This document discusses methods for improving productivity through the deployment of lean manufacturing principles and work study methods. It provides an overview of lean tools such as 5S, standardized work, bottleneck analysis and waste elimination that can be used to reduce waste and improve efficiency. It also describes work study methods like method study which is used to improve work methods, and time study which is used to set standard times for jobs. The document argues that combining lean tools and work study methods through techniques like setup time reduction can help manufacturers increase output and profits by optimizing processes.
IJRET : International Journal of Research in Engineering and Technology is an international peer reviewed, online journal published by eSAT Publishing House for the enhancement of research in various disciplines of Engineering and Technology. The aim and scope of the journal is to provide an academic medium and an important reference for the advancement and dissemination of research results that support high-level learning, teaching and research in the fields of Engineering and Technology. We bring together Scientists, Academician, Field Engineers, Scholars and Students of related fields of Engineering and Technology
The International Journal of Engineering & Science is aimed at providing a platform for researchers, engineers, scientists, or educators to publish their original research results, to exchange new ideas, to disseminate information in innovative designs, engineering experiences and technological skills. It is also the Journal's objective to promote engineering and technology education. All papers submitted to the Journal will be blind peer-reviewed. Only original articles will be published.
Manufacturing Lead Time Reduction in Monoblock (SWJ) Pump Industry [irjet-v4 ...PERUMALSAMY M
Manufacturing lead time is the time required to produce product from its raw materials to final product.A company has to fulfill its customer needs to sustain in this competitive world. Lean has served the manufacturing sector with speed and quality. This project aims at lead time reduction in pump manufacturing company. Value Stream Map(VSM) served as an initiative for identifying bottlenecks process and waste in the manufacturing line; current state map is drawn by the observation made on the shop floor. The takt time is calculated for the demand to find out the bottleneck operations. After identifying the bottleneck operations line balancing is done. The Work In Process (WIP) inventory is reduced by balancing the workstation. Future state map is developed in the perspective of reduction of lead time and to match the takt time with bottleneck process. After line balancing implementation, the lead time for assembly of the SWJ pump is reduced 32 percent and work in process inventory is reduced 25 percent.
The purpose of this paper is to evaluate the contributions of Total Productive Maintenance (TPM) initiatives in reducing equipment breakdowns, increase equipment reliability and improve productivity. This will result in increased equipment utilization and life, reduced work stoppages and machine slowdowns, closer adherence to production and delivery schedules as well as increased employee morale. The Total Productive Maintenance (TPM) concept addresses these goals. The aim of TPM is to keep the plant and equipment at its highest productive level through the cooperation of all areas of the organization. TPM is a partnership between maintenance and production organization to improve product quality, reduce waste, reduce manufacturing cost and increase equipment availability.
IJRET : International Journal of Research in Engineering and Technology is an international peer reviewed, online journal published by eSAT Publishing House for the enhancement of research in various disciplines of Engineering and Technology. The aim and scope of the journal is to provide an academic medium and an important reference for the advancement and dissemination of research results that support high-level learning, teaching and research in the fields of Engineering and Technology. We bring together Scientists, Academician, Field Engineers, Scholars and Students of related fields of Engineering and Technology
The International Journal of Engineering & Science is aimed at providing a platform for researchers, engineers, scientists, or educators to publish their original research results, to exchange new ideas, to disseminate information in innovative designs, engineering experiences and technological skills. It is also the Journal's objective to promote engineering and technology education. All papers submitted to the Journal will be blind peer-reviewed. Only original articles will be published.
Manufacturing Lead Time Reduction in Monoblock (SWJ) Pump Industry [irjet-v4 ...PERUMALSAMY M
Manufacturing lead time is the time required to produce product from its raw materials to final product.A company has to fulfill its customer needs to sustain in this competitive world. Lean has served the manufacturing sector with speed and quality. This project aims at lead time reduction in pump manufacturing company. Value Stream Map(VSM) served as an initiative for identifying bottlenecks process and waste in the manufacturing line; current state map is drawn by the observation made on the shop floor. The takt time is calculated for the demand to find out the bottleneck operations. After identifying the bottleneck operations line balancing is done. The Work In Process (WIP) inventory is reduced by balancing the workstation. Future state map is developed in the perspective of reduction of lead time and to match the takt time with bottleneck process. After line balancing implementation, the lead time for assembly of the SWJ pump is reduced 32 percent and work in process inventory is reduced 25 percent.
The purpose of this paper is to evaluate the contributions of Total Productive Maintenance (TPM) initiatives in reducing equipment breakdowns, increase equipment reliability and improve productivity. This will result in increased equipment utilization and life, reduced work stoppages and machine slowdowns, closer adherence to production and delivery schedules as well as increased employee morale. The Total Productive Maintenance (TPM) concept addresses these goals. The aim of TPM is to keep the plant and equipment at its highest productive level through the cooperation of all areas of the organization. TPM is a partnership between maintenance and production organization to improve product quality, reduce waste, reduce manufacturing cost and increase equipment availability.
MANUFACTURING LEAD TIME REDUCTION IN A SCAFFOLD MAKING INDUSTRY USING LEAN MA...IAEME Publication
The lean manufacturing techniques are used to improve the industrial benefits by reducing the wastages. Wastages mean the non-value adding processes or works. This study focus on how lean manufacturing techniques are used to reduce the manufacturing lead time of a scaffold manufacturing company. To obtain this, there is a wide variety of lean manufacturing techniques used, such as value stream mapping, 5S housekeeping tool, SMED and kaizen. Even though the main objective is to reduce lead time, there are also other objectives like increase in productivity, increase in quality, improvement in meeting the customer demands, improvement in on-time delivery, improvement in customer satisfaction, and machine utilization with reduction in wastages, inventory, huge material handling, and idle time, down time, setup time, space consumption and labor cost. Instead of investing huge amount in new machines to increase the working efficiency, it is much better to adopt these Lean techniques at this demonetized condition of India.
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.
PRODUCTION PROCESS ANALYSIS ON MANUFACTURING OF HYDRAULIC GEAR PUMPmeijjournal
Manufacturing Firms sometimes suffers from Productivity, Low Production rate and Delivery problems. Production time is the top priority at every manufacturing firm, and each firm wants to minimize it as much as possible to deliver their product on time to time their valuable customers. Some of the biggest time eaters in the industry are Setup time, Manufacturing time, Material handling time, and wait time. After the brief survey at VBC Hydraulics, we have conclude that setup time, manufacturing time, and wait time can not be utilize more than current because they are already using best possible machines and technology to manufacture Gear Pumps. But, material handling time and man-machine utilization can be improved by some engineering analysis. We did man-machine utilization by using man-machine utilization charts and some brief calculations and also focused to improve the material handling in the industry by implementation of GT(Group Technology) layout as they are mainly focused to manufacturing of Gear Pumps of different specifications with bulk Production.
The Impact of Lean Production on the Cycle Time: A Case Study of a Welding As...ijsrd.com
The growing global competition is forcing the organisations to reduce the cost for increasing the profit. Lean manufacturing is a powerful tool for attaining this. The history of lean manufacturing starts from the craft production of 1900's. It is evolved through the contributions of F.W. Taylor, Henry Ford, Eiji Toyoda & Taiichi Ohno. The main concept of the lean manufacturing is the reduction in cost by eliminating waste. However, not all lean implementations have produced such results. In this study, a critical examination of lean manufacturing implementation experience at the welding department of a medium size industry located in Kerala, India. . Cycle time reduction is an important way by eliminating or reducing non-value-added activities. To reduce the overall cycle time of manufacturing, the cycle time of each sub-assembly needs to be reduced. Reducing cycle time will have a significant impact on a company's bottom line when implemented. The outcome of this study leads to substantial reduction in cycle time, reduced defects, better utilization of human resource and machines, and reduced cost of maintenance. It has been proved and validated by an empirical relation. The cause and effect diagram is used for analysing the cycle time reduction. The Quality control chart is also used. The improved return on investment (ROI) and reduction in cycle time shows the feasibility. The data for this study were obtained through interviews, Questionnaire survey and archival sources.
Modern Software Productivity Measurement: The Pragmatic GuideCAST
The guide explains why software productivity measurement is crucial for productivity and quality improvement programs, as well as presents best practices for collecting, analyzing, and using productivity data. Recommendations are also included to implement an effective productivity improvement program.
MANUFACTURING LEAD TIME REDUCTION IN A SCAFFOLD MAKING INDUSTRY USING LEAN MA...IAEME Publication
The lean manufacturing techniques are used to improve the industrial benefits by reducing the wastages. Wastages mean the non-value adding processes or works. This study focus on how lean manufacturing techniques are used to reduce the manufacturing lead time of a scaffold manufacturing company. To obtain this, there is a wide variety of lean manufacturing techniques used, such as value stream mapping, 5S housekeeping tool, SMED and kaizen. Even though the main objective is to reduce lead time, there are also other objectives like increase in productivity, increase in quality, improvement in meeting the customer demands, improvement in on-time delivery, improvement in customer satisfaction, and machine utilization with reduction in wastages, inventory, huge material handling, and idle time, down time, setup time, space consumption and labor cost. Instead of investing huge amount in new machines to increase the working efficiency, it is much better to adopt these Lean techniques at this demonetized condition of India.
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.
PRODUCTION PROCESS ANALYSIS ON MANUFACTURING OF HYDRAULIC GEAR PUMPmeijjournal
Manufacturing Firms sometimes suffers from Productivity, Low Production rate and Delivery problems. Production time is the top priority at every manufacturing firm, and each firm wants to minimize it as much as possible to deliver their product on time to time their valuable customers. Some of the biggest time eaters in the industry are Setup time, Manufacturing time, Material handling time, and wait time. After the brief survey at VBC Hydraulics, we have conclude that setup time, manufacturing time, and wait time can not be utilize more than current because they are already using best possible machines and technology to manufacture Gear Pumps. But, material handling time and man-machine utilization can be improved by some engineering analysis. We did man-machine utilization by using man-machine utilization charts and some brief calculations and also focused to improve the material handling in the industry by implementation of GT(Group Technology) layout as they are mainly focused to manufacturing of Gear Pumps of different specifications with bulk Production.
The Impact of Lean Production on the Cycle Time: A Case Study of a Welding As...ijsrd.com
The growing global competition is forcing the organisations to reduce the cost for increasing the profit. Lean manufacturing is a powerful tool for attaining this. The history of lean manufacturing starts from the craft production of 1900's. It is evolved through the contributions of F.W. Taylor, Henry Ford, Eiji Toyoda & Taiichi Ohno. The main concept of the lean manufacturing is the reduction in cost by eliminating waste. However, not all lean implementations have produced such results. In this study, a critical examination of lean manufacturing implementation experience at the welding department of a medium size industry located in Kerala, India. . Cycle time reduction is an important way by eliminating or reducing non-value-added activities. To reduce the overall cycle time of manufacturing, the cycle time of each sub-assembly needs to be reduced. Reducing cycle time will have a significant impact on a company's bottom line when implemented. The outcome of this study leads to substantial reduction in cycle time, reduced defects, better utilization of human resource and machines, and reduced cost of maintenance. It has been proved and validated by an empirical relation. The cause and effect diagram is used for analysing the cycle time reduction. The Quality control chart is also used. The improved return on investment (ROI) and reduction in cycle time shows the feasibility. The data for this study were obtained through interviews, Questionnaire survey and archival sources.
Modern Software Productivity Measurement: The Pragmatic GuideCAST
The guide explains why software productivity measurement is crucial for productivity and quality improvement programs, as well as presents best practices for collecting, analyzing, and using productivity data. Recommendations are also included to implement an effective productivity improvement program.
Understood requirements from Horticulture departments and other stakeholders, gathered information, researched, planned & designed the Amla Project Proposal for Horticulture Department of Mizoram
Secondary research, planning & designing the project which included the implementation plan, budgeting, feasibility study analysis.
Case study- Implementing fully integrated solutions for the food industryFedegari Group
The canned food sterilization faces a great challenge: to minimize the quality losses while providing an adequate process to achieve the desired degree of sterility. Temperature deviations are costly while representing under or over processed food, waste of energy and low productivity. This paper describes the implementation of a fully integrated solution for the sterilization process in one of the biggest European tuna can manufacturers.
IMPROVING OSH & PRODUCTIVITY OF RMG INDUSTRIES BY IMPLEMENTING LEAN TOOLS AN...Karina Islam
The garment industry has played a pioneering role in the development of industrial sector of Bangladesh. The RMG sector is expected to grow despite the global financial crisis of 2009.As China is finding it challenging to make textile and foot wear items at cheap price, due to rising labor costs, many foreign investors, are coming to Bangladesh to take advantage of the low labor cost. Though Bangladesh produces garment with lowest cost but poor productivity. To survive and prosper in today's economic times, companies can no longer manage using financial measures alone, they have to track non-financial measures also such as customer satisfaction, brand preference, speed of response, employee satisfaction etc.Productivity can improve by applying lean tools like- 5s, JIT, Muda, Root Cause analysis, KPIs, VSM. For improving the ultimate productivity OHS of RMG sector of Bangladesh should be improved. In Ready Made Garments (RMG) sector of Bangladesh, the employees represent an organization's biggest and its most valuable asset. The company's productivity, and ultimately, its profitability depend on making sure all of its workers perform up to their full potential. This paper summarizes that how KPIs analysis improve productivity and OHS of RMG sectors. Appropriate indicators are first selected for KPI scoring then simulate the scores with the help of Adaptive Network-based Fuzzy Inference System (ANFIS) and finally illustrated how KPIs impacts on overall productivity.
Patanjali Ayurved Limited is an Indian FMCG company. Manufacturing units and headquarters are located in the industrial area of Haridwar while the registered office is located at Delhi. The company manufactures mineral and herbal products.
±For Education Purpose Only
Punjab technical University - scheme and syllabus of Masters in Business Administration (MBA) Batch 2012 onwards, course code MBA 202, production & operation Management. UNIT 2, ch.1 Facility Layout ch. 2 Production Planning & Control(PPC), ch.3 Method Study ch. 4 Capacity Planning
A case study on productivity improvement of wearing insert and cutting ringIJECSJournal
The objective of this paper is to present case study on a wearing insert and cutting ring for the efficient improvements in productivity with the help of various work Study Methods. In this study productivity is improved through identifying the process that involves the time required for the process as the main reason to achieve the objectives of increasing the productivity. Time and motion study is one of the necessary factors to set a standard target. The study is aimed at identifying the unwanted work processes which in turn increases the time required, efforts as well as the cost of the product. Thus the changes were made in the areas which require improving using work study methods.
This Article on WORK STUDY covers Part-I , UNIT-II of Industrial Administration and Financial Mangement Syllabus of BE 4/4(EEE/EIE/ECE) of Osmania University
The International Journal of Engineering & Science is aimed at providing a platform for researchers, engineers, scientists, or educators to publish their original research results, to exchange new ideas, to disseminate information in innovative designs, engineering experiences and technological skills. It is also the Journal's objective to promote engineering and technology education. All papers submitted to the Journal will be blind peer-reviewed. Only original articles will be published.
The papers for publication in The International Journal of Engineering& Science are selected through rigorous peer reviews to ensure originality, timeliness, relevance, and readability.
Theoretical work submitted to the Journal should be original in its motivation or modeling structure. Empirical analysis should be based on a theoretical framework and should be capable of replication. It is expected that all materials required for replication (including computer programs and data sets) should be available upon request to the authors.
Achieving operational excellence by implementing an erp (enterprise resource ...eSAT Publishing House
IJRET : International Journal of Research in Engineering and Technology is an international peer reviewed, online journal published by eSAT Publishing House for the enhancement of research in various disciplines of Engineering and Technology. The aim and scope of the journal is to provide an academic medium and an important reference for the advancement and dissemination of research results that support high-level learning, teaching and research in the fields of Engineering and Technology. We bring together Scientists, Academician, Field Engineers, Scholars and Students of related fields of Engineering and Technology
Production System optimization: Case Study of a Local Textile Companyjournal ijrtem
ABSTRACT : The manufacturing sector in Botswana has been rapidly growing in recent times. Glam Collections used as a case study organization in this research, is an SME textile manufacturing company with its base of operations in Gaborone, Botswana. The company manufactures a wide range of products in-house and supply to the local market. The company has been growing in terms of scale of production in recent times and this has necessitated it to obtain a larger base of operations which requires an overhauling of their current processes and operations. Hence this research main objective is to demonstrate how Muther’s Systematic Layout (SLP) has been effectively used for departmental layout evaluation and facility design. Lean manufacturing tools were employed in the research together with the SLP technique in order to map and analyze the business processes before the systematic layout could be carried out so as to remove waste in the current process flows and standardize the company operations.
KAIZEN: A Lean Manufacturing Techniquevivatechijri
Now-a-days the ultimate goal of all industries is to enhance productivity through simplified system
and incremental improvements by applying some modern available techniques. At present, many manufacturing
companies are facing problems such as high quality rejection, high inventories, high lead time, high costs of
production, and inability to cope with customer orders. By implementing and practicing the lean production
system many problems can be solved without employing high-tech and high-touch approaches but by involving
people on the shop floor in Kaizen activities. For continuous improvement in an organization, Japanese
philosophy Kaizen is very popular. Flawless concepts of Kaizen methodology and proper implementation of tools
can lead to a successful kaizen program in a company. Kaizen is one of the powerful tools of lean manufacturing.
Kaizen refers to continuous improvement in performance, cost and quality. Kaizen ensures that manufacturing
processes become leaner and fitter, but eliminate waste (problem) where value is added. The main objective of
this paper is to provide a background on kaizen, present an overview of kaizen concepts that are used to transform
a company into a high performing lean enterprise.
INTRODUCTION TO PRODUCTION AND OPERATIONS MANAGEMENT - Unit 1 (BBA-Bangalore ...Afsana salam
Introduction - Meaning & Definition – Classification - Objectives and Scope of Production and operation Management -Automation: Introduction – Meaning and Definition – Need – Types - Advantages and Disadvantages
Mechanical properties of hybrid fiber reinforced concrete for pavementseSAT Journals
Abstract
The effect of addition of mono fibers and hybrid fibers on the mechanical properties of concrete mixture is studied in the present
investigation. Steel fibers of 1% and polypropylene fibers 0.036% were added individually to the concrete mixture as mono fibers and
then they were added together to form a hybrid fiber reinforced concrete. Mechanical properties such as compressive, split tensile and
flexural strength were determined. The results show that hybrid fibers improve the compressive strength marginally as compared to
mono fibers. Whereas, hybridization improves split tensile strength and flexural strength noticeably.
Keywords:-Hybridization, mono fibers, steel fiber, polypropylene fiber, Improvement in mechanical properties.
Material management in construction – a case studyeSAT Journals
Abstract
The objective of the present study is to understand about all the problems occurring in the company because of improper application
of material management. In construction project operation, often there is a project cost variance in terms of the material, equipments,
manpower, subcontractor, overhead cost, and general condition. Material is the main component in construction projects. Therefore,
if the material management is not properly managed it will create a project cost variance. Project cost can be controlled by taking
corrective actions towards the cost variance. Therefore a methodology is used to diagnose and evaluate the procurement process
involved in material management and launch a continuous improvement was developed and applied. A thorough study was carried
out along with study of cases, surveys and interviews to professionals involved in this area. As a result, a methodology for diagnosis
and improvement was proposed and tested in selected projects. The results obtained show that the main problem of procurement is
related to schedule delays and lack of specified quality for the project. To prevent this situation it is often necessary to dedicate
important resources like money, personnel, time, etc. To monitor and control the process. A great potential for improvement was
detected if state of the art technologies such as, electronic mail, electronic data interchange (EDI), and analysis were applied to the
procurement process. These helped to eliminate the root causes for many types of problems that were detected.
Managing drought short term strategies in semi arid regions a case studyeSAT Journals
Abstract
Drought management needs multidisciplinary action. Interdisciplinary efforts among the experts in various fields of the droughts
prone areas are helpful to achieve tangible and permanent solution for this recurring problem. The Gulbarga district having the total
area around 16, 240 sq.km, and accounts 8.45 per cent of the Karnataka state area. The district has been situated with latitude 17º 19'
60" North and longitude of 76 º 49' 60" east. The district is situated entirely on the Deccan plateau positioned at a height of 300 to
750 m above MSL. Sub-tropical, semi-arid type is one among the drought prone districts of Karnataka State. The drought
management is very important for a district like Gulbarga. In this paper various short term strategies are discussed to mitigate the
drought condition in the district.
Keywords: Drought, South-West monsoon, Semi-Arid, Rainfall, Strategies etc.
Life cycle cost analysis of overlay for an urban road in bangaloreeSAT Journals
Abstract
Pavements are subjected to severe condition of stresses and weathering effects from the day they are constructed and opened to traffic
mainly due to its fatigue behavior and environmental effects. Therefore, pavement rehabilitation is one of the most important
components of entire road systems. This paper highlights the design of concrete pavement with added mono fibers like polypropylene,
steel and hybrid fibres for a widened portion of existing concrete pavement and various overlay alternatives for an existing
bituminous pavement in an urban road in Bangalore. Along with this, Life cycle cost analyses at these sections are done by Net
Present Value (NPV) method to identify the most feasible option. The results show that though the initial cost of construction of
concrete overlay is high, over a period of time it prove to be better than the bituminous overlay considering the whole life cycle cost.
The economic analysis also indicates that, out of the three fibre options, hybrid reinforced concrete would be economical without
compromising the performance of the pavement.
Keywords: - Fatigue, Life cycle cost analysis, Net Present Value method, Overlay, Rehabilitation
Laboratory studies of dense bituminous mixes ii with reclaimed asphalt materialseSAT Journals
Abstract
The issue of growing demand on our nation’s roadways over that past couple of decades, decreasing budgetary funds, and the need to
provide a safe, efficient, and cost effective roadway system has led to a dramatic increase in the need to rehabilitate our existing
pavements and the issue of building sustainable road infrastructure in India. With these emergency of the mentioned needs and this
are today’s burning issue and has become the purpose of the study.
In the present study, the samples of existing bituminous layer materials were collected from NH-48(Devahalli to Hassan) site.The
mixtures were designed by Marshall Method as per Asphalt institute (MS-II) at 20% and 30% Reclaimed Asphalt Pavement (RAP).
RAP material was blended with virgin aggregate such that all specimens tested for the, Dense Bituminous Macadam-II (DBM-II)
gradation as per Ministry of Roads, Transport, and Highways (MoRT&H) and cost analysis were carried out to know the economics.
Laboratory results and analysis showed the use of recycled materials showed significant variability in Marshall Stability, and the
variability increased with the increase in RAP content. The saving can be realized from utilization of recycled materials as per the
methodology, the reduction in the total cost is 19%, 30%, comparing with the virgin mixes.
Keywords: Reclaimed Asphalt Pavement, Marshall Stability, MS-II, Dense Bituminous Macadam-II
Laboratory investigation of expansive soil stabilized with natural inorganic ...eSAT Journals
Abstract
Soil stabilization has proven to be one of the oldest techniques to improve the soil properties. Literature review conducted revealed
that uses of natural inorganic stabilizers are found to be one of the best options for soil stabilization. In this regard an attempt has
been made to evaluate the influence of RBI-81 stabilizer on properties of black cotton soil through laboratory investigations. Black
cotton soil with varying percentages of RBI-81 viz., 0, 0.5, 1, 1.5, 2, and 2.5 percent were studied for moisture density relationships
and strength behaviour of soils. Also the effect of curing period was evaluated as literature review clearly emphasized the strength
gain of soils stabilized with RBI-81 over a period of time. The results obtained shows that the unconfined compressive strength of
specimens treated with RBI-81 increased approximately by 250% for a curing period of 28 days as compared to virgin soil. Further
the CBR value improved approximately by 400%. The studies indicated an increasing trend for soil strength behaviour with
increasing percentage of RBI-81 suggesting its potential applications in soil stabilization.
Influence of reinforcement on the behavior of hollow concrete block masonry p...eSAT Journals
Abstract
Reinforced masonry was developed to exploit the strength potential of masonry and to solve its lack of tensile strength. Experimental
and analytical studies have been carried out to investigate the effect of reinforcement on the behavior of hollow concrete block
masonry prisms under compression and to predict ultimate failure compressive strength. In the numerical program, three dimensional
non-linear finite elements (FE) model based on the micro-modeling approach is developed for both unreinforced and reinforced
masonry prisms using ANSYS (14.5). The proposed FE model uses multi-linear stress-strain relationships to model the non-linear
behavior of hollow concrete block, mortar, and grout. Willam-Warnke’s five parameter failure theory has been adopted to model the
failure of masonry materials. The comparison of the numerical and experimental results indicates that the FE models can successfully
capture the highly nonlinear behavior of the physical specimens and accurately predict their strength and failure mechanisms.
Keywords: Structural masonry, Hollow concrete block prism, grout, Compression failure, Finite element method,
Numerical modeling.
Influence of compaction energy on soil stabilized with chemical stabilizereSAT Journals
Abstract
Increase in traffic along with heavier magnitude of wheel loads cause rapid deterioration in pavements. There is a need to improve
density, strength of soil subgrade and other pavement layers. In this study an attempt is made to improve the properties of locally
available loamy soil using twin approaches viz., i) increasing the compaction of soil and ii) treating the soil with chemical stabilizer.
Laboratory studies are carried out on both untreated and treated soil samples compacted by different compaction efforts. Studies
show that increase in compaction effort results in increase in density of soil. However in soil treated with chemical stabilizer, rate of
increase in density is not significant. The soil treated with chemical stabilizer exhibits improvement in both strength and performance
properties.
Keywords: compaction, density, subgradestabilization, resilient modulus
Geographical information system (gis) for water resources managementeSAT Journals
Abstract
Water resources projects are inherited with overlapping and at times conflicting objectives. These projects are often of varied sizes
ranging from major projects with command areas of millions of hectares to very small projects implemented at the local level. Thus,
in all these projects there is seldom proper coordination which is essential for ensuring collective sustainability.
Integrated watershed development and management is the accepted answer but in turn requires a comprehensive framework that can
enable planning process involving all the stakeholders at different levels and scales is compulsory. Such a unified hydrological
framework is essential to evaluate the cause and effect of all the proposed actions within the drainage basins.
The present paper describes a hydrological framework developed in the form of a Hydrologic Information System (HIS) which is
intended to meet the specific information needs of the various line departments of a typical State connected with water related aspects.
The HIS consist of a hydrologic information database coupled with tools for collating primary and secondary data and tools for
analyzing and visualizing the data and information. The HIS also incorporates hydrological model base for indirect assessment of
various entities of water balance in space and time. The framework would be maintained and updated to reflect fully the most
accurate ground truth data and the infrastructure requirements for planning and management.
Keywords: Hydrological Information System (HIS); WebGIS; Data Model; Web Mapping Services
Forest type mapping of bidar forest division, karnataka using geoinformatics ...eSAT Journals
Abstract
The study demonstrate the potentiality of satellite remote sensing technique for the generation of baseline information on forest types
including tree plantation details in Bidar forest division, Karnataka covering an area of 5814.60Sq.Kms. The Total Area of Bidar
forest division is 5814Sq.Kms analysis of the satellite data in the study area reveals that about 84% of the total area is Covered by
crop land, 1.778% of the area is covered by dry deciduous forest, 1.38 % of mixed plantation, which is very threatening to the
environmental stability of the forest, future plantation site has been mapped. With the use of latest Geo-informatics technology proper
and exact condition of the trees can be observed and necessary precautions can be taken for future plantation works in an appropriate
manner
Keywords:-RS, GIS, GPS, Forest Type, Tree Plantation
Factors influencing compressive strength of geopolymer concreteeSAT Journals
Abstract
To study effects of several factors on the properties of fly ash based geopolymer concrete on the compressive strength and also the
cost comparison with the normal concrete. The test variables were molarities of sodium hydroxide(NaOH) 8M,14M and 16M, ratio of
NaOH to sodium silicate (Na2SiO3) 1, 1.5, 2 and 2.5, alkaline liquid to fly ash ratio 0.35 and 0.40 and replacement of water in
Na2SiO3 solution by 10%, 20% and 30% were used in the present study. The test results indicated that the highest compressive
strength 54 MPa was observed for 16M of NaOH, ratio of NaOH to Na2SiO3 2.5 and alkaline liquid to fly ash ratio of 0.35. Lowest
compressive strength of 27 MPa was observed for 8M of NaOH, ratio of NaOH to Na2SiO3 is 1 and alkaline liquid to fly ash ratio of
0.40. Alkaline liquid to fly ash ratio of 0.35, water replacement of 10% and 30% for 8 and 16 molarity of NaOH and has resulted in
compressive strength of 36 MPa and 20 MPa respectively. Superplasticiser dosage of 2 % by weight of fly ash has given higher
strength in all cases.
Keywords: compressive strength, alkaline liquid, fly ash
Experimental investigation on circular hollow steel columns in filled with li...eSAT Journals
Abstract
Composite Circular hollow Steel tubes with and without GFRP infill for three different grades of Light weight concrete are tested for
ultimate load capacity and axial shortening , under Cyclic loading. Steel tubes are compared for different lengths, cross sections and
thickness. Specimens were tested separately after adopting Taguchi’s L9 (Latin Squares) Orthogonal array in order to save the initial
experimental cost on number of specimens and experimental duration. Analysis was carried out using ANN (Artificial Neural
Network) technique with the assistance of Mini Tab- a statistical soft tool. Comparison for predicted, experimental & ANN output is
obtained from linear regression plots. From this research study, it can be concluded that *Cross sectional area of steel tube has most
significant effect on ultimate load carrying capacity, *as length of steel tube increased- load carrying capacity decreased & *ANN
modeling predicted acceptable results. Thus ANN tool can be utilized for predicting ultimate load carrying capacity for composite
columns.
Keywords: Light weight concrete, GFRP, Artificial Neural Network, Linear Regression, Back propagation, orthogonal
Array, Latin Squares
Experimental behavior of circular hsscfrc filled steel tubular columns under ...eSAT Journals
Abstract
This paper presents an outlook on experimental behavior and a comparison with predicted formula on the behaviour of circular
concentrically loaded self-consolidating fibre reinforced concrete filled steel tube columns (HSSCFRC). Forty-five specimens were
tested. The main parameters varied in the tests are: (1) percentage of fiber (2) tube diameter or width to wall thickness ratio (D/t
from 15 to 25) (3) L/d ratio from 2.97 to 7.04 the results from these predictions were compared with the experimental data. The
experimental results) were also validated in this study.
Keywords: Self-compacting concrete; Concrete-filled steel tube; axial load behavior; Ultimate capacity.
Evaluation of punching shear in flat slabseSAT Journals
Abstract
Flat-slab construction has been widely used in construction today because of many advantages that it offers. The basic philosophy in
the design of flat slab is to consider only gravity forces; this method ignores the effect of punching shear due to unbalanced moments
at the slab column junction which is critical. An attempt has been made to generate generalized design sheets which accounts both
punching shear due to gravity loads and unbalanced moments for cases (a) interior column; (b) edge column (bending perpendicular
to shorter edge); (c) edge column (bending parallel to shorter edge); (d) corner column. These design sheets are prepared as per
codal provisions of IS 456-2000. These design sheets will be helpful in calculating the shear reinforcement to be provided at the
critical section which is ignored in many design offices. Apart from its usefulness in evaluating punching shear and the necessary
shear reinforcement, the design sheets developed will enable the designer to fix the depth of flat slab during the initial phase of the
design.
Keywords: Flat slabs, punching shear, unbalanced moment.
Evaluation of performance of intake tower dam for recent earthquake in indiaeSAT Journals
Abstract
Intake towers are typically tall, hollow, reinforced concrete structures and form entrance to reservoir outlet works. A parametric
study on dynamic behavior of circular cylindrical towers can be carried out to study the effect of depth of submergence, wall thickness
and slenderness ratio, and also effect on tower considering dynamic analysis for time history function of different soil condition and
by Goyal and Chopra accounting interaction effects of added hydrodynamic mass of surrounding and inside water in intake tower of
dam
Key words: Hydrodynamic mass, Depth of submergence, Reservoir, Time history analysis,
Evaluation of operational efficiency of urban road network using travel time ...eSAT Journals
Abstract
Efficiency of the road network system is analyzed by travel time reliability measures. The study overlooks on an important measure of
travel time reliability and prioritizing Tiruchirappalli road network. Traffic volume and travel time were collected using license plate
matching method. Travel time measures were estimated from average travel time and 95th travel time. Effect of non-motorized vehicle
on efficiency of road system was evaluated. Relation between buffer time index and traffic volume was created. Travel time model has
been developed and travel time measure was validated. Then service quality of road sections in network were graded based on
travel time reliability measures.
Keywords: Buffer Time Index (BTI); Average Travel Time (ATT); Travel Time Reliability (TTR); Buffer Time (BT).
Estimation of surface runoff in nallur amanikere watershed using scs cn methodeSAT Journals
Abstract
The development of watershed aims at productive utilization of all the available natural resources in the entire area extending from
ridge line to stream outlet. The per capita availability of land for cultivation has been decreasing over the years. Therefore, water and
the related land resources must be developed, utilized and managed in an integrated and comprehensive manner. Remote sensing and
GIS techniques are being increasingly used for planning, management and development of natural resources. The study area, Nallur
Amanikere watershed geographically lies between 110 38’ and 110 52’ N latitude and 760 30’ and 760 50’ E longitude with an area of
415.68 Sq. km. The thematic layers such as land use/land cover and soil maps were derived from remotely sensed data and overlayed
through ArcGIS software to assign the curve number on polygon wise. The daily rainfall data of six rain gauge stations in and around
the watershed (2001-2011) was used to estimate the daily runoff from the watershed using Soil Conservation Service - Curve Number
(SCS-CN) method. The runoff estimated from the SCS-CN model was then used to know the variation of runoff potential with different
land use/land cover and with different soil conditions.
Keywords: Watershed, Nallur watershed, Surface runoff, Rainfall-Runoff, SCS-CN, Remote Sensing, GIS.
Estimation of morphometric parameters and runoff using rs & gis techniqueseSAT Journals
Abstract
Land and water are the two vital natural resources, the optimal management of these resources with minimum adverse environmental
impact are essential not only for sustainable development but also for human survival. Satellite remote sensing with geographic
information system has a pragmatic approach to map and generate spatial input layers of predicting response behavior and yield of
watershed. Hence, in the present study an attempt has been made to understand the hydrological process of the catchment at the
watershed level by drawing the inferences from moprhometric analysis and runoff. The study area chosen for the present study is
Yagachi catchment situated in Chickamaglur and Hassan district lies geographically at a longitude 75⁰52’08.77”E and
13⁰10’50.77”N latitude. It covers an area of 559.493 Sq.km. Morphometric analysis is carried out to estimate morphometric
parameters at Micro-watershed to understand the hydrological response of the catchment at the Micro-watershed level. Daily runoff
is estimated using USDA SCS curve number model for a period of 10 years from 2001 to 2010. The rainfall runoff relationship of the
study shows there is a positive correlation.
Keywords: morphometric analysis, runoff, remote sensing and GIS, SCS - method
-
Effect of variation of plastic hinge length on the results of non linear anal...eSAT Journals
Abstract The nonlinear Static procedure also well known as pushover analysis is method where in monotonically increasing loads are applied to the structure till the structure is unable to resist any further load. It is a popular tool for seismic performance evaluation of existing and new structures. In literature lot of research has been carried out on conventional pushover analysis and after knowing deficiency efforts have been made to improve it. But actual test results to verify the analytically obtained pushover results are rarely available. It has been found that some amount of variation is always expected to exist in seismic demand prediction of pushover analysis. Initial study is carried out by considering user defined hinge properties and default hinge length. Attempt is being made to assess the variation of pushover analysis results by considering user defined hinge properties and various hinge length formulations available in literature and results compared with experimentally obtained results based on test carried out on a G+2 storied RCC framed structure. For the present study two geometric models viz bare frame and rigid frame model is considered and it is found that the results of pushover analysis are very sensitive to geometric model and hinge length adopted. Keywords: Pushover analysis, Base shear, Displacement, hinge length, moment curvature analysis
Effect of use of recycled materials on indirect tensile strength of asphalt c...eSAT Journals
Abstract
Depletion of natural resources and aggregate quarries for the road construction is a serious problem to procure materials. Hence
recycling or reuse of material is beneficial. On emphasizing development in sustainable construction in the present era, recycling of
asphalt pavements is one of the effective and proven rehabilitation processes. For the laboratory investigations reclaimed asphalt
pavement (RAP) from NH-4 and crumb rubber modified binder (CRMB-55) was used. Foundry waste was used as a replacement to
conventional filler. Laboratory tests were conducted on asphalt concrete mixes with 30, 40, 50, and 60 percent replacement with RAP.
These test results were compared with conventional mixes and asphalt concrete mixes with complete binder extracted RAP
aggregates. Mix design was carried out by Marshall Method. The Marshall Tests indicated highest stability values for asphalt
concrete (AC) mixes with 60% RAP. The optimum binder content (OBC) decreased with increased in RAP in AC mixes. The Indirect
Tensile Strength (ITS) for AC mixes with RAP also was found to be higher when compared to conventional AC mixes at 300C.
Keywords: Reclaimed asphalt pavement, Foundry waste, Recycling, Marshall Stability, Indirect tensile strength.
Water scarcity is the lack of fresh water resources to meet the standard water demand. There are two type of water scarcity. One is physical. The other is economic water scarcity.
Industrial Training at Shahjalal Fertilizer Company Limited (SFCL)MdTanvirMahtab2
This presentation is about the working procedure of Shahjalal Fertilizer Company Limited (SFCL). A Govt. owned Company of Bangladesh Chemical Industries Corporation under Ministry of Industries.
NO1 Uk best vashikaran specialist in delhi vashikaran baba near me online vas...Amil Baba Dawood bangali
Contact with Dawood Bhai Just call on +92322-6382012 and we'll help you. We'll solve all your problems within 12 to 24 hours and with 101% guarantee and with astrology systematic. If you want to take any personal or professional advice then also you can call us on +92322-6382012 , ONLINE LOVE PROBLEM & Other all types of Daily Life Problem's.Then CALL or WHATSAPP us on +92322-6382012 and Get all these problems solutions here by Amil Baba DAWOOD BANGALI
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Overview of the fundamental roles in Hydropower generation and the components involved in wider Electrical Engineering.
This paper presents the design and construction of hydroelectric dams from the hydrologist’s survey of the valley before construction, all aspects and involved disciplines, fluid dynamics, structural engineering, generation and mains frequency regulation to the very transmission of power through the network in the United Kingdom.
Author: Robbie Edward Sayers
Collaborators and co editors: Charlie Sims and Connor Healey.
(C) 2024 Robbie E. Sayers
Cosmetic shop management system project report.pdfKamal Acharya
Buying new cosmetic products is difficult. It can even be scary for those who have sensitive skin and are prone to skin trouble. The information needed to alleviate this problem is on the back of each product, but it's thought to interpret those ingredient lists unless you have a background in chemistry.
Instead of buying and hoping for the best, we can use data science to help us predict which products may be good fits for us. It includes various function programs to do the above mentioned tasks.
Data file handling has been effectively used in the program.
The automated cosmetic shop management system should deal with the automation of general workflow and administration process of the shop. The main processes of the system focus on customer's request where the system is able to search the most appropriate products and deliver it to the customers. It should help the employees to quickly identify the list of cosmetic product that have reached the minimum quantity and also keep a track of expired date for each cosmetic product. It should help the employees to find the rack number in which the product is placed.It is also Faster and more efficient way.
Welcome to WIPAC Monthly the magazine brought to you by the LinkedIn Group Water Industry Process Automation & Control.
In this month's edition, along with this month's industry news to celebrate the 13 years since the group was created we have articles including
A case study of the used of Advanced Process Control at the Wastewater Treatment works at Lleida in Spain
A look back on an article on smart wastewater networks in order to see how the industry has measured up in the interim around the adoption of Digital Transformation in the Water Industry.
Immunizing Image Classifiers Against Localized Adversary Attacksgerogepatton
This paper addresses the vulnerability of deep learning models, particularly convolutional neural networks
(CNN)s, to adversarial attacks and presents a proactive training technique designed to counter them. We
introduce a novel volumization algorithm, which transforms 2D images into 3D volumetric representations.
When combined with 3D convolution and deep curriculum learning optimization (CLO), itsignificantly improves
the immunity of models against localized universal attacks by up to 40%. We evaluate our proposed approach
using contemporary CNN architectures and the modified Canadian Institute for Advanced Research (CIFAR-10
and CIFAR-100) and ImageNet Large Scale Visual Recognition Challenge (ILSVRC12) datasets, showcasing
accuracy improvements over previous techniques. The results indicate that the combination of the volumetric
input and curriculum learning holds significant promise for mitigating adversarial attacks without necessitating
adversary training.
About
Indigenized remote control interface card suitable for MAFI system CCR equipment. Compatible for IDM8000 CCR. Backplane mounted serial and TCP/Ethernet communication module for CCR remote access. IDM 8000 CCR remote control on serial and TCP protocol.
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Indigenized remote control interface card suitable for MAFI system CCR equipment. Compatible for IDM8000 CCR. Backplane mounted serial and TCP/Ethernet communication module for CCR remote access. IDM 8000 CCR remote control on serial and TCP protocol.
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Indigenized remote control interface card suitable for MAFI system CCR equipment. Compatible for IDM8000 CCR. Backplane mounted serial and TCP/Ethernet communication module for CCR remote access. IDM 8000 CCR remote control on serial and TCP protocol.
• Remote control: Parallel or serial interface
• Compatible with MAFI CCR system
• Copatiable with IDM8000 CCR
• Compatible with Backplane mount serial communication.
• Compatible with commercial and Defence aviation CCR system.
• Remote control system for accessing CCR and allied system over serial or TCP.
• Indigenized local Support/presence in India.
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• Compatible with MAFI CCR system.
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• Remote control system for accessing CCR and allied system over serial or TCP.
• Indigenized local Support/presence in India.
• Easy in configuration using DIP switches.
Hierarchical Digital Twin of a Naval Power SystemKerry Sado
A hierarchical digital twin of a Naval DC power system has been developed and experimentally verified. Similar to other state-of-the-art digital twins, this technology creates a digital replica of the physical system executed in real-time or faster, which can modify hardware controls. However, its advantage stems from distributing computational efforts by utilizing a hierarchical structure composed of lower-level digital twin blocks and a higher-level system digital twin. Each digital twin block is associated with a physical subsystem of the hardware and communicates with a singular system digital twin, which creates a system-level response. By extracting information from each level of the hierarchy, power system controls of the hardware were reconfigured autonomously. This hierarchical digital twin development offers several advantages over other digital twins, particularly in the field of naval power systems. The hierarchical structure allows for greater computational efficiency and scalability while the ability to autonomously reconfigure hardware controls offers increased flexibility and responsiveness. The hierarchical decomposition and models utilized were well aligned with the physical twin, as indicated by the maximum deviations between the developed digital twin hierarchy and the hardware.
block diagram and signal flow graph representation
Productivity improvement through lean deployment & work study methods
1. IJRET: International Journal of Research in Engineering and Technology eISSN: 2319-1163 | pISSN: 2321-7308
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Volume: 03 Issue: 02 | Feb-2014, Available @ http://www.ijret.org 429
PRODUCTIVITY IMPROVEMENT THROUGH LEAN DEPLOYMENT &
WORK STUDY METHODS
Prathamesh P. Kulkarni1
, Sagar S. Kshire2
, Kailas V. Chandratre3
1, 2
Student (Final Year), 3
Associate Professor & Head of The Department, Department of Mechanical Engineering, GES’s
R.H.S. COE, Nashik, Maharashtra, India
Abstract
The objective of this paper is to present an overview on a new combined methodology for the efficient improvement in productivity
with the help of various Work Study Methods associated with Lean Manufacturing Principles & Tools. Lean manufacturing tools are
one of the most influential & most effective methodologies for eliminating wastes (MUDA), controlling quality, and improving overall
performance of any machine, system or process in any industry with the complete assurance of large annual profit margins. This
prescriptive paper proposes genuine solutions & concepts for implementing Work Study Methods and deploying associated lean
manufacturing tools in any enterprise or industry, covering the technical, engineering, and manufacturing aspects as well as the
business etiquette affairs. Lean Manufacturing together with Work Study Methods, being the most sophisticated & vast area of studies
has a huge scope for implementation & deployment of their very own concepts.
Keywords: 5S, Wastes (Muda), Time & Method Study, Setup Time Reduction (SUR), Standardized Work (SDW).
----------------------------------------------------------------------***------------------------------------------------------------------------
1. INTRODUCTION
Productivity has been generally defined as the ratio of an
extent of output to the unit of all of the resources used to
produce this output. Productivity usually deviates from
production. Production concerns with an increment in output
over a given span of time; productivity is concerned with the
ratio of output to an input. Putting in another way, improving
productivity has to do with how effectively people combine
different resources to manufacture parts and services others
dream to purchase. With the correct choices, improved
production, higher values and elevated incomes can be
accomplished for every hour worked. [1]
With rapid increase in demand of production, manufacturing
industries need to increase their potentials in production &
effectiveness to compete against their competitors. At the
same time, the production process has to be ready with the
ability to have abated costs with higher proficiency. Hence the
route to simplify the problem regarding the production is of
paramount importance. There are many ways i.e. Standardize
Work (SDW), Setup Reduction (SUR), Cycle Time
Reduction, Waste Elimination, etc. to solve the problems
concerning & governing productivity.
Considering the inclination towards a customer-focused
environment while facing fierce juxtapositions, majority of
manufacturers are implementing Work Study Methods along
with lean manufacturing tools to help eliminate wastes and
increase proficiencies rather than depending on conventional
processes and procedures [8]. According to many researchers,
using Lean Tools is the best way to improve productivity by
eliminating or reducing time consuming actions which
generally do not contribute in actual production. It is a way by
which one can reduce the cost of manufacturing & increase
productivity, which also increases annual profitability of the
industry. [2]
1.1 Role of Lean Tools in Improving Productivity
The basic definition of Lean Manufacturing can be stated as, a
perspective to manufacturing that searches for an opportunity
to reduce the operation time of processes, increase
maneuverability, and improve the corresponding attributes.
The primary concept behind Lean manufacturing is optimizing
customer significance while minimizing wastes, thereby
achieving manufacturing excellence through the creation of
more value with fewer or absolutely no capital investments.
[4]
Specific set of tools used in/for Lean Manufacturing, which
comprises together a complete methodology and which are
interdependent on each other forming a sophisticated yet
effective system are knows as Lean Tools. They play vital role
in any productivity improvement event as they have a very
high rate of success & also long lasting improved effect.
1.2 Role of Work Study in Improving Productivity
Work Study is the systematic methodology of carrying out
different yet related activities such as to improve the efficient
use of resources and to set up standards of performance &
quality for the activities to be carried out.
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In simple language, it may be defined as the analysis of a job
for the sheer purpose of finding the subsequent method of
doing it and also determining the required standard time to
perform it by the selected or given method. [9]
Work Study generally is classified in two areas: Method study
(Motion study) and Time study (Work measurement).
2. LEAN TOOLS
Lean tools have not been derived or proposed in one single
day. They have been derived from the research of many
people throughout the history. As they are why very complex
& interdependent on each other and one can find similarities
in one another.
Fig -1: Critical Lean Tools
Currently in practice, there are approximately 25 Lean Tools,
out of which, these five tools are considered to be the most
critical Lean Tools of all, as shown in above figure. [8]
2.1 Bottleneck Analysis
A point of concourse in a machine or system that arises when
work load gathers at a point in the system more hastily than
that specific point can hope to maintain them. The intricacies
fetched about by the bottleneck often make a queue and a
longer overall cycle time. By definition, a bottleneck is a
phenomenon where the competency of a complete system or
line is restricted or limited by a single or limited number of
components or resources & analysis of such event is called as
Bottleneck Analysis.
Hence, Bottleneck Analysis is nothing but the identification of
which part/machine of the manufacturing process/line limits
the overall output and focuses on improvement the
performance of that part/machine of the process/line. [5]
Bottleneck Analysis is usually done along with the Time
Study Method. The system on which the analysis is required to
be done is first selected. Then in the form of ‘Daily Analysis’,
‘Minute to Minute Analysis; or ‘Macro Second Study
Analysis’ the entire process is carried out along with the
guidance of Time Study Methods.
An example of Minute to Minute Bottleneck Analysis is as
shown in the figure below
Fig -2: Example of Bottleneck Analysis Sheet
2.2 Wastes (MUDA)
Anything in the manufacturing process that does not add value
to the product from the customer’s perspective is known as
Waste. In simple Language, It is nothing but any process for
which the customer does not pay the company.
There are 7 most Deadly Wastes in common –
Fig -3: Seven Deadly Wastes
1.24 To 1.26 2.00 407
1.26 To 1.30 4.00
1.30 To 1.45
1.45 To 1.50 10.00
1.50 To 3.09
3.09 To 3.30 21.00
Down Time: 175Total Time: 510.0 No. of change over
Run time = 335 minutes (Total time - Down time )
Operator Away from machine, m/c Stopped
263 no's produced
M/c Stopped, Shift Change
Tool Change
Operator Away from machine, m/c Stopped
Tea break
Down Time (Min) To
7.00 To 7.34 34.00
7.34 To 7.44 10.00
7.44 To 7.51 7.00
7.51 To 8.10 19.00
8.10 To 8.19 9.00
8.19 To 8.27
8.27 To 8.32 5.00
27 no's produced
Machine Stopped, Point problem
Single job produced, Lab testing for quality
Power Loss
Operator Absent, M/c stopped due to power loss
Machine Setting and Parameters Checking
Time (Min) Remark
Operator Absent
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1. Transportation - The unnecessary movements of
operator, products or components from one place to
another result in this waste. Unnecessary transport more
commonly occurs together with product damages, lost
parts and systems, which are related with movements. [3]
2. Inventory - Inventory is the quantity of materials in
stores, which are required to manufacture a job. When
they are not used, they take up valuable storage space,
may become useless, which cannot be used for more
important goods. [3]
3. Motion - This waste comprises of all unnecessary
movements occur when operator is moving around his
work area and as a result of this; his time & efforts are
wasted. All kinds of unnecessary motion may be caused
by improper working standard practices, un-optimized
process design or work space layout. [3]
4. Waiting - If operators, machine, system or materials of
the production process are delayed by any reason,
production time is wasted, the productivity is decreased &
the cost of production will be increased.
5. Over Processing - It can also mean manufacturing the
products of a larger quality than required. This can also be
result of not checking what the customers’ real
requirements are. [3]
6. Over Production - It arises when the manufacturer is
producing more products than the customer really asks
for. This is the worst kind of waste, as it generally creates
other kinds of wastes. It increases rework factor, material
storage, processing, holding & waiting, as well as
transportation & unnecessary motion. [3]
7. Defects (Rework, Scrap) - Rework is required when
products and components are defective or damaged.
Defects are caused by bad manufacturing processes
(caused by human or machine errors). In worst case
scenario the items have to be discarded.
In these 7 wastes, ‘Over Production’ & ‘Inventory’ are
observed to be very similar to one another & hence, in modern
Lean Methodology, ‘Inventory’ is often replaced by
‘Inspection’.
Also, one more waste is being added to these 7 deadly wastes
as this waste is also observed to be of great importance, and
that is ‘Unutilized Skill’.
2.3 5S
An established methodology procreating in Japan that, when
implemented, mitigates the waste of resources and work area
in spite of increment in manufacturing & operational
proficiency. The 5S elements when translated in English are
Sort, Set-in-Order, Shine, Standardize & Sustain and are
applied in various industries to achieve lean manufacturing &
to ultimately improve productivity. [5]
Idea of 5S can be explained by following 5 Steps -
Sort: Completely Sort out & classify that which item is
required and/or not required in the work area.
Set in Order: Arrange items in required order that are
important so that they are ready to find & easy to use.
Shine: Clean the work area, tools, machine &
equipments on a continuous basis in order to identify
defects& maintain standards.
Standardize: Ensure standard & uniform procedures
and methods throughout the operation to promote
changeover.
Sustain: Stay to the regulations to maintain the
standard & continue to improve every day. [5][6]
2.4 Standardized Work (SDW)
Standardized work is a collection and implementation of the
best practices known to that point. It includes what is
mandatory to begin the procedure and the completed state of
the same. Standard Work is the sequential method for defining
the best practices and ensuring that every operator is strictly
following them to endow the value to the customers. Because
improvements in safety, quality, productivity & profitability
will arise from time to time & the standardized work is to be
updated via work instructions document, training, and
practice. These are the methodologies that improve quality,
safety, productivity & profitability.
Basically, standardized work consists of four elements:
Takt time, which is the rate at which the products
must be manufactured in order to meet customer
demand on time.
The accurate work sequence in which the operator
performs tasks within takt time.
The corresponding inventory, including jobs in
machines, required to maintain the process operation
smoothly.
The dexterity of the operator & the maneuverability
of the machine or system.
2.4.1 Steps Involved in Standardized Work
1. Identify and define the best system that bestows a quality
result, consistently.
2. Document the steps for performing the best practice, and
make it visual using combination of pictures and text.
3. Place it at each work station where this process is being
performed by the operator.
4. Train the operators to do the tasks as defined in the
Standard Operating Procedure.
Standardized work adds regimentation to the abidance, an
element that is frequently neglected but essential for lean to
take foundation.
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3. WORK STUDY METHODS
In order to understand the work study methods, we need to
understand the importance of method study and that of time
study. ‘Method study’ (sometimes also called Work Method
Design) is mostly used to improve the method of doing work.
When applied to existing products, method study aims to
allocate better methods of manufacturing the jobs that are safe,
effective, & economical, require mitigated human effort, and
need smaller make-ready time. The better method involves the
optimum use of best materials and appropriate manpower so
that work is performed in well-organized manner leading to
increased resource utilization, optimized quality and appeased
costs.
Fig -4: Work Study Methods
It can therefore be stated that through 'Method study' one can
have a systematic way of developing human resource
ascendancy, providing elevated machine and equipment use,
and making economical use of raw materials. ‘Time study’,
however, provides the standard required time, that is the time
needed by worker to complete a job by the standard method.
By the application of method study and time study together
with Lean Tools, any industry can thus achieve greater output
at less cost and of better quality, and hence can easily achieve
higher productivity. [9]
3.1 Method Study (Work Method Design)
Fig -5: Method Study Procedure
As seen earlier, Method study focuses to achieve the better
method of doing work, and for this reason method study is
sometimes called Work Method Design.
The following steps depict the procedure for creating a method
study.
1. Select (the work to be studied).
2. Record (all relevant information about that work).
3. Examine (the recorded information).
4. Develop (an improved way of doing things).
5. Install (the new method as standard practice)
6. Maintain (the new standard proactive).
3.2 Time Study (Work Measurement)
Work measurement refers to the estimation of standard time
for an activity that is the time specific for completing one job
by using the predicted method. Standard time can be defined
as the time utilized by an average experienced skillful operator
for the job with provisions for delays beyond the operator’s
control.
A work has to be measured for the following reasons:
To identify and eliminate missing or ineffective time.
To install standard times for performance & quality
measurement.
To measure performance against original expectations.
To set manufacturing & operating objectives.
Time study can be simply defined as a technique to estimate
the time to be allowed to a qualified and well-trained worker
working at a normal pace to complete a specified task by using
specified method.
Fig -6: Time Study Procedure
METHOD STUDY
Scrutinizing a Product &
searching more proficient
methods to carry it.
TIME STUDY
Deciding the time required to
perform a job & its associative
precautions.
WORK
STUDY
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4. SETUP TIME REDUCTION (SUR)
Setup is a set of activities to be prepared for the next part or
process, Whereas, Setup Time is the total elapsed time from
completion of the last good part from the previous setup to the
completion of the first good part from the new setup. Setup
Time Reduction or Change-over Time Reduction is defined as
the efficient reduction time to change from the last item of the
previous order to the first good item of the next order in order
to obtain increased productivity. [11]
Setup includes preparation, replacement, location and
adjustment activities. In setup reduction process, internal setup
activities require an inactive (shut down) process, meaning
that no jobs can be manufactured while the setup activity is
taking place & external setup activities may be done while the
machine is operational. By definition, all activities performed
while the machine is not producing parts are considered
internal activities. And, all the setup related activities that are
performed while the machine is producing good parts (either
the previous order or the new order) are considered external
activities. Incredible reductions in total setup time have been
realized simply by making internal activities external
activities. [10]
4.1 Need for Setup Time Reduction
Today’s manufacturing and business environments are
reaching a point that competition for survival and market share
is an obligation. Tracking the global economy will show that
being good is not sufficient, therefore every organization
really endeavor for transcendence if want to remain in the
competition.
Why Setup Reduction?
Simply -
“Equipment and the operator are occupied but
there is NO output”
Setup Time Reduction is one of the best methods to increase
efficiency of the overall plant and thereby improving the
profitability.
• Setup time reduction improves the equipment
availability, increasing the total capacity & results in:
– Better utilization of operator’s time.
– Better utilization of resources & capital cost.
– Reduced capital investment.
• Reduced setup time makes smaller batch sizes
possible, without the economic penalty, resulting in reduced:
– Overall lead times.
– Inventory & storage space needs.
– Reject rates.
Setup Reduction allows batch size reduction, which is critical
for continuous flow manufacturing & improves manufacturing
flexibility.
The following five-step approach to setup reduction may be
used to achieve efficient results –
Fig -7: Five Step Approach to SUR
5. SUMMARY
In summary, with the help of systematic study of all the
critical lean tools stated above along with efficient work study
methods, the required results of improving productivity can be
achieved in limited or very less resources in return.
In order to select target for the improvement, method study
can firstly be done to obtain accurate results about the system
which is crucial for defining the problem. After the
corresponding target has been selected, Bottleneck Analysis is
the best option to narrow down the area of problem. Once that
is done, advanced time study methods are to be implemented
to find out detailed problems present in the system.
Once the industry gets hold of the detailed problems, they can
be categorized in substantial groups in order to maintain their
integrity & so that, efficient solution on a particular problem
can easily be obtained. With Critical Lean tools stated above,
problems can be efficiently classified in corresponding area
and those tools can be applied one by one to get long lasting
results along with improved productivity as well as profit
margin.