Thursday, March 21, 2024

Tuesday, March 19, 2024

A to Z 2024 Blogging - Theme - McKinsey - WEF Lighthouse Smart Manufacturing Industry 4.0 Plants - Factories - Industrial Engineering 4.0

 Prof. (Retd.) K.V.S.S. Narayana Rao

Author of the 2023 Best EBook on Industrial Engineering.

INTRODUCTION TO MODERN INDUSTRIAL ENGINEERING. 

(A Collection of Blog Posts)

FREE Download from:

https://academia.edu/103626052/INTRODUCTION_TO_MODERN_INDUSTRIAL_ENGINEERING_Version_3_0


Author of Principles of Industrial Engineering

2017 IISE Pittsburgh Conference Paper published in the Conference Proceedings - Conference Presentation

____________________________



9350+ Views. Principles of Industrial Engineering - Taylor - Narayana Rao - IISE 2017 Pittsburgh Conference Presentation Video. 

https://www.youtube.com/watch?v=pU8CdWfZZdU

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I participate in this blogging challenge regularly. Good to be in touch with other bloggers and cooperate with them to learn as well as to increase readers for the blogs of participants.


Theme for the year 2024 - Industrial Engineering 4.0


In more detail it is.

A to Z 2024 Blogging - Theme - McKinsey - WEF Lighthouse Smart Manufacturing Industry 4.0 Plants - Factories

This year I want to write on Industrial Engineering 4.0 in manufacturing companies of the world. I would like to specially focus on those plants that implemented Industry 4.0 in an excellent and got noticed as lighthouse plants by McKinsey - WEF assessment.

I wish all the bloggers participating in the challenge happy and effective blogging. Look forward to interaction through comments.

I got  a more urgent exercise in April. To write on elections to the Parliament in India.

2024 India Lok Sabha - Parliament Elections Information Board

https://guide-india.blogspot.com/2024/03/2024-india-lok-sabha-parliament_19.html


Industrial Engineering 4.0 - IE in the Era of Industry 4.0

https://nraoiekc.blogspot.com/2017/12/industrial-engineering-40-ie-in-era-of.html


List of Industry 4.0 Light Houses - WEF - McKinsey.  

https://nraoiekc.blogspot.com/2024/01/list-of-industry-40-light-houses-wef.html


Proposed Posts on Companies and Factories/Plants


ACG - Pithampur

Bosch Automotive - Bursa

CEAT - Halol

Dr Reddy's - Hyderabad

Ericsson - Lewisville



Foxconn - Shenzen

Haier - Hefei

Johnson & Johnson - Xi’an

Mondelez - Sricity

The Coca-Cola Company - Ballina

Unilever - Sonepat





Date
April          Post



4                 Courses - Industrial Engineering

5                 Dissertations - Industrial Engineering



8                  Goals of  Industrial Engineering

10                Human Effort Industrial Engineering


12               Journals of  Industrial Engineering

13                Knowledge Management for Industrial Engineering    

 


18.               Organizing Industrial Engineering Department    











30.                 Zenith of Industrial Engineering           




Theme Reveal Post in A to Z Main Blog 






Ud. 19.3.2024
Pub. 10.3.2024

























Wednesday, March 13, 2024

Photos - IISE 2017 Annual Conference at PIttsburgh

 




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Prof. K.V.S.S. Narayana Rao


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IISE Album

https://www.flickr.com/photos/iise/albums/72157681799602003/


IME Penn State University  Album

https://www.flickr.com/photos/psuengineering/albums/72157681129458334/with/34064850763


Thomas named IISE Fellow


Michael Foss (left), IISE Past President, presents Distinguished Teaching Professor Emeritus Warren Thomas with the IISE Fellow Award at the 2017 IISE Annual Conference and Expo.

https://engineering.buffalo.edu/industrial-systems/news-events.host.html/content/shared/engineering/home/articles/news-articles/2017/thomas-named-iise-fellow.detail.html



2017 IISE Annual Conference & Expo-A glance to the future of ISE research

MAY 23, 2017 / LOPEZ BENSCOME

https://sites.lafayette.edu/lopezbec/2017/05/23/2017-iise-annual-conference-expo-a-glance-to-the-future-of-ise-research/












MTM - Elements

INDUSTRIAL ENGINEERING is redesign (engineering) of Products, Facilities and Processes for Productivity increase.
INTRODUCTION TO MODERN INDUSTRIAL ENGINEERING. E-Book FREE Download. 



TMU. Most predetermined motion time systems (MTM and MOST) use time measurement units (TMU) instead of seconds for measuring time. One TMU is defined to be 0.00001 hours, or 0.036 seconds.

One TMU  =  0.00001 hours  =   0.036 seconds.

There are approx. 28 TMU’s in one second.
https://www.ukmtm.co.uk/systems/mtm-1/




The 17 Basic MTM-1 Motions



Fingers or Hand
Reach
Grasp
Release
Move
Position
Turn
Disengage
Apply Pressure

Eye Motions
Eye Focus
Eye Travel

Body Motions
Foot Motion
Leg Motion
Side- Step
Turn Body
Bend, Stoop and Kneel
Sit and Stand
Walk


Chapter 5

REACH is the basic element employed when the predominant purpose is to move the hand and/or fingers to a destination or general location. 

The predominant purpose of the motion is the deciding factor in classifying it as a reach. Holding or palming a light, small item such as a screw- driver, pliers, or scissors while moving the hand does not justify classifying the motion as a move rather than a reach. For example, in the needle trades, a scissors is often held in the palm of the hand while other operations such as reaching from the cloth on the working area in front of the operator to a bin containing pins are performed. The motion to the bin should be classified as a reach if the predominant purpose is to get the hand in a position to pick up some pins for the next operation. 


Chapter 6

Move 

Definition 

MOVE is the basic element employed when the predominant purpose is to transport an object to a destination.

 

The predominant purpose of the motion is the deciding factor in classifying it as either a reach or a move. If the hand holds an object as an incidental fact to the reason for the motion, a reach will be performed. Basically, then, the decision as to predominant purpose hinges on the reason for moving the hand—was it to relocate the hand, or was it to relocate the object? Answering this question will clarify  the kind of transport motion involved. 


Turn may be defined as follows: 

Turn is the motion employed to turn the hand either, empty or loaded by a movement that rotates the hand, wrist, and forearm about the long axis of the forearm.


https://babel.hathitrust.org/cgi/pt?id=mdp.39015003722058&view=1up&seq=156&skin=2021

Engineered work measurement; the principles, data, and techniques of methods-time measurement, modern time and motion study, and related applications engineering data, by Delmar W. Karger and Franklin H. Bayha., 



CHAPTER 9 Turn 

Definition 

TURN is the basic motion employed to revolve the empty or loaded hand by an action which rotates the hand, wrist, and forearm about the long axis of the forearm. While pure Turns as defined above do sometimes occur in industrial operations, they occur more frequently in combination with Reaches and Moves. This fact has led to statements by some sources that Turn is a special way of performing a Reach or Move. Such is not the case. While it is true that Moves and Reaches may include performance of the basic motion Turn, this does not preclude the ability of the worker to accomplish pure Turns alone.

CHAPTER 10 


RELEASE LOAD 



The basic element that requires the shortest time of any to perform is Release Load. Values of 1.7 TMU and 0 TMU have been assigned to the two cases thus far established. Undoubtedly the value of 1.7 TMU is high. It was obtained as the result of the measuring procedure employed when collecting data. Even in slow-motion pictures, Release Load is often found to consume only one or two sixty-fourths of a second, which would give values of approximately .4 or .8 TMU. 


Release Load is so quick that its presence must usually be determined by analysis rather than by observation. In compiling the methods-time data, it was thought possible that Release Load might be ignored altogether in application. It was found after numerous checks with and without recognizing Release Load that the accuracy of the results was somewhat increased by including time for releasing. This may be attributable to the manner in which the data were compiled, i.e., time may have been assigned to Release Load which actually belongs to Move and Reach. Regardless of this, however, since the recognition of Release Load increases the accuracy of the methods-time data in application in their present form, it should be included in the manner outlined below. 


DEFINITION OF RELEASE LOAD 


Release Load is the basic element employed to relinquish control of an object by the fingers or hand. 


The opening of the fingers, or hand, permitting the part to be free, as shown by Fig. 53, is the motion employed. It should be noted that, like Grasp, the definition limits the basic element of Release Load to releases which are performed with the hand only. If a part is released by opening a pair of tongs, it is accompanied by performing the basic element Move. 



CHAPTER 11 

DEFINITION OF DISENGAGE 


Disengage is the basic element employed to break the contact between one object and another, and it is characterized by an involuntary movement occasioned by the sudden ending of resistance. 


chapter 12 


Walking 

Operations that involve walking occur frequently in industry. Therefore a detailed study of walking time and methods is necessary if the method-time data are to be applied to this class of work. 






MTM Maynard et al. 1948 Book chapters - Partial list


Table of Contents 

Preface 
CONTENTS 
PART I: INTRODUCTION 
1. METHODS ENGINEERING. Industry's Search for Better Manufacturing Methods History and Development of Methods Engineering - Definition of Methods Engineering-The Growing Emphasis on Better Methods - Problems Arising from Methods Changes Methods Correction or Methods Engineering — Methods-Time Measurement. - 

2. METHODS - TIME MEASUREMENT AN ADVANCED STEP IN METHODS ENGINEERING.. Definition of Methods-Time Measurement Principal Uses of Methods-Time Measurement - Developing Effective Methods in Advance of Beginning Production - Improving Existing Methods Establishing Time Standards — Developing Time Formulas — Estimating - Guiding Product Design-Developing Effective Tool Designs Selecting Effective Equipment Training Supervisors to Become Methods-conscious Research - Settling Grievances Limitations of Methods-Time Measurement. - 

3. DEVELOPMENT OF METHODS-TIME DATA.. — Origin of Methods-Time Data Procedure for Collecting Data Analysis Procedure Conclusion. 

PART II: BASIC INFORMATION 

4. METHODS-TIME DATA.... Methods-Time Data Tables - Unit of Time - Conventions for Recording Methods-Time Data. 

5. REACH - Starting and Stopping Points  Determining Definition of Reach Length of Motion - Reach Motions Involving Body Movements - Classifications of Reach. 

6. MOVE  Definition of Move Starting and Stopping Points - of Move - Other Cases of Move - Weight Factors. - Classifications 

7. TURN  - Definition of Turn-Starting and Stopping Points - Length of Turn Motion - Combination Motions - Classifications of Turn Influence of Weight of Object on Turn - Special Cases of Turn Apply Pressure. 

8. GRASP Definition of Grasp - Starting and Stopping Points - Classifications of Grasp Synthesizing Time Values for Complex Grasps — Grasp at High Performance Levels - Two-handed Operations. - 

9. POSITION  Importance of Position - Starting and Stopping Points - Variables Affecting Position Class of Fit- Symmetry. Ease of Handling - - Special Cases of Position - Theory of Positioning Motions. 

10. RELEASE Load....  Definition of Release Load-Starting and Stopping Points - Classifications of Release Load. 

11. DISENGAGE  Definition of Disengage - Starting and Stopping Points - Variables Affecting Disengage - Ease of Handling — Careful - Class of Fit - Handling. 

12. WALKING  — Study Procedure - Characteristics of Walking - Determination of Walking Time-Accuracy of Walking-Time Data. 

13. OTHER MOTIONS.. Measurement Procedure - Foot Motions Step Turn Body —  - Side - Leg Motions - Bend, Stoop, and Kneel on One Knee- - Sit and Stand from a Sitting Position Kneel on Both Knees Accuracy of Body, Foot, and Leg Methods-Time Standards. 

14. PRINCIPLE OF THE LIMITING MOTION....  Combined Motions Simultaneous Motions Simultaneous Grasps Simultaneous Positions Simultaneous Arm and Stepping Motions — Simultaneous Foot or Leg and Arm Motions - Complex Simultaneous Motions of the Body. 

15. ACCURACY OF METHODS-TIME STANDARDS. Preliminary Tests of Accuracy with Motion-picture Films Tests of Accuracy Against Time-study Data-Study of Gauze-folding Film- Additional Tests. 




Source

https://babel.hathitrust.org/cgi/pt?id=mdp.39015003722058&view=1up&seq=130&skin=2021



Productivity Management Imperative for USA - McKinsey. Returning US productivity to its long-term trend of 2.2 percent annual growth would add $10 trillion in cumulative GDP over the next ten years (2023 - 2030).

Engineered Work Measurement: The Principles, Techniques, and Data of Methods-time Measurement Background and Foundations of Work Measurement and Methods-time Measurement, Plus Other Related Material

Delmar W. Karger, Franklin H. Bayha

Industrial Press Inc., 1987 - Work measurement - 503 pages

Includes extensive information on I.E. and work measurement software. Focuses on the MTM material that has been refined for more than three decades. Provides accurate answers to all questions regarding MTM-1 found in the MTM Association for Standards and Research MTM-1 Examinations. Covers the minimum work measurement background essential to all who must understand and apply MTM-1.


https://books.google.co.in/books?id=K-JSTQ0tkkkC


MOST Work Measurement Systems, Third Edition,


K. B. Zandin

CRC Press, 19-Dec-2002 - Technology & Engineering - 552 pages

This book is an essential guide for those in training for their MOST® certification and a great value to anyone looking to enhance their marketability to prospective employers. Revised to accommodate the evolving needs of current and emerging industries, the third edition clarifies the working rules and data card format for BasicMOST®, MiniMOST® and MaxiMOST®, presents a thorough description of the application of AdminMOSTTM, a version of BasicMOST® for measuring administrative tasks in retail, banking and service environments, and contains new photographs and illustrations. It is an excellent resource for practicing professionals and newcomers in the fields of industrial engineering and management.

https://books.google.co.in/books?id=c9zSq5HyTGgC


A Long Case Study Using MTM, Therbligs and Process Charts

Improving the process of Assembling and Unassembling an Electric Mosquito Swatter


19 min read

·


Sep 17, 2022

https://medium.com/@Fiona_47125/improving-the-process-of-assembling-and-unassembling-an-electric-mosquito-swatter-85d6bda1c57



Ud. 13.3.2024
Pub. 22.9.2023

Tuesday, March 12, 2024

News for Productivity Improvement of Material Processing Operation Industrial Engineering - News for Process Improvement

Process Improvement using engineering knowledge to reduce cost through increasing productivity of machines and men by reducing machine time and man time is the main activity of industrial engineering.

Many other disciplines help industrial engineers to achieve their objectives. But the main discipline that is the foundation for IE is engineering of products and processes.







Information for IE - Case 44 - Industrial Engineering ONLINE Course. - Process Industrial Engineering ONLINE Course (Module)

My advocacy now is IEs must first concentrate on improving engineering elements and then move into productivity managerial elements and non-engineering areas. Machine work study or machine effort improvement, value engineering and design for manufacturing and assembly are major engineering based IE methods. All are available as existing methods.

Knowledge Base for Process Productivity Improvement - News - Information for







Advances in Materials and Manufacturing Engineering: Select Proceedings of ICMME 2019
T. Rajmohan, K. Palanikumar, J. Paulo Davim
Springer Nature, 21-Sept-2020 - Technology & Engineering - 689 pages
This book comprises selected papers from the Fourth International Conference on Materials and Manufacturing Engineering (ICMME 2019). The contents focus on the latest developments in the synthesis and characterization of new materials, and highlights the challenges involved in the manufacturing and machinability of different materials. Advanced and cost-effective manufacturing processes and their applications are also discussed in the book. In addition, it covers topics like robotics, fluid dynamics, design and development, and different optimization techniques. The contents of this book will be beneficial to students, researchers, and industry professionals.



There is a three way break up of time in a process.

Value added activity time + Non-value added activity time + No value added time.

Cost is incurred all the time. Time reduction is cost reduction if resources are same. (Narayana Rao, 19 July 2021)


Questions on Machine, Equipment and  Tools to Improve Elements of Value-Adding Operations or Processing Operations

Operations Analysis - Maynard and Stegemerten (1939)

Barnes has focused on the motions and activities of the operators and he mentioned machines in a brief manner. It is Maynard and Stegemerten who documented the practice of Westinghouse in the book "Operational Analysis." In this description of productivity improvement many aspects related to machine are covered first and then only at the end of standardizing the machine related aspects, motion study, the work of the operator is investigated. Thus we can see in process improvement, process machine effort improvement and process human effort improvement. Better machines, more useful cutting tools, faster movements of required machine parts, better machine accessories etc. increase productivity and reduce costs.

The following questions are suggested by Maynard and Stegemerten for logical analysis of machine, equipment and tools.

About Machine


1. Is the machine tool best suited to the performance of the operation of all machine tools available?

2. Would the purchase of a better machine be justified?

About Fixture - Workholding


3. Can the work be held in the machine by other means to better advantage?

4. Should a vise be used?

5. Should a jig be used?

6. Should clamps be used?

7. Is the jig design good from a motion-economy standpoint?

8. Can the part be inserted and removed quickly from the jig?

9. Would quick-acting cam-actuated tightening mechanisms be desirable on vise, jig, or clamps?

10. Can ejectors for automatically removing part when vise or jig is opened be installed?

11. Is chuck of best type for the purpose?

12. Would special jaws be better?

13. Should a multiple fixture be provided?

14. Should duplicate holding means be provided so that one may be loaded while machine is making a cut on a part held in the other?

About Cutting Tools


15. Are the cutters proper?

16. Should high-speed steel or cemented carbide cutting tool be used?

17. Are tools properly ground?

18. Is the necessary accuracy readily obtainable with tool and fixture equipment available?

19. Are all operators and machines provided with the same tools?

20. Can a special tool be made to improve the operation?

Because of the wide variety of tools available for different kinds of work, this list could be  extended almost indefinitely with specific questions. Foundries, forge shops, processing industries, assembly plants, and so on all have different kinds of tools, and different questions might be asked in each case. The list given above, drawn up principally and by no means completely for machine work, will indicate the kind of searching, suggestive questions that should be asked. 


A special list might well be drawn up by each individual plant to cover the questions on the kind of machines, machine tools that are used in its own work.
Source: https://nraoiekc.blogspot.com/2019/06/machine-work-study-productivity.html




News Relating to Flow Process Chart Operations - Value-Adding Operation - Inspection - Transport - Temporary Delay - Storage


Say YES to Knowledge Based Industrial Engineering. 

Use recent developments in engineering & technologies in process improvement for productivity.

Forward Thinking About Productivity: Assess each engineering and technology development about its productivity benefit for the processes of your organization.

Machine Shop Cost Reduction News - 2020 - 2019 - 2018 - 2017 - 2016 - 2015 - Up to 2014



News Relating to Value-Adding Operation in the Process


Do it. It is Real Engineering. Industrial Engineering is Engineering Primarily.

Find 5 new engineering developments every day in elements related to facilities, products and processes in your organization and assess their use for industrial engineering. 
Best Practices in #IndustrialEngineering 



2024

Optimizing mixing efficiency: 5 strategies for industrial manufacturers
Nov. 7, 2023
https://www.processingmagazine.com/mixing-blending-size-reduction/article/53077360/optimizing-mixing-efficiency-5-strategies-for-industrial-manufacturers

Mixing by stirring: Optimizing shapes and strategies
Maximilian F. Eggl and Peter J. Schmid
Phys. Rev. Fluids 7, 073904 – Published 27 July 2022
https://journals.aps.org/prfluids/abstract/10.1103/PhysRevFluids.7.073904#:~:text=Enhancements%20in%20mixing%20efficiency%20can,and%20produce%20a%20homogeneous%20mixture.


[Submitted on 16 Aug 2021 (v1), last revised 11 Aug 2022 (this version, v2)]
Mixing by stirring: optimizing shapes and strategies
Maximilian F. Eggl, Peter J. Schmid
The mixing of binary fluids by stirrers is a commonplace procedure in many industrial and natural settings, and mixing efficiency directly translates into more homogeneous final products, more enriched compounds, and often substantial economic savings in energy and input ingredients. Enhancements in mixing efficiency can be accomplished by unorthodox stirring protocols as well as modified stirrer shapes that utilize unsteady hydrodynamics and vortex-shedding features to instigate the formation of fluid filaments which ultimately succumb to diffusion and produce a homogeneous mixture. We propose a PDE-constrained optimization approach to address the problem of mixing enhancement for binary fluids. Within a gradient-based framework, we target the stirring strategy as well as the cross-sectional shape of the stirrers to achieve improved mixedness over a given time horizon and within a prescribed energy budget. The optimization produces a significant enhancement in homogeneity in the initially separated fluids, suggesting promising modifications to traditional stirring protocols.
https://arxiv.org/abs/2108.07064




2023


9FS1 CBN grinding wheels for Wood-Mizer,Lenox,Fenes,Ro-Ma,Pilana HSS band saw blade
August 24, 2023

Unleash the Power of Operations Automation for Business Growth and Innovation

May 30, 2023  Operations Automation  by HogoNext Editor team

https://hogonext.com/unleash-the-power-of-operations-automation-for-business-growth-and-innovation/



Adding Feeder Bowls to An Existing Multi-Axis Robot or Cobot Station
POSTED BY FEEDING CONCEPTS ON AUGUST 1, 2022

Know more about parts feeding by visiting https://feedingconcepts.com/

CNC Sewing Machines - Productivity & Quality Benefits


2022


Adaptix Soft Jaw 
9/12/2022  12 September
The highlight of this product is it can be dropped onto different vises, such as Schunk, Kurt, etcetera.
The product offer benefits such as instant setup, elimination of storage, interchangeable pin tips, vise compatibility, durability and field repairability.  Adaptix is said to solve several machining problems by being able to grip nearly any part with repeatability and noted clamping force. When designing this product, Norgren wanted to bring reduced setup and changeover times, costs and time spent designing, creating and storing vises and soft jaws.
https://www.mmsonline.com/suppliers/norgren-workholding


Published 4/20/2022
3 Types of 3D Printed Tooling for Injection Molding
3D printed tooling for injection molding, including mold inserts, components and end of arm tooling, were on display at the Plastics Technology Expo.
https://www.additivemanufacturing.media/articles/3-types-of-3d-printed-tooling-for-injection-molding

Additive Manufacturing Process Improvement - SST Technology (SST).

Part setup time reduced from 4 hours to 25 minutes. Manufacturing 7 times as many parts. Machining cycle time halved from 15 hours to 7.5 hours.

60,000 rpm Spindle Speed

Desktop Metal Announces New Printer
April 21, 2022
By Desktop Metal
Press Release
https://www.sme.org/technologies/articles/2022/april/desktop-metal--announces-new-printer/

Aerospace part production cost saving being  explored.
15 FEBRUARY 2022

Leading aerospace companies including Airbus and Safran Landing Systems are working with a consortium to reduce part production costs through a combination of forging, forming and additive manufacturing.

Funded by the Aerospace Technology Institute (ATI), and supported by the High Value Manufacturing Catapult, the Hybrid Direct Energy Deposition (DED) Sprint, the consortium  include NMIS Digital Factory, Cranfield University and the Northern Ireland Technology Centre (NITC).

The group is working to devise a new Hybrid DED process.

Complete machining of truck camshafts in one clamping
Cutting Tool Engineering
February 14, 2022

Inexpensive, Lightweight Motorcycle Aluminum Frames with High Design Appeal
Aluminum frames made with our CF die-casting technology
https://global.yamaha-motor.com/business/cf/case/case05/

Magnesium Chassis Parts for Motorcycles
Examples of large, cast magnesium parts with thin sections
Based on our CF (controlled filling) die-casting technology for aluminum, Yamaha was able to successfully develop casting methods yielding even melt flow and solidification for magnesium-specific part designs; optimized control of vacuum degree in the mold cavity, mold temperature, and melt injection speed; and melt control that minimizes impurity content. These and other achievements made it possible to cast large magnesium parts with thin sections, thereby practicalizing the use of magnesium for large motorcycle chassis parts.
https://global.yamaha-motor.com/business/cf/case/case04/


Interesting Videos

2020 Best Improvements

42,902 views. 20 Dec 2020

2017 Best Improvements
90,407 views. 23 Dec 2017

Continuous process improvement: Penny Weller at TEDxKalamazoo
165,435 views. 7 Feb 2014



Potential of welding automation to improve productivity and efficiency.
By Engineering Department | Arc Machines, Inc. January 25, 2022

https://www.allaboutpiping.com/what-is-orbital-welding/

   
Orbital welding is a technique whereby the welding tool is rotated through 360° (or 180° in double up welding) around a static workpiece. Originally developed to solve the problem of operator error in Tungsten Inert Gas (TIG) welding (also known as Gas Tungsten Arc Welding (GTAW)), and allow for a uniform weld around pipes and tubes, which can be difficult to achieve with manual welding processes.

The orbital welding process can create high quality repeatable welds with the use of a computer, meaning that there is little need for intervention from a welding operator. The process is used for two main applications; tube-to-tube / pipe-to-pipe joining and tube-to-tubesheet joining.
https://www.twi-global.com/technical-knowledge/faqs/what-is-orbital-welding

The Orbital Welding Process 
Orbital Welding was developed to address the issue of operator error in GTAW processes.  The process was developed 50 years ago, but is becoming increasingly popular in recent years.   With automated welding, the computer-controlled process runs with little intervention from the operator.   Computer controlled systems combine arc current, feed and speed to allow the ‘orbital weld head’ to travel around the tube in a steady and repeatable manner.   The operator’s responsibility becomes simply fit-up and monitoring in most cases.  Once a weld schedule (program) has been developed for a specific ‘heat’ of material, the weld profile should remain consistent.

High quality, repeatable welds can be delivered for critical applications but this comes with a price.  The cost of Orbital Welding Equipment when compared with conventional equipment is 5-10 times the initial capital cost. The good news is that much of this cost can be recovered over time as productivity ranges between 2-3 times that of conventional means.
https://www.criticalsystemsinc.com/orbital-welding/orbital-welding-vs-traditional-gtaw



Questions and Answers on Manufacturing Processes

Video 1


Video 2


3

4

5



Milling Head with Sensors for High-Speed Zero-Defect process.



The aim of the activity is to bring to market a new sensory milling head, with the scope of upgrading large scale machining to a High-Speed Zero-Defect process.

The milling head will be based on the Sensory Tool Holder, which has been developed by TU Wien together with MyTool IT and Schunk. This development goes beyond the state of the art, integrating vibration and temperature monitoring modules with a specific interface between milling head and tool holder for energy and information transfer in a single tool system that also provides adaptive control of milling process parameters for large scale machining. The milling head will be commercialized by Walter tools and MyTool IT in accordance with a user and sales agreement. Voestalpine HPM will act as an end user for this product, having a large experience in large scale machining. Other markets such as aerospace, energy, etc. will contribute to scale up the solution after the project.

Start date:

1 January 2021

https://www.eitmanufacturing.eu/news-media/activities/sensor-integrated-high-speed-machining-for-zero-defects/



Machining connecting rods with Junker grinding machines
Author Cutting Tool Engineering
Published January 31,2022 - 09:30pm
https://www.ctemag.com/news/industry-news/machining-connecting-rods-junker-grinding-machines

Multi-Axis Machining: Beyond Mainstream
January 10, 2022
Ed Sinkora
By Ed Sinkora
Contributing Editor,
SME Media
Five-axis machining has progressed from exotic to mainstream over the past few years. Assessing how that transition plays out in the broader job shop environment requires untangling the many machine tool options available that exceed five-axis configurations.
https://www.sme.org/technologies/articles/2022/january/multi-axis-machining-beyond-mainstream/

Artificial intelligence enabled smart machining and machine tools
Yu Sung Chuo, Ji Woong Lee, Chang Hyeon Mun, In Woong Noh, Sina Rezvani, Dong Chan Kim, Jihyun Lee, Sang Won Lee & Simon S. Park 
Journal of Mechanical Science and Technology volume 36, pages1–23 (2022)
https://link.springer.com/article/10.1007/s12206-021-1201-0






2021

Automating Image Feeding for Computer Vision based Machine Learning.

20/20 computer vision for artificial intelligence
Toyota, Intel and LinkedIn use Israeli startup Dataloop to slash the time and cost of building AI image banks
By LISA GANN
19 December 2021, 12:00 pm 

Ubiquity of Industrial Engineering Principle of  Industrial Engineering.


Engineering subjects belong to one engineering branch or other. Every #engineering branch has product design process, process design process, production process, inspection process, material handling process, storage process, equipment operating process, equipment maintenance process, equipment replacement process, equipment retirement process, reuse and recycling process.

Industrial engineers have to develop productivity science based on #productivity measurements for all engineering processes and output, do productivity engineering to improve productivity and do productivity management to plan, manage and realize productivity improvement. To do it, industrial engineers need to have the knowledge of the concerned engineering subject, process or output.
 #IndustrialEngineering



Zurich, Switzerland, 2021/12/15 - Global technology company ABB has today launched its Tundish EMS solution to enable steelmakers to overcome the limited ability of the tundish vessel in controlling the flow of molten metal, and therefore steel quality and temperature - ABB.com. ABBN: SIX Swiss Ex
• ABB’s new Tundish EMS (electromagnetic stirring) offering will improve quality, productivity and profitability in billet and bloom casting and metal powder production;
• The new technology enables steel plant operators to overcome challenges of controlling flow, steel quality and temperature in tundish not yet solved by furniture systems;
• Solution will match the industry’s higher requirements for steel cleanliness.

Tundish EMS is placed on the outside of the tundish and uses non-contact electromagnetic stirring technology to generate an electromagnetic field that creates a stirring effect in the bath melt. This continuous stirring significantly increases mixing zone volume for virtually the entire tundish, with higher flow speeds, elimination of dead zones and homogenization of temperature.

Adoption of this electromagnetic stirring technology will be particularly important for steelmakers with multiple casting strands coming from one tundish. It will mean greater removal of inclusions, resulting in smoother, cleaner steel and reductions in nozzle clogging.

By creating a stirring flow throughout the entire tundish melt bath, Tundish EMS delivers rapid homogenization of temperature and chemical composition that results in better quality steel, more uniform and repeatable casting conditions across multiple strands and overall improved quality, productivity and profitability in billet and bloom casting and metal powder production.

“The new Tundish EMS is a result of ABB’s know-how in stirrer design and unrivalled process insight gained from thousands of installations as well as track record in collaborative product development,” said Zaeim Mehraban, Global Sales Manager, Metallurgy Products at ABB. “It allows steelmakers to overcome a challenge that tundish furniture has not yet be

Modify a Hex Head into Torx Head with 0.02" (0.49mm) Tool!
9 Dec 2021
https://www.youtube.com/watch?v=thdnBKGHGzY
NYC - https://www.youtube.com/channel/UCe0IyK4ntgdPTTjsxjvyHPg

https://www.productionmachining.com/blog/post/understanding-cnc-collet-chucks


Mass production construction elements

Delhi man designs contactless golgappa machine. Watch  video
November 25, 2021

Automatic Fish Meat Separator

Size J150- $ 1,325


Renishaw - Two New AM Machines in  RenAM 500 range
November 23, 2021

Renishaw,  UK, launched a new range of Additive Manufacturing machines, based on its RenAM 500 range, the RenAM 500S Flex, a single-laser AM machine, and the RenAM 500Q Flex, a four-laser AM machine.  Both machines feature a simplified powder handling system said to be well suited to manufacturers who must regularly swap build materials during production, such as research and development (R&D), pre-production or bureau environments. The range features the same optical, chamber and gas-flow designs as the RenAM 500 series and produces the same quality parts, but provides additional flexibility when changing powders.

Gripper, Pneumatic Vise Help Automate VMC

Nov. 18, 2021

KURT WORKHOLDING and ABSOLUTE MACHINE TOOLShave created an automation package featuring a Mitsubishi LoadMate Plus robot, Kurt 3600A pneumatic vise, and Kurt RV36 robotic gripper working in tandem with a Tongtai VP-10 mass-production, high-speed vertical machining center.

“Absolute is very excited to have this opportunity to collaborate with Mitsubishi Electric to design and build the new LoadMate Plus robotic automation cell.
https://www.americanmachinist.com/new-products/article/21181687/gripper-pneumatic-vise-help-automate-vmc-kurt-workholding

ExOne announces first sales of new InnoventPro 3L machines to Siemens and Neoshapes

November 17, 2021
The ExOne Company,  Pennsylvania, USA, has announced multiple sales of its new InnoventPro™ 3L Binder Jetting (BJT) Additive Manufacturing machine. Siemens and Swiss startup Neoshapes SA placed early orders.

The InnoventPro 3L is an advanced entry-level model, designed to provide the ease-of-use features of the Innovent+ and  bigger build areas,  the speed and technology features of the company’s production-ready AM machines, such as the X1 25Pro® and X1 160Pro™.

The InnoventPro features Siemens controls, which integrate with the printer drives, motors, sensors, as well as Siemens MindSphere IoT operating system, which powers ExOne’s Scout machine monitoring and analysis app. Siemens intends to use the InnoventPro at its Charlotte Advanced Technology Collaboration Hub (CATCH), Charlotte, North Carolina, USA, to develop materials and processes before taking scaling them on the X1 160Pro.

Optima Group Introduces New Machine Solutions for Glass Syringes

Assembly machine covers tray handling, product separation, inserting and bonding the cannula, and various hardness and test procedures.
11.11.21

At the Compamed and Medica trade shows taking place between November 15 and 18, 2021, Optima Life Science and Optima Automation are showcasing new solutions.

Optima Automation, also a subsidiary of the Optima Group, will provide information at Compamed about a new assembly Solution for glass syringes, among other things. The OPTIMA GSM has been optimized for even gentler product handling, higher efficiency and greater flexibility. The assembly machine covers the processes of tray handling, product separation, inserting and bonding the cannula as well as various hardness and test procedures.


Optomec - Two New Production Additive Manufacturing Machines 
Fully Automated Metal Additive and 3D Printed Electronics machines reduce production costs

November 16, 2021 
Optomec Inc., a leader in production solutions for Metal Additive Manufacturing and 3D Printed Electronics, is now offering two new Additive Manufacturing machines. Both of these machines are specifically designed for high volume production, incorporate automated part-handling options and are designed with operator-friendly production software for error-free job sequencing in a manufacturing setting. 

The first of these machines is the HC-TBR, a compact, all-in-one Metal Additive Manufacturing machine that uses LENS® Directed Energy Deposition (DED) to build or repair 3D metal parts with a wide variety of alloys. In particular, this new machine is capable of processing reactive metal alloys such as titanium and aluminum at high volume in an oxygen-free chamber to ensure superior mechanical properties. Using advanced laser optics, the machine can remotely change the size and power profile of its laser beam, enabling significant reductions in print times. This is a first for the industry. The machine was designed in response to manufacturers in several industries that are seeking lower cost methods of producing and repairing titanium components as the industrial use of titanium continues to grow worldwide.

The second machine to be highlighted is the new Aerosol Jet® HD2 3D Electronics Printer for 3D Semiconductor Packaging/Assembly. The Aerosol Jet HD2, uses Optomec’s patented Aerosol Jet solution to produce high resolution circuitry (with features as small as 10 microns), including a unique ability to dispense conformal 3D interconnects between die, chips, components and substrates. This interconnect approach is all the more powerful due to its improved performance at high signal frequencies, enabling longer range and reduced power consumption in emerging segments such as 5G communications, automotive radar and defense applications. As a primary application, the Aerosol Jet HD2 can serve as a drop-in replacement for the decades-old method of connecting electrical components with wire bonds, which suffer from several critical deficiencies including space inefficiency, high scrap and poor signal performance.

Optomec is a privately-held, rapidly growing supplier of Additive Manufacturing systems. Optomec’s patented Aerosol Jet Systems for printed electronics, and LENS and Huffman brand 3D Printers for metal component production and repair, are used by industry to reduce product cost and improve performance. Together, these unique printing solutions work with the broadest spectrum of functional materials, ranging from electronic inks to structural metals and even biological matter. Optomec has delivered more than 500 of its proprietary Additive Manufacturing systems to more than 200 marquee customers around the world, for production applications in the electronics, energy, life sciences and aerospace industries. The users include GE, Samsung, Raytheon, Siemens, Lockheed and LiteOn, as well as the US Air Force, US Navy, US Army and NASA

08.11.2021
"New machine function improves cycle time of Injection Moulding and protects the engine"
The new SmartTurn option for 2K injection molding


After six months of development, KraussMaffei has tested the SmartTurn optimization option not only in field tests at selected customers but also in-house on five different rotary platen and insert machines. 

The new function SmartTurn from KraussMaffei not only optimizes the turning speed but above all adjusts acceleration and deceleration based on the motor's characteristic curve. This does not only improve cycle times, but also protects the engine. In general, the lighter the tool, the more interesting this feature becomes and the greater the potential it offers. One of the first customers to successfully test the new SmartTurn function in field tests is Nifco. For the specific application, more than one second of cycle time could be saved. You can download,   interview of Andreas Handschke, Technology Manager and responsible for multi-component injection molding and foaming at KraussMaffei, explaining  the functionality and advantages of the new function.
https://ahead.kraussmaffei.com/en/topics/partners-projects/d/new-machine-function-improves-cycle-time-and-protects-the-engine

New laser-cutting system for half-cut, shingled PV cells
German manufacturer 3-D Micromac said it has developed a new machine that can produce more than 6,000 wafers per hour. It is suitable for solar cells with temperature-sensitive coatings, or depositions such as heterojunction devices.
November 9, 2021 
https://www.pv-magazine.com/2021/11/09/new-laser-cutting-system-for-half-cut-shingled-pv-cells/




PRODUCTIVITY IMPROVEMENT IN METAL-CUTTING TECHNOLOGIES - CONVENTIONAL & UNCONVENTIONAL
Dr Nageswara Rao Posinasetti, Professor, Department of Technology, University of Northern Iowa, USA


Part 1Part 2 -   Part 3 -  Part 4 - Part 5 - Part 6 - Part 7 -  Part 8
Eight Major Steps to Semiconductor Fabrication, Part 9: Packaging and Package Testing
on June 17, 2015


Robot Cell for Flexible Machine Tool Tending
LoadMate Plus aims to increase throughput in high-mix, low-volume machine shops, using automation to free operators for other tasks.
MAY 06, 2021


Modular system of workholding

ATLAS COPCO LAUNCHES FIRST FULLY INTEGRATED SMART TOOL RANGE
Published: 21/04/2021
Evolving its ‘Smart Connected Assembly’ philosophy to the next level, Atlas Copco Tools and Industrial Assembly Solutions has launched a brand-new tool range with in-built controllers.


reCool for ER
reCool lets you retrofit your existing static or driven tooling system to internal cooling at low-cost.
Suitable for both oil and emulsion.

Features of reCool rotary RCR for driven tools
reCool for ER System by REGO-FIX
Cost-friendly conversion of existing driven tooling systems to through coolant in only two minutes
For ER and ERM thread in driven tools and turning machines and for ER collets to DIN 6499 / ISO 15488
Speeds up to 12,000 rpm and 6,000 rpm with RCR / ER 40
Coolant pressures up to 150 bar with high-pressure hose, standard hose max. 100 bar
Low-maintenance coolant lubricated bearings
For coolant through tools (with sealing disks DS/ER) and for peripheral cooling (with coolant flush disks KS/ER)
For emulsion and oil coolants
Convert inner-threaded driven tools to outer-threaded, using the reCool adapter. Thus, successfully prepare different types of driven tooling for the use of reCool
Not for use with sealed collets DM
Only clamp the nominal collet diameter



Features of reCool static RCS for use with static holders
reCool static RCS for ER System by REGO-FIX
Cost-friendly conversion of existing static tooling systems to through coolant in only two minutes
For ER collets (DIN 6499 / ISO 15488) in stationary colletholders with external fine threads*
Coolant pressures of up to 150 bar**
RCS/ERMX for emulsion and oil coolants
Low-maintenance design
For coolant through tools (with sealing disks DS/ER) and for peripheral cooling (with coolant flush disks KS/ER)

* reCool static can also be used for internal threading with the corresponding adapter.
** With high-pressure hoses RHS-HP. 100 bar with standard hose.
https://in.rego-fix.com/en/solutions/recool-er



UPGRADE YOUR DRILLS TO SOLID CARBIDE.
Many benefits. Even Carbide tipped drills are available
Kennametal and Gurhing
Jul 24, 2020


Next-Generation Gundrilling Machines Emphasize Flexibility, Performance
UNISIG's new UNE machine-tool product line is engineered and designed to simplify gundrilling for shops with high-volume/low-mix or low-volume/high-mix manufacturing programs.
JUN 25, 2020
https://www.americanmachinist.com/machining-cutting/article/21135195/gundrilling-series-emphasize-flexibility-performance-unisig


Finishing the part after Machining by Manual Processes is a Cost-Cutting Opportunity
Jeff Elliott
JUN 24, 2020

Secondary finishing operations  are conducted offline to remove excess material on semi-finished parts  by hand using oscillating tools, grinders, files, abrasive hand pads, and wire brushes.
These secondary operations  can be automated effectively using a variety of abrasive tools mounted in a toolholder and carousel without removing the part from the machine.

Wolfram Manufacturing produces a range of complex parts with through-holes. Removing burrs and sharp edges in cross-drilled holes and other difficult-to-access areas — such as undercuts, grooves, slots, or internal holes is essential as  burrs can cause blockages or create turbulence in the flow of fluids, lubricants and gases through critical passages.

Wolfram  has automated the cross-hole deburring process by incorporating  Flex-Hone tools in a variety of sizes in its tool carousels. The Flex-Hone is , supplied by Los Angeles-based Brush Research Manufacturing (BRM).
https://www.americanmachinist.com/machining-cutting/article/21135131/finish-machining-and-cutting-costs-brush-research-mfg


Assembly Line Theory and Practice
Book, 2011
https://www.intechopen.com/books/assembly-line-theory-and-practice

Updated  2023  14 March
2021  5 June 2021, 11 May 2021
5 August 2020
26 June 2020