Low Volume Plastics Manufacturing Strategies

2007 ◽  
Vol 129 (12) ◽  
pp. 1225-1233 ◽  
Author(s):  
Ruchi Karania ◽  
David Kazmer
Keyword(s):  
Injection Molding ◽  
Product Development ◽  
Lead Time ◽  
Development Time ◽  
Numerical Control ◽  
Production Costs ◽  
Lead Times ◽  
Total Production ◽  
Fused Deposition ◽  
Production Quantity

Plastic components are vital components of many engineered products, frequently representing 20–40% of the product value. While injection molding is the most common process for economically producing complex designs in large quantities, a large initial monetary investment and extended development time are required to develop appropriate tooling. For applications with lower or unknown production quantities, designers may prefer another process that has a lower development cost and lead time albeit with higher marginal costs and production times. A methodology is presented that assists the designer to select the most appropriate manufacturing process that trades off the total production costs with production lead times. The approach is to develop aggregate component cost and lead-time models as a function of production quantity from extensive industry data for an electrical enclosure consisting of two components. Binding quotes were secured from multiple suppliers for a variety of manufacturing processes including computer numerical control machining, fused deposition modeling, selective laser sintering, vacuum casting, direct fabrication, and injection molding with soft prototype and production tooling. The methodology yields a Pareto optimal set that compares the production costs and lead times as a function of the production quantity. The results indicate that the average cost per enclosure assembly is highly sensitive to the production quantity, with average costs varying by more than a factor of 100 for production quantities varying between 100 and 10,000 assemblies. Each of the processes is competitive with respect to total production cost and total production lead time under differing conditions; a flow chart is provided as an example of a decision support tool that can be provided to assist process selection during the product development process and thereby reduce the product development time and cost.

Plastics Product and Process Design Strategies

2004 ◽  
Author(s):  
Ruchi Karania ◽  
David Kazmer ◽  
Christoph Roser
Keyword(s):  
Injection Molding ◽  
Lead Time ◽  
Fused Deposition Modeling ◽  
Manufacturing Cost ◽  
Design Strategies ◽  
Chain Flexibility ◽  
Fused Deposition ◽  
Supply Chain Flexibility ◽  
Time Sensitivity ◽  
Production Quantity

Plastic components are vital components of many engineered products, frequently representing 20–40% of the product value. While injection molding is the most common process for economically producing complex designs in large quantities, a large initial monetary investment is required to develop appropriate tooling. Accordingly, injection molding may not be appropriate for applications that are not guaranteed to recoup the initial costs. In this paper, component cost and lead-time models are developed from industry data for an electrical enclosure consisting of two parts produced by a variety of low to medium volume manufacturing processes including fused deposition modeling, direct fabrication, and injection molding with used tooling, soft prototype tooling, and hard tooling. The viability of each process is compared with respect to the manufacturing cost and lead time for specific production quantities of one hundred, one thousand, and ten thousand. The results indicate that the average cost per enclosure assembly is highly sensitive to the production quantity, varying in range from $243 per enclosure for quantity one hundred to $0.52 per enclosure for quantity ten thousand. The most appropriate process varies greatly with the desired production quantity and cost/lead time sensitivity. As such, a probabilistic analysis was utilized to evaluate the effect of uncertain demand and market delays, the result of which demonstrated the importance of maintaining supply chain flexibility by minimizing initial cost and lead time.

Creativity Just in Time? The Role of Delivery Precision in Product Development

2015 ◽  
Vol 12 (05) ◽  
pp. 1550026
Author(s):  
Katarina Lund Stetler
Keyword(s):  
Product Development ◽  
Automotive Industry ◽  
Lead Time ◽  
Project Planning ◽  
Survey Study ◽  
Just In Time ◽  
Lead Times ◽  
The Creation ◽  
The Relationship

This paper presents the results from a quantitative survey study in the research and development (R&D) department of company in the automotive industry. The focus of the study has been on exploring the relationship between delivery precision and creativity. Given today's increasingly competitive market, companies must be able to both cut lead times and maintain high creativity and innovativeness in the organization. This study is an attempt to increase our understanding of how one means of cutting lead time, the imposition of high demands on delivery precision, is related to the creation of novel ideas in the industrialization phase of product development. The results point to an interesting relationship in which the imposition of high demands on delivery precision actually increases the perception of the creation of novel ideas. The results have implications for project planning and the role of time dedicated to exploratory tasks in product development.

Pengendalian Kualitas Dengan Menggunakan Pendekatan Lean Six Sigma di PT. XYZ

2019 ◽  
Vol 2 (2) ◽  
Author(s):  
Khawarita Siregar ◽  
Khalida Syahputri ◽  
Rahmi M Sari ◽  
Farida Putri
Keyword(s):  
Six Sigma ◽  
Lead Time ◽  
Lean Six Sigma ◽  
Production Data ◽  
Lead Times ◽  
Total Production ◽  
Manufacturing Companies ◽  
Sigma Level ◽  
Market Product ◽  
Six Sigma Approach

Persaingan yang sangat kuat diantara perusahaan yang semakin ketat terhadap produk yang sejenis di dalam hal menghasilkan suatu produk pasar nasional maupun internasional untuk pemasaran produk. Berdasarkan data yang didapatkan dari pengamatan pendahuluan yang dilakukan di PT. XYZ bahwa untuk setiap periode produk yang dihasilkan adalah diantara 2.500-4.000 unit produk. Salah satunya berdasarkan data produksi produk berupa sprocket gear sebagai objek penelitian, didapatkan data produksi pada bulan Maret 2016 sebanyak 3.050 unit dengan jumlah kecacatan mencapai sebesar 15% dari jumlah produksi sekitar 458 unit produk cacat. Penerapan metode lean six sigma dengan mengurangi lead time dan cacat pada produk pada proses produksi. Hasil dengan menggunakan distribusi normal yang terdapat pada batas kontrol dan mempunyai nilai ARL= 200 dan UCL = 12,78, namun tingkat sigma perusahaan dalam produksi produk sprocket gear diperoleh nilai sigma sebesar 3. Hal ini bahwa setiap 1.000.000 kali produksi menunjukkan kemungkinan mengakibatkan kecacatan diantara 70.675,1055 ~ 70.675. Hal tersebut memperlihatkan bahwa tingkat sigma perusahaan masih berada jauh dibawah rata rata karena tingkat sigma dalam persaingan yang terjadi secara global diantara perusahaan manufaktur sejenis, yaitu 4,0-4,5 Sigma.   Very strong competition among companies that are increasingly strict on similar products in terms of producing a national and international market product for product marketing. Based on data obtained from preliminary observations conducted at PT. XYZ that for each period the product produced is between 2,500-4,000 units of product. One of them is based on product production data in the form of gear sprocket as the object of research, obtained production data in March 2016 as many as 3,050 units with a number of disabilities reaching 15% of the total production of about 458 units of defective products. Application of lean six sigma methods by reducing lead times and defects in products in the production process. The results using the normal distribution found at the control boundary and have ARL = 200 and UCL = 12.78, but the sigma level of the company in the production of gear sprocket products is obtained by sigma value of 3. This is that every 1,000,000 times the production shows the possibility disability between 70,675,1055 ~ 70,675. This shows that the company's sigma level is still far below the average because the sigma level in competition that occurs globally among similar manufacturing companies, namely 4.0-4.5 Sigma. Keyword: Quality Control, Lean Six Sigma Approach.

Low Volume Plastics Manufacturing Strategies

2005 ◽  
Author(s):  
Ruchi Karania ◽  
David Kazmer
Keyword(s):  
Injection Molding ◽  
Lead Time ◽  
Fused Deposition Modeling ◽  
Selective Laser Sintering ◽  
High Volume ◽  
Cnc Machining ◽  
Process Selection ◽  
Fused Deposition ◽  
Deposition Modeling ◽  
Plastic Components

Plastic components are vital components of many engineered products, frequently representing 20–40% of the product value. While injection molding is the most common process for economically producing complex designs in large quantities, a large initial monetary investment is required to develop appropriate tooling. Accordingly, injection molding may not be appropriate for applications that are not guaranteed to recoup the initial costs. This paper extends previous work [1] with component cost and lead-time models developed from extensive industry data. The application is an electrical enclosure consisting of two parts produced by a variety of low to high volume manufacturing processes including CNC machining, fused deposition modeling, selective laser sintering, vacuum casting, direct fabrication, and injection molding with soft prototype and production tooling. The viability of each process is compared for production quantities of one hundred, one thousand, and ten thousand. The results indicate that the average cost per enclosure assembly is highly sensitive to the production quantity, varying in range from US$0.35 per enclosure for ten thousand assemblies produced via injection molding to US$49.30 per enclosure for one hundred assemblies produced via fused deposition modeling. The results indicate the cost and lead time advantages of the alternative processes; a flow chart is provided to assist process selection in engineering design.

Push and pull contracts in a supply chain selling two products with different lead times

2018 ◽  
Vol 13 (4) ◽  
pp. 1007-1024
Author(s):  
Zhenyu Zhang ◽  
Zhiying Tao
Keyword(s):  
Supply Chain ◽  
Lead Time ◽  
Lead Times ◽  
Single Product ◽  
Content Type ◽  
Multiple Products ◽  
Supply Chain Efficiency ◽  
Production Quantity ◽  
Short Lead Time ◽  
Push And Pull

Purpose Previous researchers have studied push and pull contracts in the single product scenario, although in practice, supply chains often produce and sell multiple products. In a multiproduct scenario, the sales of a product will be influenced by its complements or substitutes, which requires consideration when the supply chain members negotiate contracts. This paper aims to fill this gap by studying push and pull contracts in a supply chain which distributes two products to a market and discusses how the degree of complementarity/substitutability between the two products affects the supplier’s decisions and supply chain efficiency. Design/methodology/approach The paper uses the model of a single-supplier, single-retailer supply chain which sells a product with a long lead time and another product with a short lead time simultaneously in a market. This research compares the production quantity and supply chain efficiency under a push contract with those under a pull contract. Findings First, when the two products are complements, the equilibrium production quantity of Product 2 is higher under a pull contract than that under a push contract. Second, a pull contract is found to be optimal for both the supplier’s profit and supply chain efficiency when the two products are complements, while if they are substitutes, then a push contract is the better choice in some situations. Originality/value The existing literature discusses push and pull contracts in the single product scenario. The current paper pays attention to the two-product scenario and investigates how the complementarity/substitutability degree between the two products affects the supplier’s decisions and supply chain efficiency.

Manufacturability Analysis of Multi-Material Objects Molded by Rotary Platen Multi-Shot Molding Process

2003 ◽  
Author(s):  
Xuejun Li ◽  
Satyandra K. Gupta
Keyword(s):  
Injection Molding ◽  
Product Development ◽  
Development Time ◽  
Systematic Approach ◽  
Geometric Algorithms ◽  
Material Objects ◽  
Injection Molding Process ◽  
Mold Design ◽  
Molding Process ◽  
Opening And Closing

This paper describes a systematic approach for manufacturability analysis of multi-material objects molded using rotary platen multi-shot injection molding process. In this paper we first identify potential manufacturability problems that are associated with objects molded by the rotary platen process. Identified problems include infeasibility of molding sequences, unnecessary mold complexity, undesired friction during mold opening and closing, and undesired material flash on finished faces. These problems are unique to multi-material molding and do not occur in traditional injection molding. For each of the above four potential manufacturability problems, this paper also describes geometric algorithms for detecting the potential occurrence of the problem based on the object and mold design, finding its causes, and offering appropriate redesign suggestions. We expect that these algorithms will help in decreasing the product development time and improving the product quality for molded multi-material objects.

Platform-Based Design and Development: Current Trends and Needs in Industry

2006 ◽  
Author(s):  
Timothy W. Simpson ◽  
Tucker Marion ◽  
Olivier de Weck ◽  
Katja Ho¨ltta¨-Otto ◽  
Michael Kokkolaras ◽  
...  
Keyword(s):  
Product Development ◽  
Product Family ◽  
Cost Effective ◽  
Production Costs ◽  
Lead Times ◽  
Design Development ◽  
Platform Design ◽  
Product Families ◽  
Strategic Innovation ◽  
Future Work

Many companies constantly struggle to find cost-effective solutions to satisfy the diverse demands of their customers. In this paper, we report on two recent industry-focused conferences that emphasized platform design, development, and deployment as a means to increase variety, shorten lead-times, and reduce development and production costs. The first conference, Platform Management for Continued Growth, was held November–December 2004 in Atlanta, Georgia, and the second, 2005 Innovations in Product Development Conference — Product Families and Platforms: From Strategic Innovation to Implementation, was held in November 2005 in Cambridge, Massachusetts. The two conferences featured presentations from academia and more than 20 companies who shared their successes and frustrations with platform design and deployment, platform-based product development, and product family planning. Our intent is to provide a summary of the common themes that we observed in these two conferences. Based on this discussion, we extrapolate upon industry’s needs in platform design, development, and deployment to stimulate and catalyze future work in this important area of research.

scholarly journals Pengembangan Model Economic Production Quantity Mengakomodasi Continue dan Discrete Demand serta Kebijakan Rework Secara Simultan

2020 ◽  
Vol 1 (1) ◽  
pp. 8
Author(s):  
Nurike Oktavia ◽  
Henmaidi Henmaidi ◽  
Prima Fithri
Keyword(s):  
Geometric Mean ◽  
Mathematical Formulation ◽  
Production Costs ◽  
Production Cycle ◽  
Total Production ◽  
Inventory Costs ◽  
Economic Production Quantity ◽  
Economic Production ◽  
Epq Model ◽  
Production Quantity

Inventory of finished goods needs to be planned and controlled regularly. Fulfilling customer demand whenever and wherever is the main purpose of the supply. This issue is related to production activities. Many companies use the Economic Production Quantity (EPQ) Model in determining the size of their lot productions. This model is able to show how to minimize total production costs by reducing inventory costs. Customer behavior at PT XYZ makes product delivery divided into 2 types. The first type, finished goods is sent continuously in small amounts called continue demand. The second type, products is sent between certain time intervals in large quantities called discrete demand. Basic EPQ Model’s parameters do not accommodate a system like this. In addition, PT XYZ requires rework for products that do not pass the quality test. Therefore, this research was developed to formulate EPQ model that can accommodate two types of demand, continue and discrete, as well as the existence of rework policy. This study tries to provide another approach in solving the derivation problem using the "Arithmetic-Geometric Mean" method. The results of this study will display a mathematical formulation to find the optimal production cycle time for PT XYZ. Numerical examples are discussed to show practical models.

Application of CAD/CAE/CAM Technology in Plastics Injection Mould Design and Manufacture

2011 ◽  
Vol 399-401 ◽  
pp. 2271-2275
Author(s):  
Ming He Dai ◽  
Zhi Dong Yun
Keyword(s):  
Injection Molding ◽  
Product Development ◽  
3D Model ◽  
Numerical Control ◽  
Injection Mould ◽  
Integrated Technology ◽  
Manufacture Process ◽  
Mould Design ◽  
Design And Manufacture

The process of injection mould design and manufacture was introduced by taking the cover as an example. Firstly, the 3D model of the part and the injection mould structure were designed based on SolidWorks software. Secondly, the injection molding progress was analyzed and simulated based on Moldflow software. Finally, the toolpaths of cavity and core were designed based on MasterCAM software, and its manufacture process and numerical control programming was simulated. The period of product development was shortened effectively and the quality of design and manufacture was improved by CAD/CAE/CAM integrated technology.

Immaterial Cost and Production: Maximum Production Cost Level Through Marginal Approach

2020 ◽  
Vol 8 (2) ◽  
pp. 128-149
Author(s):  
Dini Maulana Lestari
Keyword(s):  
Quantitative Study ◽  
Marginal Cost ◽  
Production Cost ◽  
Maximum Level ◽  
Production Costs ◽  
Total Production ◽  
Sugar Factory ◽  
Maximum Production ◽  
Cost Approach ◽  
South Sulawesi

This paper will discuss about the immaterial costs and production yields at one of the refined sugar factory companies in Makassar, South Sulawesi. The theory is based on the fact that Immaterial is a cost that is almsgiving, meaning costs that are outside of the basic costs of the company in producing production, so this research aims to find out: (1) what is the production cost needed to produce this production, (2) the maximum level of production at company from 2013 to 2017. This type of research is a quantitative study because it uses a questionnaire in the form of values ​​that are processed using the marginal cost approach formula. The results of the analysis show that (1) the maximum level of production costs occurred in 2016 amounting to 6,912 with an Immaterial cost of Rp. 2,481,796,800 and the total production produced is 359,077.3 tons (2) The required workforce with the total production produced is 359,077.3 tones of 180 people including the maximum production point which means that the lowest value is achieved (optimal).    

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