The optimization design of uniform’s hanging production line

2015 ◽  
Vol 27 (3) ◽  
pp. 370-389 ◽  
Author(s):  
Huirong Cui ◽  
Yinong Yan
Keyword(s):  
Production Process ◽  
Production Line ◽  
Production Efficiency ◽  
Assembly Line ◽  
Group Technology ◽  
Lean Production ◽  
Optimization Methods ◽  
Theoretical Research ◽  
Utilization Rate ◽  
Content Type

Purpose – Garment manufacturing is a traditional industry with global competition. The most critical part is streamline, as it generally involves a great number of operations. The purpose of this paper is to, based on the model of group technology (GT), sum up the methods of assembly line optimization to optimize the streamline, so that the machines of the workstation can perform the assigned tasks with a balanced loading. Design/methodology/approach – In this paper, the methods of obtaining and optimizing data includes literature, research and optimization methods of basing on GT model. The main direction of literature has two aspects: Lean production theory and streamline assignment. Research mainly concludes three aspects: research place, research object and the research content. The method of time determination is averaging the testing values of repeated measurements. Optimization methods of basing on GT model mainly include combination of the same type of technologic processes in sequence, combination of independent branch process, the combination of mainstream and branch processes and offside combination of the same type of processes. Findings – After optimization, in the utilization rate of equipment: hanging system ratio was increased from 22.95 to 62.12 percent, which greatly improved the utilization rate of enterprise equipment. In equipment layout: hanging equipment layout was turned linear type into “U” type, which realized the synchronization of production. GT model will be well applied in the garment production streamline. Compared with other enterprises, A company has large garment hanging system, which reflects the advanced, comprehensive, representative. Therefore, the paper applied optimization methods to trousers, production efficiency has been improved greatly, the utilization rate of equipment is promoted and reworking phenomenon is reduced greatly. Research limitations/implications – Through the optimization of the production process and equipment layout, the A company’s compiling efficiency has been greatly improved, but how can the system become computerized, accurately and intelligence, which has been an important direction of research now. Practical implications – By optimizing, it is fully proved that applying GT to the streamline optimization is feasible. GT is an important branch of Lean production, summing up the optimization methods basing on the GT model to optimize the streamline not only enriches the relevant theory research, but also provides a theoretical basis for the practical production. GT model not only can be used in the shirt production process, as for other production processes, for example, trousers, skirts can also be widely applied, which realizes the theory application in the practical production. Originality/value – The originality of this paper is that through the analysis of the model of GT, the paper sums up the methods of assembly line optimization to optimize the streamline. Although the model of GT is used widely in electronics, automobile and industry, it is relatively weak in the optimization of garment production line, there are not many literatures on practical application of group technology in the clothing. Besides, the paper is applied to practical production, which not only can improve production efficiency, but also make the theoretical research have basis and combine the theory and practical production.

scholarly journals Modular Home off-site Construction Production Line Improvement

2015 ◽  
pp. 503-512
Author(s):  
Youyi Zhang ◽  
Mana Moghadam ◽  
Mohamed Al-Hussein
Keyword(s):  
Production Line ◽  
Lean Manufacturing ◽  
Production Efficiency ◽  
Assembly Line ◽  
Modular Construction ◽  
Commercial Building ◽  
Market Competitiveness ◽  
Novel Approach ◽  
Building Information ◽  
High Production

Today modular and off-site construction practices are widely used as a novel approach to residential and commercial building construction. Although this approach is known for its high production efficiency and low material waste, manufacturers are facing the challenge of fully differentiating their modular construction procedures from the conventional construction approach. Manufacturers are thus seeking to continuously implement efficient methodologies to improve their production line effectiveness, thereby enhancing their market competitiveness. This paper proposes a methodology enabling the modular manufacturer to overcome this challenge and increase their assembly line productivity by implementing building information modelling (BIM)-supported lean manufacturing concepts, with a particular focus on the importance of the upstream pre-assembly line. This technique was implemented on a case-study, a residential modular factory, and increased the production line productivity by implementing the Lean-assembly concept. This approach is supported by the information provided from an enhanced BIM model generated to deliver accurate resource quantity required at each assembly station.

scholarly journals Research and Implementation of Lean Production Mode in Shipbuilding

Processes ◽  
2021 ◽  
Vol 9 (11) ◽  
pp. 2071
Author(s):  
Tingxin Song ◽  
Jincheng Zhou
Keyword(s):  
Production Process ◽  
Large Scale ◽  
High Efficiency ◽  
Lean Production ◽  
Original Data ◽  
Utilization Rate ◽  
Production Cycle ◽  
Manufacturing Execution System ◽  
High Flexibility ◽  
Manufacturing Execution

This paper studies the production process of a shipbuilding enterprise. The company suffers from long manufacturing cycle, low utilization rate of personnel and an unbalanced production line. To solve these problems, the lean shipbuilding mode, mainly divided into shipbuilding work breakdown, production plan and virtual flow operation in this paper, is put forward, which combines the lean production and modern information management technology with shipbuilding. Supported by the theory of work breakdown structure and task package scheduling, the shipbuilding task package is reasonably divided. The priority of task package manufacturing is determined by calculating the task package manufacturing sequence coefficient, and a reasonable number of operators is calculated to ensure the continuity of segmented manufacturing. After determining the manufacturing priority of the task pack and the number of allocable personnel, the corresponding work can be scheduled. Production planning drives all production activities of the shipbuilding enterprise, and just-in-time production is achieved through the reasonable arrangement of these production plans, thus reducing the waste of personnel and time. Then, the virtual flow operation is carried out, which can achieve high efficiency of flow production and high flexibility of fixed workstation production during the production process of large-scale and heavy-duty products. The virtual assembly production system of the workshop is established according to the characteristics of shipbuilding operation and the actual production situation. On this basis, a lean shipbuilding manufacturing execution system for small and medium-sized shipbuilding enterprises is developed to achieve lean production in a shipbuilding workshop. Through the implementation of the lean shipbuilding mode based on task package scheduling and its manufacturing execution system, compared with the original data, the ship production cycle is reduced to 76.7%, the number of workers is reduced by 16.7% and the production balance rate is up to 81%.

Research on production process optimization of precast concrete component factory based on value stream mapping

2019 ◽  
Vol 27 (4) ◽  
pp. 850-871 ◽  
Author(s):  
Shuqiang Wang ◽  
Jia Tang ◽  
Yiquan Zou ◽  
Qihui Zhou
Keyword(s):  
Production Process ◽  
Process Optimization ◽  
Production Line ◽  
Precast Concrete ◽  
Value Stream Mapping ◽  
Content Type ◽  
Value Stream ◽  
Current Value ◽  
Concrete Component ◽  
Component Production

Purpose The purpose of this paper is to investigate the process optimization of a precast concrete component production line by using value stream mapping. Design/methodology/approach This paper is an empirical focused on of lean production theory and value stream mapping. The data in the case study were collected in real time on-site for each process during the production process of a prefabricated exterior wall. Findings The results of the current value stream map indicate that the main problems of the current production process are related to equipment, technology and organization. The equipment problems include simple demolding and cleaning tools and the lack of professional transfer channels. The technology problems include the lack of a marking mechanism and pipeline exit mechanism. There is a lack of standard operating procedures and incomplete process convergence. A comparison and analysis of the current value stream and the future value flow indicate that optimizations of the process flow, the production line layout, and the standard operating procedures have shortened the delivery cycle, reduced the number of workers, improved the operator’s operating level and balanced the production line. Practical implications The results of this study provide practitioners with a clear understanding of the optimization of the precast concrete component production and represent a method and basis for the process optimization of a factory production line; the approach is suitable for process optimization in other areas. Originality/value This research represents an innovative application of lean production theory and value stream mapping in a complex production line of precast concrete components and thereby fills the gap between the theory and practice of the optimization of a precast concrete component production line.

Research on 5S Concept Used in Production Line Balance Based on Line Balance Chart Method-S Production Line as an Example

2013 ◽  
Vol 328 ◽  
pp. 28-33
Author(s):  
Qiong He ◽  
Yu Liu ◽  
Hong Ye Ma
Keyword(s):  
Production Process ◽  
Calculation Method ◽  
Production Line ◽  
Utilization Rate ◽  
Addition Line ◽  
Working Ability ◽  
Line Balance ◽  
On Line ◽  
Rate Calculation

5S concept has a great effect on site-improvements, and it has been used to promote productivity, improve the environment of production process, and upgrade the working ability of workers etc. In this paper, 5S concept has been used to balance the production line, and S production line has been shown as an example. In addition, line balance chart and production line utilization rate calculation method have been used to exhibit the effect of 5S site-improvements on production line balance and increasing productivity.

The Design of Industrial Robot Sorting and Pallet System

2014 ◽  
Vol 536-537 ◽  
pp. 1009-1014
Author(s):  
Dong Du ◽  
Jun Ying Zhao ◽  
Jian Yuan Lu ◽  
Cheng Sheng Wang ◽  
Feng Chuang Yu
Keyword(s):  
Production Process ◽  
Industrial Production ◽  
Production Line ◽  
Assembly Line ◽  
Industrial Robot ◽  
Technology Training ◽  
Automatic Identification ◽  
Industrial Manipulator ◽  
Industrial Assembly

industrial assembly line development in the direction of automation and flexibility. Not only more and more automated machinery and more industrial manipulator into the production line. Manipulator instead of artificial heavy labor, realize mechanization, automation and flexibility production process. But in the process of production, first of all to the parts, then is all kinds of processing actions. So, will the application of automatic identification in combination with manipulator is very necessary. This paper introduces a can demonstrate the technology training equipment, from the development of the technology are integrated into the software are introduced. Hope that this technology can be widely used in industrial production.

Development of part families for a reconfigurable machine

2019 ◽  
Vol 18 (5) ◽  
pp. 991-1014
Author(s):  
Vennan Sibanda ◽  
Khumbulani Mpofu ◽  
John Trimble ◽  
Mufaro Kanganga
Keyword(s):  
Production Process ◽  
Sheet Metal ◽  
Group Technology ◽  
The Body ◽  
Part Family ◽  
Content Type ◽  
Part Families ◽  
Reconfigurable Machine Tool ◽  
Variable Production ◽  
Machine Work

Purpose Reconfigurable machines tools (RMTs) are gaining momentum as the new solutions to customised products in the manufacturing world. The driving force, among others, behind these machines is the part envelope and the part family of products that they can produce. The purpose of this paper is to propose a new class of RMT known as a reconfigurable guillotine shear and bending press machine (RGS&BPM). A part family of products that this machine can produce is developed using hierarchical clustering methodologies. The development of these part families is guided by the relationship of the parts in the family in terms of complexity and geometry. Design/methodology/approach Part families cannot be developed in isolation, but that process has to incorporate the machine modules used in the reconfiguration process for producing the parts. Literature was reviewed, and group technology principles explored, to develop a concept that can be used to develop the part families. Matrices were manipulated to generate part families, and this resulted in the development of a dendrogram of six possible part families. A software with a graphic user interface for manipulation was also developed to help generate part families and machine modules. The developed concept will assist in the development of a machine by first developing the part family of products and machine modules required in the variable production process. Findings The developed concepts assist in the development of a machine by first developing the part family of products and machine modules required in the variable production process. The development of part families for the RGS&BPM is key to developing the machine work envelope and modules to carry out the work. This work has been presented to demonstrate the importance of machine development in conjunction with a part family of products that the machine will produce. The paper develops an approach to manufacturing where part families of products are developed prior to developing the machine. The families of products are then used to develop modules that enable the manufacture of the parts and subsequently the size of the machine. Research limitations/implications The research was limited to the development of part families for a new RGS&BPM, which is still under development. Practical implications The study reflects the development of reconfigurable machines as a solution to manufacturing challenges in terms of group technology approaches adopted in the design phase. It also highlights the significance of the concepts in the reconfigurable machine tool design. The part families define the machine work envelop and its reconfiguration capability. Social implications The success of the research will usher an alternative to smaller players in sheet metal work. It will contribute to the easy development of the machine that will bridge the high cost of machine tools. Originality/value The study contributes to the new approach in sheet metal manufacturing where dedicated machines may be substituted by a highly flexible reconfigurable machine that has a dual operation, making the investment for small to medium enterprises affordable. It also contributes to the body of knowledge in reconfigurable machine development and the framework for such activities, especially in developing countries.

scholarly journals Optimization of the Production Process of Vibrocasted Refractory Products

2019 ◽  
Vol 299 ◽  
pp. 05001
Author(s):  
Martin Kyncl ◽  
Jiri Kyncl ◽  
Michal Slany
Keyword(s):  
Production Process ◽  
Production Efficiency ◽  
Theoretical Research ◽  
Optimized Design ◽  
Increase Production Efficiency ◽  
Current State ◽  
Expert Analysis ◽  
Design Options ◽  
Ideal Process ◽  
The Ideal

This paper deals with the optimization of the production process of vibrocasted refractory products. The main goal is to make efficient and automate the production of moulds for refractory blocks. A theoretical research was followed by an expert analysis of the current state of the manufacturing process at an industrial partner. The next step was to analyze complete portfolio of refractory vibrocasted products, which results in choosing a representative sample whose dimensions most correspond to majority of the moulds produced. Subsequently, a design was done, to make the production process more effective with respect to time, technology and construction aspects, focusing on increasing productivity, reducing human labour and increasing production modernization. In the end, the design options were evaluated in terms of time and cost, and the ideal process of the manufacturing production was recommended with respect to the latest technology. It includes a solution for material composition and optimized design of moulds for vibrocasted refractory materials to increase production efficiency moulds and cost reduction while maintaining mould accuracy and quality. These products are subject to high demands in terms of material quality and precision, and at the same time costly to produce due to manual manufacturing.

scholarly journals Mitigation against DDoS Attacks on an IoT-Based Production Line Using Machine Learning

2021 ◽  
Vol 11 (4) ◽  
pp. 1847
Author(s):  
Ladislav Huraj ◽  
Tibor Horak ◽  
Peter Strelec ◽  
Pavol Tanuska
Keyword(s):  
Production Process ◽  
Production Line ◽  
Production Efficiency ◽  
Denial Of Service ◽  
Basic Element ◽  
Ddos Attacks ◽  
Increase Production Efficiency ◽  
Denial Of Service Attack ◽  
Service Attack ◽  
Iot Devices

Industry 4.0 collects, exchanges, and analyzes data during the production process to increase production efficiency. Internet of Things (IoT) devices are among the basic technologies used for this purpose. However, the integration of IoT technology into the industrial environment faces new security challenges that need to be addressed. This is also true for a production line. The production line is a basic element of industrial production and integrating IoT equipment allows one to streamline the production process and thus reduce costs. On the other hand, IoT integration opens the way for network cyberattacks. One possible cyberattack is the increasingly widely used distributed denial-of-service attack. This article presents a case study that demonstrates the devastating effects of a DDOS attack on a real IoT-based production line and the entire production process. The emphasis was mainly on the integration of IoT devices, which could potentially be misused to run DDoS. Next, the verification of the proposed solution is described, which proves that it is possible to use the sampled flow (sFlow) stream to detect and protect against DDoS attacks on the running production line during the production process.

An ECRS-based line balancing concept: a case study of a frozen chicken producer

2014 ◽  
Vol 20 (5) ◽  
pp. 678-692 ◽  
Author(s):  
Pornthipa Ongkunaruk ◽  
Wimonrat Wongsatit
Keyword(s):  
Production Process ◽  
Cycle Time ◽  
Production Line ◽  
Line Balancing ◽  
Theory Of Constraints ◽  
Work Study ◽  
Production Network ◽  
Content Type ◽  
Current Production

Purpose – The purpose of this paper is to improve the productivity of a large-sized frozen chicken manufacturer in Thailand. It analyses the production process based on work study principles and identifies the bottleneck operation. It develops three models for the chicken preparation process. Design/methodology/approach – First, analyse the current production system by collecting the cycle time of all operations in the production process based on work study principles. Then, design the production network and identify the bottleneck operation. After that, three methods – based on line balancing (LB), theory of constraints, and JIT concepts or ECRS (eliminate, combine, rearrange and simplify) – are proposed and implemented in the actual production line. Findings – With the ECRS concept, the authors implement combine by combining two stations into one station, such as handling and weighing, or weighing batter and mixing it with chicken. Then, Simplify is implemented at job E, or transporting chicken using a cart instead of walking. This method can improve the cycle time and reduce the number of employees. It can increase the line efficiency by up to 94.20 per cent, reduce the number of employees by 14 persons, and reduce the labour cost by 356,160 baht/year. Originality/value – Most agro-industry manufacturing processes are labour intensive. Thus, production LB can help increase productivity and reduce costs. The authors found that the case study company designed the production line without aligning it with the production network. A simple improvement can be made by adjusting the sequence of the work. In addition, the current production line was not lean. Implementation of the ECRS concept to improve production can reduce the waiting time and simplify the job.

Design of the Automatic Shell Production Line

2014 ◽  
Vol 556-562 ◽  
pp. 2309-2312
Author(s):  
Hui Zhang ◽  
Ling Tao Zhang
Keyword(s):  
Production Process ◽  
Production Line ◽  
Production Efficiency ◽  
Low Noise ◽  
Automatic Production ◽  
Automatic Production Line ◽  
Shell Production ◽  
Executive Body

In order to make the shell production automatically and efficiently, reduce the injury to the worker’s health caused by the harmful dust, this paper describes an automatic shell production line controlled by PC and PLC. The executive body of the shell production line is robots, PLC transmits signals between robot and PC. The new automatic shell production line can not only stucco but also possess the features of smooth operation for shell making and reliable use and low noise. It has been proved that the shells automatic production line has improved production efficiency, reduce the contact with harmful environment of manipulators greatly, and make the production process are controlled well and safely.

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