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1
Content available remote Improvement of the Production Process Using Lean Management - Case Study
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Purpose: The aim of the article is to present the benefits of using selected Lean Management elements in the production process on the example of a company producing mechanical seals. Design/methodology/approach: The article is theoretical and empirical in nature and is based on the analysis of a selected case. In the empirical part, the analysis concerns selected elements of the production process in the examined enterprise. Findings: The results obtained in the article refer to the benefits of using Lean Management in the production process in the analyzed enterprise. The use of identification and elimination of waste and standardization of activities at workplaces (introduction of job instructions) in selected areas of the production process allowed for the improvement of its parameters, which was presented in the article. Research limitations/implications: The limitations in the empirical area could be the reference only to selected aspects of Lean Management and the analyzed process. Future research will cover the broader scope of Lean Management and other companies. Practical implications: The results of the case study show the direct impact of Lean Management on the parameters of the analyzed production process. Thanks to the use of Lean Management, the process parameters have improved, which is an important factor in the context of the effectiveness of the company's functioning as a system. Originality/value: The added value of the article is the practical presentation of the use of Lean Management to improve the parameters of the production process.(original abstract)
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Celem jest skonstruowanie i komputerowe oprogramowanie matematycznego modelu opisującego wielofazowy proces produkcyjny o dowolnym stopniu złożoności. Złożoność ta zależy przede wszystkim od liczby podstawowych parametrów determinujących stopień komplikacji procesu produkcyjnego, tj. od liczby faz przetwórczych, liczby surowców, materiałów i półfabrykatów poddawanych przetworzeniu oraz liczby wzajemnych powiązań technologicznych między nimi. Stopień złożoności procesu produkcyjnego rośnie gwałtowanie w miarę wzrostu liczby wymienionych parametrów. Równie gwałtownie spada wówczas niezawodność takiego procesu oraz, co jest chyba najważniejsze, spada możliwość szybkiej reakcji przedsiębiorstwa produkcyjnego na sygnały związane z zapotrzebowaniem na nowe wyroby. Skutecznym sposobem złagodzenia niedogodności będących wynikiem obu tych wad jest odpowiednie matematyczne wymodelowanie takiego procesu produkcyjnego, a następnie właściwe przygotowanie go przy wykorzystaniu szeroko rozumianej symulacji komputerowej. Analizujemy złożony, wielofazowy proces produkcyjny o pewnym stopniu zawodności, której miarą jest rozmiar niewykonania pożądanego poziomu produkcji w żadnym odcinku czasowym. Wymaga to odpowiedniego opisania takiego procesu i zbudowania dla niego właściwego modelu matematycznego uwzględniającego powiązania technologiczne między poszczególnymi fazami tego procesu. (fragment tekstu)
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In the paper a possibility of in-process inspection of gear and spline shafts during forming was discussed. Different methods of forming toothed elements were discussed as well as the other technologies were mentioned. Coordinate measurement technique as a way of post process inspection was presented. However, it is not possible to use it for checking features during forming process. To do it different sensors were used and their combinations were described. (original abstract)
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Content available remote On the Search for Conditions for Production Process Optimization
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The experimental design methodology mainly deals with the estimation of a usually unknown response surface function. An important problem in the field of design of experiments is to determine the number of experimental trials, taking into account certain limitations resulting from the nature of the manufacturing process. The experimental design methodology also includes - as if a separate section - methods of searching for conditions for the optimization of processes and the optimal design of experiments. The aim of this paper is to present a method of searching for conditions for the optimization of manufacturing process results. The proposed method uses non-classical statistical methods and is presented for selected empirical data.(original abstract)
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At present, the speed of production and its complexity increases with each passing year due to the shorter product life cycle and competition in the global market. This trend is also observed in the machine-building industry, therefore, in order to ensure the competitiveness of enterprises and reduce the cost of production, it is necessary to intensify production. This is especially true in the machining of complex parts that require a great number of setups, and technological equipment. The problem-oriented analysis of complex parts was carried out, the parts classification was structured and developed according to the design and technological features. This made it possible to offer advanced manufacturing processes for complex parts like levers, forks, and connecting rods. The flexible fixtures for specified complex parts were developed. The effectiveness of the proposed manufacturing processes, as compared with the typical ones, provides significant improvement in the production. (original abstract)
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Results of scientific researches show the trend of active using nitrides and borides of transition metals and their combination in developing protective materials. While single elements nitrides have been well studied, their multilayer modifications and combinations require more detailed study. Physical-mechanical properties and structural-phase state of multilayer coating according to the deposition conditions is an important task for the study. It will be the analysis of physical-mechanical and electrical properties of coatings based on refractory metals nitrides, their structure and phase composition and surface morphology depending on the parameters of condensation. It was established the structure and behavior of nano scale coatings based on refractory metals nitrides (Ti, Zr) depending on the size of nano grains, texture, stress occurring in coatings. (original abstract)
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In the two-sided mixed-model assembly line, there is a process of installing two single stations in each position left and right of the assembly line with the combining of the product model. The main aim of this paper is to develop a new mathematical model for the mixed model two-sided assembly line balancing (MTALB) generally occurs in plants producing large-sized high-volume products such as buses or trucks. According to the literature review, authors focus on research gap that indicate in MTALB problem, minimize the length of the line play crucial role in industry space optimization.In this paper, the proposed mathematical model is applied to solve benchmark problems of two-sided mixed-model assembly line balancing problem to maximize the workload on each workstation which tends to increase the compactness in the beginning workstations which also helps to minimize the length of the line. Since the problem is well known as np-hard problem benchmark problem is solved using a branch and bound algorithm on lingo 17.0 solver and based on the computational results, station line effectiveness and efficiency that is obtained by reducing the length of the line in mated stations of the assembly line is increased. (original abstract)
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W artykule omówiono metodą 8D zarządzania jakością w procesie produkcyjnym. Zwrócono uwagę na znaczenie jakości w procesie produkcyjnym, wskazując na metodą 8D jako narządzie do jej podnoszenia. (abstrakt oryginalny)
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The application of specific instructions and regulations are needed to meet customer demands. The production of faulty products is the biggest source of danger and loss for factories and also for end-customers. The reduction of deficiency number is the task of quality management. Continuous development, feedback, intervention and efficient actions are needed to minimize the number of faulty machines. This article is an overall introduction to quality techniques used at production processes. The aim of this work is to point out how difficult the product realization process is and the handling of possible production problems after serial production. The most efficient tool of this is the successful 8D-method. The introduction of the 8D-method is the basis of our work. (original abstract)
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The sales market requires both the highest quality of offered goods and satisfactory prices for the buyer. In addition to the reliability of the important aspects are also the time of order fulfillment, reliability, readiness to act around the clock, and service of sold goods after their sale. In the production and confection of conveyor belts, the priority is a customer who, having strictly defined product requirements, also has individually focused goals. To meet these aspects, you need to look after the product both during its production and after. The products of this industry are specific, so that they can be used, after sales service is often required to be installed at the customer and possible actions to maintain their good condition during operation. The article analyzes selected production processes of transmission belts to identify disturbances. The analysis uses the value stream mapping method. Then, improvement methods were proposed. (original abstract)
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W artykule przedstawiono identyfikację ryzyka procesu produkcyjnego oraz możliwość jego wyceny.
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Ekonomika procesu skrawania i analiza kosztów związana jest z optymalizacją procesu skrawania, która jest częścią szerszego zagadnienia, polegającego na racjonalnym doborze warunków skrawania w aspekcie obejmującym całokształt czynników charakteryzujących bardzo złożony przebieg obróbki skrawaniem i jej skutków 1. Szczególnym problemem technologicznym jest dobór parametrów skrawania oraz nagrzewania podczas laserowego wspomagania toczenia. Zagadnienie doboru parametrów obróbkowych w laserowym wspomaganiu toczenia ze względu na minimalizację kosztów narzędziowych Kn [zł/szt.] lub kosztów jednostkowych Kj [zł/szt.] jest zagadnieniem szerzej nie poruszanym. Możliwość zastosowania technologii LAM (Laser Assisted Machining) w przemyśle lotniczym, górniczym bądź chemicznym wymaga pogłębionej analizy ekonomicznej. W pracy przedstawiono analizę korzyści wynikających z zastosowania wiązki lasera diodowego w procesie skrawania dla takich materiałów konstrukcyjnych jak Waspaloy oraz Inconel 718. (abstrakt oryginalny)
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The economics of the machining and cost analysis are related to the optimization of process parameters which are part of a wider issue based on a rational selection of cutting conditions. Selection of these parameters constitutes a crucial aspect since it involves a whole range of factors of a very complex process and its effects. The selection and optimization of cutting and heating parameters during laser assisted turning is a particular technological problem. The problem of machining parameters selection in laser assisted turning regarding tool costs minimization [PLN/unit] or unit costs [PLN/unit] is not widely discussed. The possibility of LAM technology application in the aircraft, mining or chemical industries requires an in-depth economic analysis. This paper presents an analysis of the benefits resulting from the use of laser beam energy in the machining process for construction materials such as Waspaloy or Inconel 718. (original abstract)
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The design of experiments is an important tool to improve production processes that use statistical methods. Designing experiments empowers not only setting properly the parameters of the production process and describing the influence of factors on the results, but also leads to improving the economic results of the analyzed process. The aim of this article is the issue of choosing the appropriate layout of experiments when the experimenter, because of the cost or conditions, has no possibility to implement the completion of the design of experiments. The suggested method takes into account the division of the experimental area and uses measures of spatial autocorrelation to determine the design points to carry out an experiment. The implementation of the mentioned method will be presented for selected factorial designs with particular reference to plans used to estimate the non-linear response surface.(original abstract)
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In general, the production processes are more and more complex. This is the result of more and more sophisticated materials used, the pressure to save them as well as other production resources (ecological perspective), also the tendency to buy mobile products lighter and less power consuming than before. In previous years using highly specialized technology was very costly for the company. Nowadays, this situation is possible to be changed because of emerging types of modern micro-controllers and variety of compatible sensors. Some of those micro-controllers are more power saving, some are more powerful in terms of computing power. The common denominator is that both purchasing them as well as programming is possible for ordinary person, a hobbyist building DIY projects. This sheds new light to the professional usage of modern micro-controllers-based solutions that can become possible to offer comparable level of precision at the fraction of cost. The authors recognized the strong potential in modern micro-controllers and made the research among professionals in the area of production companies. The outcome of research showed that the professionals share the opinion of the authors. Therefore, the outbreak of usage of such inexpensive solutions in professional applications is expected. However, the research showed, that there is possible to find single situations, where usage of modern micro-controllers may be limited, for example in the company targeted to produce hand-made products or handicraft (manufacture). (original abstract)
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Rozpoznanie charakteru, miejsc występowania i poziomu ryzyka w poszczególnych obszarach funkcjonowania systemów produkcyjnych sprzyja podejmowaniu zasadnych decyzji. Znaczenie ryzyka w systemach produkcyjnych oraz jego wpływ na finansową sytuację przedsiębiorstw uzasadnia systemowe podejście do zarządzania ryzykiem. (fragment tekstu)
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W niniejszym artykule przedstawiono treść i główne zasady funkcjonowania systemu sygnalizacji świetlno-fonicznej, którego celem zastosowania jest usprawnienie procesu usuwania zakłóceń toku pracy na stanowiskach roboczych. Prezentowany projekt systemu stanowił część opracowania pt. "Uproszczony projekt organizacji przebiegu produkcji na stanowiskach obróbki skrawaniem i wzorcowej organizacji tych stanowisk", wykonanego przez Zespół Organizacji Produkcji Przemysłu Maszynowego na zlecenie Widzewskiej Fabryki Maszyn Włókienniczych "WIFAMA" w Łodzi. W ramach nadzoru autorskiego projekt systemu wdrożono w kilku wybranych wydziałach produkcyjnych "WIFAMY", co pozwoliło wstępnie ocenie jego skuteczność. (fragment tekstu)
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The paper presents the worked out and introduced system of the current control production process. Suggested system improves the process of the disturbance elimination in the normal work procedure on the working stand. In compare with the traditional solutions the light-phonic system considerable quicknes the transmition of informations connected with the disturbances of the production process, successfully prevents of the deformation of these informations or their loosing and induces to more careful reparation of the activities composing the current working stand service. The direct effect of the applied system is the reduction of the wasting by the workers because of organizational-technical disturbances. (original abstract)
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W artykule przedstawiono zasady projektowania przepływu pomocy warsztatowych w warunkach integracji podstawowych i pomocniczych procesów wytwórczych, na przykładzie wyspecjalizowanych gniazd produkcyjnych. (abstrakt oryginalny)
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One of the ways of further raising of labour efficiency in industry is to integrate basical and auxiliary production processes. Creation of integrated-specialized production nests is a main, practical form of this integration. The efficiency of material and informational flow connected with functioning of the nests, in that the efficiency of information circulation, decide about the efficiency of such nests most of all. The article is devoted to these problems and particularly to the organization of preparation and transportation of the workshop aids. Apart from the description of various variants of solution of preparation and transportation it also contains an attempt to formulate a program of designing of tools and equipment flow. (original abstract)
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W artykule przedstawiono analizę struktury przedmiotowej technicznego przygotowania produkcji zarówno w aspekcie teoretycznym jak i praktycznym. Ponadto zaprezentowano model sterowania tym systemem dla wybranego przedsiębiorstwa przemysłu dziewiarskiego. (abstrakt oryginalny)
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The objective structures of the technical system of preperation of production, in its theoretical and practical bearings have been analysed in this paper. Moreover, the functions of controlling of the preparation of production in textile enterprises have been analysed. The objective structure of the examined system for the chosen type of conduct of knitting industry has been also planned. Finally, the model of controlling of the technical system of preparation of production for the knitting industry enterprise, which can be characterized by self-dependent and developmental type of conduct, has been considered. (original abstract)
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Przedmiotem rozważań są problemy związane z wykryciem rzeczywistej przyczyny stwierdzonych nieprawidłowości w funkcjonowaniu systemu. Do tej klasy zagadnień można zaliczyć problemy statystycznej kontroli jakości, dotyczące umiejscowienia awarii powodującej zakłócenia w przebiegu procesu produkcyjnego lub awarii urządzania. Operator po uzyskaniu informacji o rozregulowaniu agregatu produkcyjnego jest zobowiązany do identyfikacji przyczyny tego rozregulowania oraz do ewentualnej naprawy. Klasyfikacja Jest dokonywana na podstawie znajomości pewnego wektora stanu wadliwego produktu. Po wyłączeniu przypadków, gdy możliwa Jest identyfikacja zakłócenia na podstawie bezpośrednio obserwowalnej przyczyny, problem polega na umiejscowieniu awarii dzięki posiadaniu kilkunastu charakterystyk opisujących badany obiekt. Tymi zagadnieniami zajmuje się między innymi teoria rozpoznawania obrazów. Ta stosunkowo młoda dziedzina wiedzy wypracowała już kilka tysięcy algorytmów pozwalających identyfikować na podstawie tak zwanego ciągu uczącego nieznany obiekt i kwalifikować go do jednej z wcześniej podanych klas.(fragment tekstu)
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In the paper a computer aided tool is described to support identification of the factors causing out-tuning of a production aggregate. Geometric methods of pattern recognition were applied to build a program. User can use any of four ways to compute distance, four techniques to check variables to make them comparable, four routines and seven methods of recognition.(original abstract)
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Wear of the working surfaces of the forging dies in the process of manufacturing products with the die forging technique leads to deterioration of their operational properties as well as their technological quality. A characteristic feature of production in small and medium-sized enterprises is the high variability of the product range and short production series, which can be repeated in the case of re-orders by customers. In this type of production conditions, a technological criterion in form of - a change in the characteristic and selected dimension of forging is usually used to assess the quality of products. An important problem is, whether by taking up another order for a series of the same type of product, it will be possible to implement it with the existing die, or should a new die be made? As a result of the research carried out in the company implementing this type of contract, a procedure was proposed for forecasting the abrasive wear of die working surfaces on the basis of a technological criterion, easy to determine in the conditions of small and medium-sized enterprises. The paper presents the results of the wear assessment of a die made out of hot-work tool steel X37CrMoV5-1 (WCL) and dies made of 42CrMo4 alloy structural steel with hardfacing working surfaces by F-818 wire. To determine and forecast the process of die wear, a mathematical model in the form of neural networks was used. Their task was to forecast the ratio of the increment in introduced wear intensity indicator to the number of forgings made during the process. Taking into account the ability of neural networks to learn, their use in the diagnostic process is justified. (original abstract)
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W referacie przedstawiono proces produkcyjny żelbetowych żerdzi energetycznych typu ŻN stosowanych do budowy linii elektroenergetycznych niskich napięć. Przy określaniu parametrów wydajnościowych i organizacyjnych procesu produkcyjnego założono wystąpienie warunków losowych. Ich wpływ wyrażony został zmiennym czasem trwania sumarycznych czynności na kolejnych stanowiskach roboczych. Jako interpretacja graficzna posłużyły krzywe gęstości prawdopodobieństwa wystąpienia zakładanego sumarycznego czasu trwania czynności na danych stanowisku roboczym. Ocenę prawdopodobieństwa zaistnienia na wstępie przyjętych parametrów procesu produkcyjnego przeprowadzono metodą symulacyjną Monte Carlo. (abstrakt oryginalny)
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The paper presents a production process of ferroconcrete electric poles used for the construction of overhead power lines of low voltage. The conditions of chance variations have been taken into account while determining the productivity and organizational parameters of the production process. Their influence was expressed in varying duration of summary activities on subsequent work stations and graphically presented by probability destiny functions. Assessment of occurrence probability of parameters assumed at the outset of the production process was carried out using Monte Carlo simulation method. (original abstract)
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