technology-Enhanced Learning, especially in Intelligent Tutoring Systems and Adaptive Learning Environments, ontologies serve as the basis of adaptivity and personalization. For mathematics learning and similarly structured domains, ontologies and their usage for adaptive learning are well understood and established. This contribution presents an ontology for the industrial shop floor (the area of a factory where operatives assemble products) and illustrates its usage in several learning services.
Plant location refers to establishing an industry at a particular place. There are two types: localization/centralization concentrates similar industries in one area, while delocalization/decentralization spreads them out. Key factors in choosing a location include availability of resources like materials, labor, transportation; market access; and operating costs. Methods for evaluating potential sites include comparative cost charts, which assess total costs, and dimensional analysis, which assigns weights to qualitative factors.
Rules for Adaptive Learning and Assistance on the Shop FloorCarsten Ullrich
Today’s shop floor, the area of a factory where operatives assemble products, is a complex and demanding work environment. The employed and produced technology becomes ever more complex, and employees are responsible for an increasing amount of tasks. As a consequence, the employee is under constant pressure to solve problems occurring on the shop floor as fast as possible, and simultaneously to improve his work-related knowledge, skills, and capabilities.
This paper gives an account how adaptive technology can support the employee on the shop floor in these respects. It describes the organizational requirements to take into consideration and describes a set of rules that support the employee in problem solving and knowledge acquisition.
It gives the complete information about plant layout- objectives of plant layout-factors affecting plant layout- types of plant layouts-advantages and disadvantages of those layouts-methods of designing plant layout-computerised algorithms to design plant layout-geometric modelling of plant layout-soft wares available to design plant layouts-advantages of using soft wares for the preparation of plant layouts.
IRJET- A Review of Data Mining and its Methods Used in Manufacturing and How ...IRJET Journal
This document provides a review of data mining methods used in manufacturing and how warehousing impacts manufacturing. It discusses how data mining techniques can be applied to extract patterns from manufacturing data to improve quality, optimize processes, and predict demands. Common data mining methods used include decision trees, neural networks, clustering, and regression. The document also examines the role of warehousing in managing inventory and supporting efficient manufacturing operations. Issues like demand variability, labor costs, and inventory inaccuracies are discussed. Automating warehouse processes through technologies like RFID is presented as a way to improve performance.
The presentation content Introduction
Objective, Factors affecting layout, Scope of facility of layout, Type of facility of layout and Process designing
Prerequisites for Developing a Facility Layout
Level of plants, Technique for designing a facility layout, Case study with example
6. process selection and facility layoutSudipta Saha
The document discusses process selection and facility layout. It describes different types of processes - job shop, batch, repetitive, continuous flow, and project - and factors like volume, variety, and flexibility that determine which type is suitable. It also covers automation levels from fixed to programmable to flexible. Facility layout depends on the process and aims to optimize efficiency, flow, and safety. Product and process layouts are introduced.
The document provides an introduction to production and operations management. It defines production, production management, and operations management. It explains why operations management is studied and discusses the historical development of the field from Adam Smith to Frederick Taylor. It also outlines different types of production systems such as flow, intermittent, mass production, and job/batch production. Finally, it discusses the role and importance of operations strategy and criteria for evaluating production and operations management systems.
This document presents a mathematical model for analyzing a generic single channel, multi-phase production line. The model aims to minimize system costs by reducing idle machine times and work-in-process inventory levels between machines. The model accounts for machine cycle times and calculates the times at which products enter and exit each machine in the production line. It assumes deterministic arrival rates and develops equations to determine the optimal level of service to minimize the total expected costs of providing service and of waiting for service.
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.
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 OEE to 75%. Further improvements could bring OEE closer to the target world-class level.
Modeling and Simulation of Manufacturing Line Improvementijceronline
In the paper an example of manufacturing line form automotive industry is analyzed. The line consists of five presses, that can be operated by humans or industrial robots. Since human factors affect destabilization of the production processes, robots are preferred to apply. The problem is how to determine the real difference in the work efficiency between human and robot. Because of problem complexity, Discrete Events Simulation (DES) method have been used. Three models have been developed including manufacturing line before and after robotization and taking into account stochastic parameters of availability and reliability of the machines, operators and robots. Analysis of the production efficiency of the press shop lines operated by human operators or industrial robots are presented. We apply OEE (Overall Equipment Effectiveness) indicator to present how the availability and reliability parameters influence over the performance of the workstations, in particular in the short and long time period.
This document is intended to serve as a guide for
professionals in the High Volume Manufacturing Industries who want to understand what Overall Equipment Effectiveness (OEE) can deliver for their business.
Agent-Based Modeling: Methods and Techniques for Scheduling Industrial Machin...ijtsrd
Owing to its impact on the industrial economy, job shop scheduler and controller are vital algorithms for modern manufacturing processes. Hence a production scheduling and control that performs reactive (not deterministic) scheduling and can make decision on which job to process next based solely on its partial (not central) view of the plant becomes necessary. This requirement puts the problem in the class of agent based model (ABM). Hence this work adopts an alternative view on job-shop scheduling problem where each resource is equipped with adaptive agent that, independent of other agents makes job dispatching decision based on its local view of the plant. A combination of Markov Chain instruments and agent oriented analysis is used in the analysis of the proposed agent based model (ABM) for the job shop scheduling problem. The Markov Chain approach allows a rigorous analysis of the ABM. It provides a general framework of aggregation in agent-based and related computational models by making use of Markov Chain aggregation and lumpability theory in order to link the micro and the macro level of observation. Simulated annealing technique is used for carrying out the optimization modeling for the ABM. Chiagunye Tochukwu | Inyiama Hyacinth | Aguodoh Patrick C."Agent-Based Modeling: Methods and Techniques for Scheduling Industrial Machine Operation" Published in International Journal of Trend in Scientific Research and Development (ijtsrd), ISSN: 2456-6470, Volume-2 | Issue-1 , December 2017, URL: http://www.ijtsrd.com/papers/ijtsrd7018.pdf http://www.ijtsrd.com/engineering/computer-engineering/7018/agent-based-modeling-methods-and-techniques-for--scheduling-industrial-machine-operation/chiagunye-tochukwu
Simulative study of cause-effect interdependencies in tool logisticsIDES Editor
Today, the forging industry is facing new challenges.
The day-to-day business is characterized by fluctuating order
quantities and the production of high numbers of variants.
Under this condition the tool logistics is gaining more
importance in order to minimize production downtimes
through guaranteeing high tool availability with minimal tool
costs. This paper presents an approach for a synchronisation
of tool supply processes to production requirements by
evaluation of the cause-effect interdependencies from tool life
quantity and tool stock level on production performance and
tool utilization. Therefore the developed simulation model and
its usage for an extensive simulation study is specified in this
paper. It presents the findings from the cause-effect analysis
and is subdivided into four sections. In the first section the tool
logistic is described by a typical tool loop in massive forging
industries which is confirmed by a survey in 27 German forging
companies. Elements of a tool loop and the influencing factors
are specified. From this, the objectives of tool logistics (e. g.
high tool availability and low tool stock level) are deduced in
the second section. For the quantification of objectives in tool
logistics basic key indicators are defined and described
mathematically. In the third section an ideal tool loop is defined
and associated key indicators, such as “Maximum production
output rate per tool” are calculated. The modular structure of
the simulation model and the experimental design for the
simulation study is described in section four. The simulation
study is carried out in order to describe cause-effect
interdependencies between influencing factors and objectives
(e. g. tool availability) in tool logistics. Therefore a one by one
factor study gives significant value ranges for fully factorial
experiments. This is used to analyze the effects of interactions
between influencing factors on the tool logistics objectives.
Finally the basic conclusions from the experimental simulation
study are described as well as the ongoing research which is
facing an approximation function, that enables to calculate tool
operating points.
RESEARCH ON PLANT LAYOUT AND PRODUCTION LINE RUNNING SIMULATION IN PISTON FAC...IAEME Publication
The aim of this paper is to create a better understanding of how simulation is used in industry especially in the area of facility layout planning. The project in which this paper is based upon concerns the development of a factory layout which will be created in a production line simulation. Background research was conducted in the field of simulations including the history, advantages, current capabilities, steps of development, and current uses. Research also concerning layout planning will also be reported in the research sections of this paper.
This document discusses using simulation software to model and optimize a production line layout for a piston factory. It begins with background on simulation software and how it is used for facility layout planning. It then describes modeling the layout and production process of a piston factory in the Arena simulation software. The simulation is used to analyze material flow and optimize the layout to improve production rates by minimizing bottlenecks. The goals are to better understand how simulation can be applied to layout planning and prove its benefits for increasing efficiency in a factory setting.
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.
The document discusses facilitators for increasing after-sales service business, specifically focusing on marking hydraulic hose-assemblies in construction machines. After-sales business provides significant revenue potential, but most OEMs have not capitalized on this opportunity. The objective is to analyze the need for marking hose-assemblies and propose an efficient marking framework. Markings help customers order the right spare part and reduce downtime, but the permanence of the marking must be suitable for the machine's operating environment to avoid unnecessary costs.
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
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Operating Maintenance Model for Modern Printing Machines
1. Acta Polytechnica Hungarica
Vol. 5, No. 3, 2008
Operating Maintenance Model for Modern
Printing Machines
Csaba Horváth
Institute of Mediatechnology, Budapest Tech
Doberdó út 6, H-1034 Budapest, Hungary
E-mail: horvath.csaba@nyt.hu, horvath.csaba@rkk.bmf.hu
Zoltán Gaál
Institute of Economics, University of Pannonia
Egyetem u. 10, H-8200 Veszprém, Hungary
E-mail: gaal@gtk.uni-pannon.hu
Abstract: The authors outlined a model to examine the modern printing machines’
unexpected breakdowns. They had been analysing the different downtimes for years. The
results of the researches help to organize the pro-active maintenance at the graphic arts
industry.
Keywords: printing machines, predictive and pro-active maintenance, breakdown
1
Introduction
The problems of maintenance have accompanied and ‘threatened’ the working
people ever since the application of equipments. It was experienced from the
beginning that equipments could go wrong and machines could break down.
Humans have been and still are working on solutions to these problems, so it is not
an exaggeration to say that maintenance is the same age as humanity and
manufacturing activities. [1]
Maintenance techniques have changed over time from correction (breakdown) to
prevention to prediction and pro-active continuous improvement. Effective
maintenance is a series of progressive steps to improve operational effectiveness
and the key step in this process is the transition of pro-active working. Companies
that optimise their maintenance select and combine the techniques that match the
needs of their equipment and operations.
– 39 –
2. Cs. Horváth et al.
Operating Maintenance Model for Modern Printing Machines
Moving up the maintenance stairway requires a planned approach that brings
together the right procedures, tools, training and the knowledge the feature and
history of our machines’ breakdowns. [2]
2
Maintenance Characteristics and Requirement of
the Modern Printing Machines
The user of printing industry machines and any other operating systems, expects
the machine or system to stand a heavy-duty use during a given period. This
period is not constant. It depends on the construction, the nature of use, the mode
of operation and the quality of maintenance as well. However the analysis of these
technical systems, the profound knowledge of the characteristics of building
elements and the operating indices are essential to establish an adequate
operational and maintenance concept. [3]
Following this approach this chapter summarizes the technical, technological
features, handling and maintenance characteristics of printing industry machines
from the maintenance point of view.
3
Operating Maintanace Model for Printing
Machines
Despite the possible big differences between printing machines we treat them with
a united approach based on their fundamentally common characteristics. One of
the major reasons for the synthesis is originates from maintenance practice.
Generally, the printing offices perform the maintenance duties with staff small in
number. Consequently, there is a little chance to gain special knowledge and
subdivide the maintenance approach and practice. The machines, which are
different in structure and technological tasks, have a lot of common characteristics
from the operational and maintenance point of view in case of printing office
applications, which makes the united approach acceptable.
Consequently, we developed a simple model (Figure 1) that reflects the general
structure of printing machines (divisions and detailing are included), which is
needed to analyse the features of maintenance and maintenance-management.
The technological elements of modern printing machines unite two equally
important operations. The major operation, which performs informational types of
formation on the product, is based on a highly accurate transmitting operation of
the processing material (mostly paper). Therefore, the input and the output units
– 40 –
3. Acta Polytechnica Hungarica
Vol. 5, No. 3, 2008
are very important elements of printing machines. These elements ensure the
assembly of machine systems. Moreover, if the bigger systems were divided into
elements we would always get division three, in the model. The units of operation,
management and supply set the same claims up for the technological units
regarding their structural form, complexity and especially their maintenance
requirements.
Figure 1
Operating maintenance model for the printing machines
3.1
Maintenance Features of Printing Machines
The similarities between the manufacturing processes, raw materials and products
of printing machines result in similar defective, corrective and maintenance
features, which should be considered during management and organizational
tasks. Therefore I thoroughly analysed those sources of faults and damaging
processes, with which we struggle during the operation of printing machines.
At present, according to the results of our survey – carried out among 25 leading
Hungarian and 5 significant printing offices – the major cause (46%) of
maintenance events is the unexpected breakdown. This big proportion also means
– 41 –
4. Cs. Horváth et al.
Operating Maintenance Model for Modern Printing Machines
that this is the most influential factor of designing and managing tasks. Therefore,
the knowledge about unexpected breakdowns, as a phenomenon, is extremely
important for the maintenance management. [4]
The authors could collect data on unexpected breakdowns of printing machines for
a long period of time at Alföldi Printing Plant Plc., Hungary’s largest book
printing plant. A computer-assisted system could continuously record the basic
data of the important processing machines. The historical datasets were set as the
starting point for our analysis. The continuous data collection was carried out on
the most important processing machines of Alföldi Printing Plant Plc. During the
monitoring the machines were replaced from time to time following the
technological development. We monitored 65 printing machines. These represent
the previous, current and following generations. Their age varied between 1 and
27 years and 22 completely new machines were purchased during our monitoring.
Every machine was operated at a specific site, the centre site of Alföldi Printing
Plant.
We used the data of unexpected breakdowns from a wide period of time (data of
17 years of full operation between 1988 and 2004).
The extent of generalization based on the characteristics of printing machines
might obviously raise a few questions from the reader. The printing machines and
the relatively complex technology of Alföldi Printing Plant and their loading give
an extensive cross-section of today’s typical printing machines. It was a limiting
factor that there were only a few similarly detailed and accessible historical
databases even for a shorter period of time. However we could make a comparison
with the data of similar Hungarian printing plants; Szikra Lapnyomda., Révai. and
Petőfi Printing Plant. The data on downtime and reparation time showed
similarities with the calculations from our database.
Figure 2
Most relevant data characterising the unexpected breakdowns of printing machines
(Examination period: 1 January 1988 – 31 December 2004)
– 42 –
5. Acta Polytechnica Hungarica
Vol. 5, No. 3, 2008
Figure 2 shows the major conclusions and the calculated characteristics. The 65
printing machines ran nearly 1.7 million operating hours, while 58317
maintenance events originated from unexpected breakdowns were recorded. The
reparation of the machines caused more than 105,000 operational hours of dropout
in the production and more than 130,000 reparation hours.
The first and the most important conclusion of the calculated values is that the
average value of the reparation times of unexpected breakdowns is low, in other
words dropouts from production due to downtime are short. The average value is
1.80 hour.
According to the Alföldi Printing Plant’s instructions the reparation time is the
period between the report of breakdown and the short check of operation after the
troubleshooting. The troubleshooting takes about 2.24 working hours on average.
We only took those reparation times into consideration that didn’t last more than
24 hours. On one hand the number of longer reparation times are negligible, on the
other hand these breakdowns are not considered to be unexpected by the
maintenance strategy applied at Alföldi Printing Plant.
The machine monitoring system identifies the operation hours of the machines
with the ‘on’ position of the main switch. The identified annual average operating
time is 2.883 working hours, which is equal to nearly 1.5-shift production. The
inequality of technologies and capacities – even within Alföld Printing Plant –
should be considered. There are continuously running basic machines and there
are several other machines performing special technological steps working with
identical speed as the server machines, but these are poorly utilized.
The development of maintenance efficiency obviously has a great impact on
unexpected breakdowns. The change in average values during the past few years
show a slightly decreasing tendency as shown on Figure 3, conforming that the
maintenance efficiency has also improved at Alföldi Printing Office Plc. The
slowly changing tendency of downtimes however proves that the fundamental
maintenance characteristics are originated from structures and technological
conditions. These are independent from the quality of maintenance. The number
of machines used after 2000 didn’t modify the average values of downtime and
reparation times significantly.
– 43 –
6. Cs. Horváth et al.
Operating Maintenance Model for Modern Printing Machines
Figure 3
Time dependence of the average downtime and reparation time
The data also show that the maintenance characteristics of pressing and bounding
machines didn’t differ significantly. The values (shown at Figure 4) confirm the
correctness of the principle; these should be treated together, like we didn’t
distinguish them in the maintenance model either.
Figure 4
Characteristics related to the troubleshooting of unexpected breakdowns for different types of printing
machines
The unexpected breakdowns of printing machines are quickly reparable; these
generally require small maintenance events. The downtime, which is not more
than two hours, caused by operational failure is more than 80%, which generates
more than 50% of this kind of troubleshooting. The originated reduction of losses
requires concentration to details and predictive organisation. The relatively low
average value might just well have a great influence on the future developmental
concepts of maintenance systems. The relatively short reparation times typically
contain several elements that are not actual professional work (reaction time,
approaching the reparation scene, information transfer, etc.). The relative
frequency of values characterising the reparation times of unexpected breakdowns
is shown on a histogram of Figure 5. These data contain extremely important
information for maintenance managers.
– 44 –
7. Acta Polytechnica Hungarica
Vol. 5, No. 3, 2008
Figure 5
Histogram of the relative frequency of time needed to troubleshoot the unexpected breakdowns of
printing machines
Values of Figure 6 give information about the time expected to be needed for the
reparation of the consequences of unexpected breakdowns for printing machines.
Special attention should be paid to these data when designing because the
relatively rare breakdowns require longer reparation time, which need
considerable labour input as shown in the table of Figure 6. More than 8 hours of
reparation time, which appears with less than 3% probability, is the 18% of the
overall reparation expenditure. Whereas the 50% of the reparations resulting less
than an hour of downtime is only 20% of expenditure.
Figure 6
Probability values of time needed to troubleshoot the unexpected breakdowns (based on the histogram)
– 45 –
8. Cs. Horváth et al.
3.2
Operating Maintenance Model for Modern Printing Machines
Typical Breakdowns of the Printing Machines
There is another important approach in this chain of thoughts. What breakdowns
are typical for printing machines? The classification of breakdowns is carried out
according to the 10 big structural groups characterising the printing machines
mentioned in the maintenance event log system, based on the previously presented
model.
Figure 7 shows the breakdown proportion of the distinguished parts. The input
and output units – the units of the above-mentioned transmitting machines – give
the 39% of all breakdowns.
There is a high occurrence of breakdowns due to failures of mechanical
propulsion, sensors and beacons. Units performing technologically important
operation have relatively smaller breakdown proportion compared to their
importance in the machinery. The breakdown proportion of the electrical parts is
20% as shown on the diagram. The proportion of the electrical type of unexpected
breakdowns is 29% including electrical faults of any part.
The knowledge of proportions is especially interesting when preparing for
condition-assessment and modernisation.
Figure 7
Distribution of unexpected breakdowns of printing machines between given main units
Conclusions related to unexpected breakdowns mainly refer to equipments of
printing and further processing. It is also notable that the planned reparations and
the proportion of troubleshooting at the maintenance of Alföldi Printing Plant
correspond to the average in the industry. Characteristics related to prepress
equipment corresponds to the characteristics of computer technology.
Conclusions
For the productivity maintenance of printing machines the detailed knowledge of
relations of failures are crucial. Reparation of unexpected breakdowns generally
requires management of short/reactive reparation. Knowledge about the typical
– 46 –
9. Acta Polytechnica Hungarica
Vol. 5, No. 3, 2008
failure rates of major parts of printing machines is the fundamental pillar to apply
pro-active maintenance management.
Acknoledgement
The authors wish to thank Mrs. Katalin Kerekes, the technical director of Alföldi
Printing Plant Plc. for her help and support.
References
[1]
Tsang, A.: Strategic Dimension of Maintenance Management
Journal of Quality in Maintenance Engineering, 2002/1, pp. 7-39
[2]
Best Practice: Maintenance, p. 24
PrintWeek, December 2003, www.visioninprint.co.uk
[3]
Gaál Z.: Karbantartás-menedzsment
Pannon Egyetemi Kiadó, 2007, p. 236
[4]
Claypole T., Wells N.: Productivity Maintenance in the UK Printing
Industry, p. 84
Vision in Print, March 2005, www.visioninprint.co.uk
– 47 –