Abstract: The purpose of this project is to carry out an analysis
and determine the profile of actual lean manufacturing processes in
the Metropolitan Area of Bucaramanga. Through the analysis of
qualitative and quantitative variables it was possible to establish how
these manufacturers develop production practices that ensure their
competitiveness and productivity in the market.
In this study, a random sample of metallurgic and wrought iron
companies was applied, following which a quantitative focus and
analysis was used to formulate a qualitative methodology for
measuring the level of lean manufacturing procedures in the industry.
A qualitative evaluation was also carried out through a multivariate
analysis using the Numerical Taxonomy System (NTSYS) program
which should allow for the determination of Lean Manufacturing
profiles.
Through the results it was possible to observe how the companies
in the sector are doing with respect to Lean Manufacturing Practices,
as well as identify the level of management that these companies
practice with respect to this topic. In addition, it was possible to
ascertain that there is no one dominant profile in the sector when it
comes to Lean Manufacturing.
It was established that the companies in the metallurgic and
wrought iron industry show low levels of Lean Manufacturing
implementation. Each one carries out diverse actions that are
insufficient to consolidate a sectoral strategy for developing a
competitive advantage which enables them to tie together a
production strategy.
Abstract: A novel simulation method to determine the
displacements of machine tools due to thermal factors is presented.
The specific characteristic of this method is the employment of
original CAD data from the design process chain, which is
interpreted by an algorithm in terms of geometry-based allocation of
convection and radiation parameters. Furthermore analogous models
relating to the thermal behaviour of machine elements are
automatically implemented, which were gained by extensive
experimental testing with thermography imaging. With this a
transient simulation of the thermal field and in series of the
displacement of the machine tool is possible simultaneously during
the design phase. This method was implemented and is already used
industrially in the design of machining centres in order to improve
the quality of herewith manufactured workpieces.
Abstract: Identification and selection of appropriate product and
manufacturing technologies are key factors for competitiveness and
market success of technology-based companies. Therefore, many
companies perform technology intelligence (TI) activities to ensure
the identification of evolving technologies at the right time.
Technology monitoring is one of the three base activities of TI,
besides scanning and scouting.
As the technological progress is accelerating, more and more
technologies are being developed. Against the background of limited
resources it is therefore necessary to focus TI activities. In this paper
we propose a concept for defining appropriate search fields for
technology monitoring. This limitation of search space leads to more
concentrated monitoring activities. The concept will be introduced
and demonstrated through an anonymized case study conducted
within an industry project at the Fraunhofer Institute for Production
Technology IPT.
The described concept provides a customized monitoring
approach, which is suitable for use in technology-oriented companies.
It is shown in this paper that the definition of search fields and search
tasks are suitable methods to define topics of interest and thus to
align monitoring activities. Current as well as planned product,
production and material technologies and existing skills, capabilities
and resources form the basis for derivation of relevant search areas.
To further improve the concept of technology monitoring the
proposed concept should be extended during future research e.g. by
the definition of relevant monitoring parameters.
Abstract: Innovations not only contribute to competitiveness of
the company but have also positive effects on revenues. On average,
product innovations account to 14 percent of companies’ sales.
Innovation management has substantially changed during the last
decade, because of growing reliance on external partners. As a
consequence, a new task for purchasing arises, as firms need to
understand which suppliers actually do have high potential
contributing to the innovativeness of the firm and which do not.
Proper organization of the purchasing function is important since
for the majority of manufacturing companies deal with substantial
material costs which pass through the purchasing function. In the past
the purchasing function was largely seen as a transaction-oriented,
clerical function but today purchasing is the intermediate with supply
chain partners contributing to innovations, be it product or process
innovations. Therefore, purchasing function has to be organized
differently to enable firm innovation potential.
However, innovations are inherently risky. There are behavioral
risk (that some partner will take advantage of the other party),
technological risk in terms of complexity of products and processes
of manufacturing and incoming materials and finally market risks,
which in fact judge the value of the innovation. These risks are
investigated in this work. Specifically, technological risks which deal
with complexity of the products, and processes will be investigated
more thoroughly. Buying components or such high edge technologies
necessities careful investigation of technical features and therefore is
usually conducted by a team of experts. Therefore it is hypothesized
that higher the technological risk, higher will be the centralization of
the purchasing function as an interface with other supply chain
members.
Main contribution of this research lies is in the fact that analysis
was performed on a large data set of 1493 companies, from 25
countries collected in the GMRG 4 survey. Most analyses of
purchasing function are done by case study analysis of innovative
firms. Therefore this study contributes with empirical evaluations that
can be generalized.
Abstract: The systematic evaluation of manufacturing
technologies with regard to the potential for product designing
constitutes a major challenge. Until now, conventional evaluation
methods primarily consider the costs of manufacturing technologies.
Thus, the potential of manufacturing technologies for achieving
additional product design features is not completely captured. To
compensate this deficit, final evaluations of new technologies are
mainly intuitive in practice. Therefore, an additional evaluation
dimension is needed which takes the potential of manufacturing
technologies for specific realizable product designs into account. In
this paper, we present the approach of an evaluation method for
selecting manufacturing technologies with regard to their potential
for product designing. This research is done within the Fraunhofer
innovation cluster »AdaM« (Adaptive Manufacturing) which targets
the development of resource efficient and adaptive manufacturing
technology processes for complex turbomachinery components.
Abstract: The manufacturing technology of band cotton is very
delicate and depends to choice of certain parameters such as torsion
of warp yarn.
The fabric elasticity is achieved without the use of any elastic
material, chemical expansion, artificial or synthetic and it’s capable
of creating pressures useful for therapeutic treatments.
Before use, the band is subjected to treatments of specific
preparation for obtaining certain elasticity, however, during its
treatment, there are some regression parameters. The dependence of
manufacturing parameters on the quality of the chemical treatment
was confirmed.
The aim of this work is to improve the properties of the fabric
through the development of manufacturing technology appropriately.
Finally for the treatment of the strip pancake 100% cotton, a
treatment method is recommended.
Abstract: Mass flow measurement is the basis of most technoeconomic
formulations in the chemical industry. This calls for
reliable and accurate detection of mass flow. Flow measurement
laboratory experiments were conducted using various instruments.
These consisted of orifice plates, various sized rotameters, wet gas
meter and soap bubble meter. This work was aimed at evaluating
appropriate operating conditions and accuracy of the aforementioned
devices. The experimental data collected were compared to
theoretical predictions from Bernoulli’s equation and calibration
curves supplied by the instrument’s manufacturers. The results
obtained showed that rotameters were more reliable for measuring
high and low flow rates; while soap-bubble meters and wet-gas
meters were found to be suitable for measuring low flow rates. The
laboratory procedures and findings of the actual work can assist
engineering students and professionals in conducting their flow
measurement laboratory test work.
Abstract: This paper presents an anthropometric study
conducted to 300 employees in a maquiladora industry that belongs
to the cluster of medical products as part of a research project to
pretend simulate workplace conditions under which operators
conduct their activities. This project is relevant because traditionally
performed a study to design ergonomic workspaces according to
anthropometric profile of users, however, this paper demonstrates the
importance of making decisions when the infrastructure cannot be
adapted for economic whichever put emphasis on user activity.
Abstract: This study aimed at designing and developing a
mechanical force gauge for the square watermelon mold for the first
time. It also tried to introduce the square watermelon characteristics
and its production limitations. The mechanical force gauge
performance and the product itself were also described. There are
three main designable gauge models: a. hydraulic gauge, b. strain
gauge, and c. mechanical gauge. The advantage of the hydraulic
model is that it instantly displays the pressure and thus the force
exerted by the melon. However, considering the inability to measure
forces at all directions, complicated development, high cost, possible
hydraulic fluid leak into the fruit chamber and the possible influence
of increased ambient temperature on the fluid pressure, the
development of this gauge was overruled. The second choice was to
calculate pressure using the direct force a strain gauge. The main
advantage of these strain gauges over spring types is their high
precision in measurements; but with regard to the lack of conformity
of strain gauge working range with water melon growth, calculations
were faced with problems. Finally the mechanical pressure gauge has
advantages, including the ability to measured forces and pressures on
the mold surface during melon growth; the ability to display the peak
forces; the ability to produce melon growth graph thanks to its
continuous force measurements; the conformity of its manufacturing
materials with the required physical conditions of melon growth; high
air conditioning capability; the ability to permit sunlight reaches the
melon rind (no yellowish skin and quality loss); fast and
straightforward calibration; no damages to the product during
assembling and disassembling; visual check capability of the product
within the mold; applicable to all growth environments (field,
greenhouses, etc.); simple process; low costs and so forth.
Abstract: The purposes of this research were to study concepts
and strategies of human resource development in the automotive
manufacturers and to articulate the proposals against the government
about the human resource development for automotive industry. In
the present study, qualitative study was an in-depth interview in
which the qualitative data were collected from the executive or the
executive of human resource division from five automotive
companies - Toyota Motor (Thailand) Co., Ltd., Nissan Motor
(Thailand) Co., Ltd., Mitsubishi Motors (Thailand) Co., Ltd., Honda
Automobile (Thailand) Co., Ltd., and Suzuki Motor (Thailand) Co.,
Ltd. Qualitative data analysis was performed by using inter-coder
agreement technique. The research findings were as follows:
The external factors included the current conditions of the
automotive industry, government’s policy related to the automotive
industry, technology, labor market and human resource development
systems of the country. The internal factors included management,
productive management, organizational strategies, leadership,
organizational culture and philosophy of human resource
development. These factors were affected to the different concept of
human resources development -the traditional human resource
development and the strategies of human resource development. The
organization focuses on human resources as intellectual capital and
uses the strategies of human resource development in all
development processes. The strategies of human resource
development will enhance the ability of human resources in the
organization and the country.
Abstract: Lead (Pb) poisoning is one of the most common and
preventable environmental health problems. There are different
sources of environmental pollution with lead as lead alkyl additives
in petrol and manufacturing processes. Pb in the atmosphere can be
deposited in urban soils, and may then be re-suspended to re-enter the
atmosphere. This could increase human exposure to Pb and cause
long-term health effects. Thus, monitoring Pb pollution is considered
one of the major tasks in controlling pollution. Scalp hair can be
utilized for the determination of lead (Pb) concentration. It provides a
lasting record of metal intakes of weeks or even months, and for most
metals, their accumulation in hair reflects their accumulation in the
whole body. This work was conducted to investigate the
concentration of lead in male scalp hair of Cairo (residential-traffic
and residential-industrial) and rural residents after twenty years of
phasing out of leaded gasoline. Results indicated that the mean
concentration of lead in hair of residential-traffic (9.7552 μg/g ±0.71)
and residential-industrial (12.3288 μg/g ±1.13) was significantly
higher than that in rural residents (4.7327 μg/g ±0.67). The mean
concentration of lead in hair of resident’s industrial areas was the
highest among Cairo residents and not the traffic areas as it was
before phasing out of leaded gasoline. Twenty years of phasing out of
leaded gasoline in Cairo has greatly improved the lead pollution
among residents of traffic areas, but industrial areas residents were
still suffering from lead pollution, which needs more efforts to
control the sources of lead pollution.
Abstract: It is known that residual welding deformations give
negative effect to processability and operational quality of welded
structures, complicating their assembly and reducing strength.
Therefore, selection of optimal technology, ensuring minimum
welding deformations, is one of the main goals in developing a
technology for manufacturing of welded structures.
Through years, JSC SSTC has been developing a theory for
estimation of welding deformations and practical activities for
reducing and compensating such deformations during welding
process. During long time a methodology was used, based on analytic
dependence. This methodology allowed defining volumetric changes
of metal due to welding heating and subsequent cooling. However,
dependences for definition of structures deformations, arising as a
result of volumetric changes of metal in the weld area, allowed
performing calculations only for simple structures, such as units, flat
sections and sections with small curvature. In case of complex 3D
structures, estimations on the base of analytic dependences gave
significant errors.
To eliminate this shortage, it was suggested to use finite elements
method for resolving of deformation problem. Here, one shall first
calculate volumes of longitudinal and transversal shortenings of
welding joints using method of analytic dependences and further,
with obtained shortenings, calculate forces, which action is
equivalent to the action of active welding stresses. Further, a finiteelements
model of the structure is developed and equivalent forces
are added to this model. Having results of calculations, an optimal
sequence of assembly and welding is selected and special measures to
reduce and compensate welding deformations are developed and
taken.
Abstract: The aim of this paper is to create a proposal for determining the costs of logistics processes by using process-oriented calculation methods. The traditional approach is that logistics costs are part of manufacturing overhead which is usually calculated as a percentage surcharge. Therefore in the traditional approach it is not obvious where and in which activities costs were incurred. So it is impossible to trace logistics costs to products. Our point of view is trying to fix or at least improve this issue. Another benefit of applying the process approach is identification of logistics processes which are otherwise part of manufacturing overhead. In the first part this paper describes the development of process-oriented methods over time. The next part shows the possibility of implementing the process-oriented method called Prozesskostenrechnung to logistics processes. The conclusion summarizes advantages and disadvantages of using this method in logistics.
Abstract: Flow forming is widely used in many industries, especially in defence technology industries. Pressure vessels requirements are high precision, light weight, seamless and optimum strength. For large pressure vessels, flow forming by 3 rollers machine were used. In case of long range rocket motor case flow forming and welding of pressure vessels have been used for manufacturing. Due to complication of welding process, researchers had developed 4 meters length pressure vessels without weldment by 4 rollers flow forming machine. Design and preparation of preform work pieces are performed. The optimization of flow forming parameter such as feed rate, spindle speed and depth of cut will be discussed. The experimental result shown relation of flow forming parameters to quality of flow formed tube and prototype pressure vessels have been made.
Abstract: This article aims to study the effect of pressure on rocket motor case by Finite Element Method simulation to select optimal material in rocket motor manufacturing process. In this study, cylindrical tubes with outside diameter of 122 mm and thickness of 3 mm are used for simulation. Defined rocket motor case materials are AISI4130, AISI1026, AISI1045, AL2024 and AL7075. Internal pressure used for the simulation is 22 MPa.
The result from Finite Element Method shows that at a pressure of 22 MPa rocket motor case produced by AISI4130, AISI1045 and AL7075 can be used. A comparison of the result between AISI4130, AISI1045 and AL7075 shows that AISI4130 has minimum principal stress and confirm the results of Finite Element Method by the used of calculation method found that, the results from Finite Element Method has good reliability.
Abstract: Biometallic materials are the most important materials for use in biomedical applications especially in manufacturing a variety of biological artificial replacements in a modern worlds, e.g. hip, knee or shoulder joints, due to their advanced characteristics. Titanium (Ti) and its alloys are used extensively in biomedical applications based on their high specific strength and excellent corrosion resistance. Beta-Ti alloys containing completely biocompatible elements are exceptionally prospective materials for manufacturing of bioimplants. They have superior mechanical, chemical and electrochemical properties for use as biomaterials. These biomaterials have the ability to introduce the most important property of biochemical compatibility which is low elastic modulus. This review examines current information on the recent developments in alloying elements leading to improvements of beta Ti alloys for use as biomaterials. Moreover, this paper focuses mainly on the evolution, evaluation and development of the modulus of elasticity as an effective factor on the performance of beta alloys.
Abstract: The paper gives basic information on application of
rotation bending for manufacturing ship hull parts from steel plates
and on MGPS machines, employed for this purpose.
Abstract: When it comes to last, it is regarded as the critical foundation of shoe design and development. Not only the last relates to the comfort of shoes wearing but also it aids the production of shoe styling and manufacturing. In order to enhance the efficiency and application of last development, a computer aided methodology for customized last form designs is proposed in this study. The reverse engineering is mainly applied to the process of scanning for the last form. Then the minimum energy is used for the revision of surface continuity, the surface of the last is reconstructed with the feature curves of the scanned last. When the surface of a last is reconstructed, based on the foundation of the proposed last form reconstruction module, the weighted arithmetic mean method is applied to the calculation on the shape morphing which differs from the grading for the control mesh of last, and the algorithm of subdivision is used to create the surface of last mesh, thus the feet-fitting 3D last form of different sizes is generated from its original form feature with functions remained. Finally, the practicability of the proposed methodology is verified through later case studies.
Abstract: The work presented in this paper was performed for a workstation of an assembly section in a company that manufactures radio modules and air conditioning for cars. After performing a workstation analysis and a questionnaire to the operators it was possible to understand the need to investigate the risk of musculoskeletal disorders originated from both the handling of loads as the incorrect dimensioning of the workstation. Regarding the handling of loads the NIOSH Equation was used and it was verified that there was no risk of musculoskeletal disorders. As the operators expressed their lack of satisfaction regarding back pains due to posture adopted they were established the appropriate dimensions (to satisfy 97.5% of the population and using the table of anthropometric data of the Portuguese population) for the workstation and it was proposed the availability of a chair for the workers.
Abstract: In this study, Electrical Discharge Machining (EDM) is used to modify the surface of high carbon steel En31 with the help of tool electrode (Copper-Chromium-Nickel) manufactured by powder metallurgy (PM) process. The effect of EDM on surface roughness during surface alloying is studied. Taguchi’s Design of experiment (DOE) and L18 orthogonal array is used to find the best level of input parameters in order to achieve high surface finish. Six input parameters are considered and their percentage contribution towards surface roughness is investigated by analysis of variances (ANOVA). Experimental results show that an hard alloyed surface (1.21% carbon, 2.14% chromium and 1.38% nickel) with surface roughness of 3.19µm can be generated using EDM with PM tool. Additionally, techniques like Scanning Electron Microscope (SEM) and Energy Dispersive Spectroscopy (EDS) are used to analyze the machined surface and EDMed layer composition, respectively. The increase in machined surface micro-hardness (101%) may be related to the formation of carbides containing chromium.