Wyniki wyszukiwania - BazTech

1

Effective data usage for the proper and beneficial automotive production cost improvement

Krzesniak G.

Journal of Achievements in Materials and Manufacturing Engineering

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2023

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Vol. 119, nr 1

27-34

EN

Purpose The article aims to present a proposal and discuss the investment cost calculation procedures based on data collected during the manufacturing process, according to standard SPC control chart evaluation and standard PDCA. It is applied as a tool to support the process of continuous improvement of the manufacturing process and improve profitability by proper allocation the cost of investment and resources. Design/methodology/approach The study uses the results of a literature review on the issue of cost analysis and their modelling. Key elements are the main cost components, but also those that are considered less important and maybe overall decisive. Application cost to benefit relations – as a method of data evaluation for cost modelling to improve overall cost structure is proposed. Findings The relationship between return on investment and amortisation time allows to easily visualise which of the proposed changes are the most cost-effective over time. Based on the analysis conducted the results, the change is proposed below, in order from the most cost-effective. Research limitations/implications Further research should focus on the impact if a decision were based on the findings and proposals defined. Practical implications Each production process is based on the use of resources. This applies to both production plants and other activities. A resource can be anything that will be used in the manufacturing process. Of key importance for the success of the project is their proper use and not only effective but most of all efficient. Originality/value The considerations presented in the study may be the basis for determining the key factors of the cost of production and investment. The proposed simulation model allows for determining the efficient direction for investment. This, in turn, should enable us to define the main directions of searching for the optimisation of the product cost to achieve the expected cost and quality level.

2

Assessing the representative elementary volume of rock types by X-ray computed tomography (CT) – a simple approach to demonstrate the heterogeneity of the Boda Claystone Formation in Hungary

Abutaha Saja M., Geiger János, Gulyás Sándor, Fedor Ferenc

Geologos

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2021

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Vol. 27, No. 3

157--172

EN

X-ray computed tomography (CT) can reveal internal, three-dimensional details of objects in a non-destructive way and provide high-resolution, quantitative data in the form of CT numbers. The sensitivity of the CT number to changes in material density means that it may be used to identify lithology changes within cores of sedimentary rocks. The present pilot study confirms the use of Representative Elementary Volume (REV) to quantify inhomogeneity of CT densities of rock constituents of the Boda Claystone Formation. Thirty-two layers, 2 m core length, of this formation were studied. Based on the dominant rock-forming constituent, two rock types could be defined, i.e., clayey siltstone (20 layers) and fine siltstone (12 layers). Eleven of these layers (clayey siltstone and fine siltstone) showed sedimentary features such as, convolute laminations, desiccation cracks, cross-laminations and cracks. The application of the Autoregressive Integrated Moving Averages, Statistical Process Control (ARIMA SPC) method to define Representative Elementary Volume (REV) of CT densities (Hounsfield unit values) affirmed the following results: i) the highest REV values corresponded to the presence of sedimentary structures or high ratios of siltstone constituents (> 60%). ii) the REV average of the clayey siltstone was (5.86 cm3) and (6.54 cm3) of the fine siltstone. iii) normalised REV percentages of the clayey siltstone and fine siltstone, on the scale of the core volume studied were 19.88% and 22.84%; respectively. iv) whenever the corresponding layer did not reveal any sedimentary structure, the normalised REV values would be below 10%. The internal void space in layers with sedimentary features might explain the marked textural heterogeneity and elevated REV values. The drying process of the core sample might also have played a significant role in increasing erroneous pore proportions by volume reducation of clay minerals, particularly within sedimentary structures, where authigenic clay and carbonate cement were presumed to be dominant.

3

Application of X-S Control Cards to Parameter Control in the Machining Process of Piston Castings for Internal Combustion Engines

Krępa Adam, Piątkowski J.

Archives of Foundry Engineering

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2021

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Vol. 21, iss. 4

116--120

EN

This article discusses the possibility of using a two-track X-S control card on a Mesas device to control the production process parameters of piston castings for combustion engines. The research was carried out at the Federal-Mogul Gorzyce company. The basis for estimating the variability of the process results from the mean value (X) is the standard deviation (S). Thanks to specially designed measuring stations that use algorithms to calculate process indicators (Cp and/or Cpk) and their visualization, the cost of manufacturing products and the number of non-compliant products (scraps) are reduced. The process stability was investigated by measuring the key dimensions of the piston casting in a specific population and a given measurement cycle. Taking into account the precision of details, their technical condition, and surface quality, the production machines and cutting tools were optimally selected. It has been found that an important element of the effective use of Statistical Process Control (SPC) are trained/experienced operators who can correctly interpret the resulting control chart forms.

4

The improvement of manufacturing process through the use of statistical process control

Jardzioch A., Marczak W., Krebs I.

Journal of Machine Construction and Maintenance - Problemy Eksploatacji

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2018

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no. 4

105--111

EN

In the present paper, we describe a sample application of Statistical Process Control aimed at improving the manufacturing process and enhancing the quality of the manufactured product. The selected object of study included a high-density polyethylene (HDPE) film manufacturing system and mass-produced plastic bags. The examination carried out during technological tests confirmed process capability for manufacturing a oproduct of proper quality. The reexamination which followed the identification of non-conformance of the product indicated the loss of this capability. It resulted in detecting variations and their source and, consequently, any non-conformances arising in the manufacturing process were eliminated.

PL

Przedstawiono przykład zastosowania Statystycznego Sterowania Procesem (SPC) w celu doskonalenia procesu produkcyjnego oraz poprawy jakości produkowanego wyrobu. Jako obiekt badawczy przyjęto system produkujący folię polietylenową wysokiej gęstości HDPE oraz torebki foliowe w warunkach produkcji masowej. Badania przeprowadzone w trakcie prób technologicznych potwierdziły zdolność procesu do produkcji wyrobu o odpowiedniej jakości. Powtórne badania przeprowadzone po wykryciu niezgodności wyrobów gotowych wskazały na utratę zdolności do produkcji odpowiedniej jakości wyrobów. W wyniku przeprowadzonych badań zidentyfikowano nieprawidłowości występujące w procesie produkcyjnym, wskazano przyczyny ich występowania oraz zaproponowano rozwiązania pozwalające na wyeliminowanie wykrytych niezgodności.

5

Implementation of Statistical Process Control (SPC) in the Sewing Section of Garment Industry for Quality Improvement

Abtew M. A., Kropi S., Hong Y., Pu L.

Autex Research Journal

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2018

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Vol. 18, no. 2

160--172

EN

The main aim of this research was to implement appropriate Statistical Process Control (SPC) techniques for quality characteristics on sewing floor of garment Industry. Among different SPC quality improvements tools, control charts have been selected. After analyzing and selecting different critical parameters based on company and customer requirements, the X-bar and R charts for variable and c-charts for attribute quality characteristics have been identified and implemented in the trouser sewing lines for quality improvement. The check points for selected control chart implementation have also been designed. Remedial action plans for the occurred special cause variations and process stability were developed. The project incorporated theoretical and on-job training schemes for different quality team members, to understand the SPC concept and its implementation procedure. After implementation, significant improvements in the sewing section were achieved. The four months analysis before and after implementation of the SPC tools showed that the rejection percentage was reduced from 9.141% to 6.4%. Successful implementation of the result of this project can significantly improve process performance of other similar manufacturing units with appropriate modification.

6

System przetwarzania danych pomiarowych wykorzystujący SPC do obróbki krótkich serii zgodny z ideą Przemysłu 4.0

Oborski P., Bielicki B.

Pomiary Automatyka Robotyka

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2017

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R. 21, nr 2

71--78

PL

W artykule przedstawiono wyniki badań opracowanej metody efektywnego pomiaru części w przemyśle lotniczym, redukującej zaangażowanie pracowników i umożliwiającej sterowanie procesem w oparciu o wyniki pomiarów. Stosując ideę SPC opracowano metodę analizy danych dostosowaną do nadzorowania i sterowania produkcją krótkich serii wysoko dokładnych części. Została ona zaimplementowana w zbudowanym w ramach badań systemie pomiarowym składającym się z dedykowanej aplikacji informatycznej współpracującej z systemem ERP zarządzającym zlecaniami produkcyjnymi, systemem zarządzania danymi technologicznymi i pomiarowymi oraz elektronicznymi urządzeniami pomiarowymi. Zbudowany system pomiarowy pozwalający na automatyzację zaawansowanego przetwarzania danych pomiarowych jest obecnie poddawany testom przemysłowym.

EN

The article presents results of the research on new data analysing method suitable for control of production of high quality parts manufactured in short batches. The method was implemented in the IT measurement system. It allows automation of most of operations done by machine operator. It is also integrated with the ERP system for orders management, the system of process data management, barcodes sensors for parts and documentation identification and electronic measurement tools.

7

Computer supervision of the group of compressors connected in parallel

Cechowicz R., Stączek P.

Eksploatacja i Niezawodność

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2014

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Vol. 16, no. 2

198--202

PL

W pracy przedstawiono własne, wdrożone rozwiązanie problemu automatyzacji sterowania i nadzorowania procesu wytwarzania sprężonego powietrza na potrzeby średniej wielkości systemu produkcyjnego. Opracowane rozwiązanie jest zgodne z podejściem Condition-Based Maintenance. Jego istotą było zintegrowanie funkcji sterowania bezpośredniego oraz nadzorowania przebiegu procesu w celu zapewnienia możliwie najlepszych warunków pracy maszyn i wydłużenia przez to okresu ich eksploatacji. Wdrożenie opisanego rozwiązania pozwoliło na: wyeliminowanie konieczności przebywania ludzi w środowisku o bardzo dużym poziomie hałasu, poprawę jakości procesu poprzez ustabilizowanie przebiegu jego podstawowych charakterystyk (zmiennych), zautomatyzowanie procedur obsługi sytuacji awaryjnych, zwiększenie niezawodności maszyn poprzez ich racjonalne wykorzystanie i zapewnienie prawidłowych warunków pracy, oraz dokumentowanie przebiegu procesu. Uwolnienie operatora od zadań sterowania i wyposażenie go w narzędzia wspomagające diagnostykę procesu spowodowały, że był on w stanie wcześniej wykryć zagrożenia dla przebiegu procesu (potencjalne awarie) i podjąć stosowne działania zaradcze.

EN

The paper presents the original solution of the control and monitoring system of the compressed air production plant. The plant was supplying the mid–size production system. The developed solution is consistent with the Condition–Based Maintenance approach. Its aim was to integrate the functions of direct control and monitoring of the process to ensure the best possible working conditions of machines (compressors) and to extend the period of their operation. The implementation of the described solution allowed: to eliminate the need for human presence in an environment with very high levels of noise, to improve the quality of the process by stabilising the course of its basic characteristics (variables), to automate the handling of alarm conditions, to increase machines' reliability through their rational use and ensuring proper working conditions, and to document the process. Freeing the operator from the common, repetitive control tasks and equipping him with diagnostic tools enabled him to detect threats (potential failures) sooner and to undertake appropriate corrective actions.

8

Using control charts X-R in monitoring a chosen production process

Dudek-Burlikowska M.

Journal of Achievements in Materials and Manufacturing Engineering

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2011

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Vol. 49, nr 2

487--498

EN

Purpose: A new approach to production process monitoring in organization using control chart type X-R has been presented. Design/methodology/approach: The possibility of use of basic element of Statistical Process Control ( SPC method) is connected with continuous quality improvement of each production process in an enterprise. Interdependence of the quality research methods and production process’s requirements have been taken into account. Findings: At the present time the metallurgical enterprises should integrate quality management system and quality control with customer’s requirements, with defined both parameters of processes and quality methods. Such kind of strategy will enable to achieve success for these companies. Research limitations/implications: Control chart type X-R is very important quality tool. Its determined statistical measures are recorded properties of product obtained as a result of inspections taking randomly samples of products in the determined place of the process. Aim of control chart type X-R is observation and registration of the changeability of the characteristic of the researched element of the production process. Practical implications: The example of implementing control chart type X-R shows possibility of monitoring chosen parameters of production process according to an idea of defect prevention. Usage of this method allows for monitoring of production process, providing opportunities for cost reduction, and maintaining of production process stability. Originality/value: Application of basic element of Statistical Process Control in polish metallurgical companies have been presented. Purpose: A new approach to production process monitoring in organization using control chart type X-R has been presented. Design/methodology/approach: The possibility of use of basic element of Statistical Process Control ( SPC method) is connected with continuous quality improvement of each production process in an enterprise. Interdependence of the quality research methods and production process’s requirements have been taken into account. Findings: At the present time the metallurgical enterprises should integrate quality management system and quality control with customer’s requirements, with defined both parameters of processes and quality methods. Such kind of strategy will enable to achieve success for these companies. Research limitations/implications: Control chart type X-R is very important quality tool. Its determined statistical measures are recorded properties of product obtained as a result of inspections taking randomly samples of products in the determined place of the process. Aim of control chart type X-R is observation and registration of the changeability of the characteristic of the researched element of the production process. Practical implications: The example of implementing control chart type X-R shows possibility of monitoring chosen parameters of production process according to an idea of defect prevention. Usage of this method allows for monitoring of production process, providing opportunities for cost reduction, and maintaining of production process stability. Originality/value: Application of basic element of Statistical Process Control in polish metallurgical companies have been presented.