An integrated TRIZ approach for technological process and product innovation

2015 ◽  
Vol 231 (6) ◽  
pp. 1062-1077 ◽  
Author(s):  
Miao Li ◽  
Xinguo Ming ◽  
Maokuan Zheng ◽  
Lina He ◽  
Zhitao Xu
Keyword(s):  
Problem Solving ◽  
Technological Process ◽  
Manufacturing Process ◽  
Product Innovation ◽  
Interaction Matrix ◽  
Function Model ◽  
Manufacturing Defects ◽  
Root Cause ◽  
Innovative Solution

Process trimming (also can be called as trimming for process) helps to trim and eliminate process operations by redistributing their functions among other operations. It offers one way to eliminate key disadvantages in product and manufacturing process that other methods do not see. However, few methods have been disclosed in a structured way for process trimming effectively. Therefore, this article proposes an integrated process focused on technological process and product innovation to solve the key problems with process trimming-based TRIZ (theory of inventive problem-solving) approach. This method helps to identify and inventively solve the key problems and maximize use resource of system and supersystem. First, process trimming candidates are identified based on component function model, component trimming rules, process function model analysis, component–process interaction matrix, and root cause analysis. Then, three types of process trimming strategies are presented. Algorithm of process trimming is developed to identify key problems in technological process. TRIZ problem-solving tools are used to solve these key problems. Finally, a case study of refrigerator door foam innovative design and manufacturing process is investigated to test the efficiency of the approach. The innovative solution significantly decreases manufacturing defects and service cost.

scholarly journals A Factory Analysis on the Proportion of Defects Reduction in The Animal Feed Pellet Production Process using Design of Experiment Analysis

2019 ◽  
Vol 3 (2) ◽  
pp. 26-33
Author(s):  
Keyword(s):  
Production Process ◽  
Failure Modes ◽  
Animal Feed ◽  
Fractional Factorial ◽  
Pareto Chart ◽  
Manufacturing Defects ◽  
Root Cause ◽  
Pellet Production ◽  
Feed Pellet

The aim of this research is to reduce a number of defects during a feed pellet production process to improve customer satisfaction. A factory case study produces the feed pellets for several species such as food for pigs, chickens, and ducks. Production data from January to June 2017 manufacturing found that the manufacturing defects rate were about 3.32%. The data showed that the overall defects originated from different problems; 1) cracked or broken food; 2) high humidity; 3) distorted of product color; and 4) an ingredient error, respectively. Statistical methods, design analysis, and cause analysis techniques e.g. the Ishikawa diagram, Pareto chart, and FMEA (Failure Mode and Effects Analysis) were applied to help the factory to identify the main root cause of the defects and the potential failure modes of the factory case study. Due to an increasing number of complaints, this study only concentrated on the duck feed pellet production process. The study was divided into two parts: finding the root cause of the defects, which are the most critical factors for further analysis, and applying an experimental statistical design to decrease the number of defects during the duck pellet production process. The problem with cracked or broken pellets (dust) was found as the main factor affecting the production defects. Results showed that the main factors contributing to the amount of dusk in the duck feed productions came from three factors as follow: the thickness of die, distance between compression rollers and die, and time and temperature of mill machine needed during compressing the duck feed pellet production. Both the fractional factorial experimental design, 2k and 3k, were used to evaluate the influence of each factor on the duck feed production defects. The results by using the factorial 2K experimental show that the most important variable in duck pellets production were thickness of the die, distance between compression rollers and die, and temperature of mill machine needed during compressing the duck feed pellet production while time was not an interaction effect in this problem. The 3k factorial design was used to determine the interaction effects for the duck pellets production process. The experiment was ran and tested for 3 months. The final outcomes showed a significant reduction of defects from 2.51% to 1.09% (P<0.01). The results indicated that thickness -20 mm. of the die, 0.05 mm of distance between compression rollers and die, and 95 degree Celsius of temperature of mill machine needed during compressing the duck feed pellet production would be the most appropriate set of pelleting machine for the duck production process case study.

scholarly journals PRODUCT INNOVATION TOOL ADOPTION BEHAVIOUR IN TECHNOLOGY-BASED NEW VENTURES

2012 ◽  
Vol 16 (03) ◽  
pp. 1240001 ◽  
Author(s):  
GERRIT A. DE WAAL ◽  
PAUL KNOTT
Keyword(s):  
Resource Management ◽  
Problem Solving ◽  
Product Innovation ◽  
New Ventures ◽  
New Venture ◽  
Experienced Team ◽  
Established Firm ◽  
Over Time ◽  
Exclusive Focus

Despite the attention it gives to innovation tools, the product innovation literature does not address the behavioural motivation behind practitioners' adoption of particular tools, or relate this to new venture development. This paper focuses on technology-based new ventures executing their first projects and presents insights into how their innovation tool adoption evolves over time. The paper synthesises case study findings into a hierarchy of tool adoption states encapsulating how new venture teams started with an exclusive focus on effectiveness, and over time progressively attended to problem solving, efficiency, and finally resource management. They often progressed to the next state only in response to costly mistakes and delays, whereas the experienced team in our comparison well-established firm operated within all four states from project initiation. Knowledge of this hierarchy of tool adoption states could help new venture teams to optimise the time they invest in product innovation tools.

Life Cycle Assessment of Timber Formwork: Case Study

2014 ◽  
Vol 1001 ◽  
pp. 155-161
Author(s):  
L'uboš Krišták ◽  
Rastislav Igaz ◽  
Dušan Brozman ◽  
Roman Réh ◽  
Petra Šiagiová ◽  
...  
Keyword(s):  
Life Cycle Assessment ◽  
Life Cycle ◽  
Experimental Model ◽  
Technological Process ◽  
Experimental Research ◽  
Manufacturing Process ◽  
Energy Savings

The article deas with evaluation of the selected parts of a life cycle of timber formwork on a wooden basis, notably in the field of manufacturing and usage. Experimental research focused mainly on assessing the possibilities of energy savings in a manufacturing process through shortening a technological process of moulding. By optimalisation of a moulding period, it is possible to achieve considerable energy savings. Based upon the experiments, we created an experimental model in order to determine optimum moulding time. Withing a process of usage, we evaluated particular materials with regard to re-use cycle based upon the experience of commercial manufacturers.

CAN THE BIG 3 OVERTAKE TOYOTA? — A STUDY BASED ON THE THEORY OF CONSTRAINTS

2007 ◽  
Vol 06 (02) ◽  
pp. 145-157 ◽  
Author(s):  
SIMON WU ◽  
SAMUEL WANG ◽  
MAURICIO F. BLOS ◽  
H. M. WEE
Keyword(s):  
Problem Solving ◽  
Coming Out ◽  
Optimal Solution ◽  
Complex Problem ◽  
Theory Of Constraints ◽  
Root Cause ◽  
Thinking Process ◽  
Core Problem ◽  
Current Reality

Purpose — The aim of this paper is to provide answers to two significant questions. The first question is "what is the comprehensive action for the Big 3 to overtake Toyota Company?" The second question is "Can TOC (Theory of Constraints) really deal with this kind of complicated problem effectively?" Design/methodology/approach — In order to address this question and come out with a reasonable answer, this study uses the Theory of Constraints to discover the root causes and countermeasures for the Big 3 to break through their paradigms. Findings — It is worthwhile to highlight that we have demonstrated that a sophisticated case in global competition of the motor market can provide solutions with only four TOC logic trees. Furthermore, it is interesting to note that the four TOC logic trees fit perfectly well with each of the four problem solving steps in two aspects: (1) It provides a shortcut through mirror imaging process and (2) It enhances the clarity of the thinking process. Research limitations/implications — However, there remains some issues open for further exploration: (1) How can we make sure that the appropriate core problem(s) or root cause(s) has been identified in CRT (Current Reality Tree) and it is indeed the most meaningful one? (2) How can we proceed from CRT to FRT (Future Reality Tree) & further from FRT to PT (Prerequisites Tree) more effectively? (3) How can we discover key obstacles from PT and how to develop action plans from TT (Transition Tree) smoothly? (4) How to refine and integrate these feasible solution sets coming out from TT into the optimal solution scheme to be adapted in the real world? Originality/value — This study demonstrates how TOC problem solving can help to solve the core problems and root causes of "can the Big 3 overtake Toyota?" It not only gives managerial insights for the Big 3 to break through their paradigms to fight back Toyota; but also identify how a complex problem beyond production field can be analyzed and dealt with effectively. Paper type–Case study paper.

scholarly journals Improved Model for Generating Incremental Product Innovation Schemes

2021 ◽  
Vol 2021 ◽  
pp. 1-11
Author(s):  
Lisha Geng ◽  
Jinge Xing ◽  
Xiaofei Shi ◽  
Liran Zu ◽  
Meiqun Chai
Keyword(s):  
Problem Solving ◽  
Product Innovation ◽  
Quality Function Deployment ◽  
Evaluation Process ◽  
Decision Makers ◽  
Generation Process ◽  
House Of Quality ◽  
Cone Model ◽  
Improved Model

To realize incremental product innovation, the key problems of existing products need to be identified and solved with feasible innovation schemes. This study examines the generation process of innovation schemes by integrating Quality Function Deployment (QFD) and the Theory of Inventive Problem Solving (TRIZ). This study has the following advantages: first, this study proposes new rules for distinguishing physical conflicts with technical conflicts and the method for calculating conflict importance after building House of Quality (HoQ) in QFD. Second, an improved integrated model of QFD and TRIZ is constructed, which generates innovation schemes by solving not only the conflicts between technical characteristics but also the problems of product parts. Third, the uncertainty and subjectivity of the data provided by decision-makers in the evaluation process of innovation schemes are processed by interval grey numbers. Moreover, a cone model is built to make the evaluation results more reliable. Last, a case study of water purifiers is conducted to illustrate the validity of the generation process of incremental product innovation schemes.

scholarly journals Knowledge-Driven Manufacturing Process Innovation: A Case Study on Problem Solving in Micro-Turbine Machining

Micromachines ◽  
2021 ◽  
Vol 12 (11) ◽  
pp. 1357
Author(s):  
Dong Zhang ◽  
Gangfeng Wang ◽  
Yupeng Xin ◽  
Xiaolin Shi ◽  
Richard Evans ◽  
...  
Keyword(s):  
Problem Solving ◽  
Manufacturing Process ◽  
Design Method ◽  
Process Innovation ◽  
Machining Process ◽  
Knowledge Network ◽  
Design System ◽  
Industrial Sectors ◽  
Micro Turbine

Micromachining techniques have been applied widely to many industrial sectors, including aerospace, automotive, and precision instruments. However, due to their high-precision machining requirements, and the knowledge-intensive characteristics of miniaturized parts, complex manufacturing process problems often hinder production. To solve these problems, a systematic scheme for structured micromachining process problem solving and an innovation support system is required. This paper presents a knowledge-based holistic framework that enables process planners to achieve micromachining innovation design. By analyzing innovation design procedures and available knowledge sources, an open multi-source Machining Process Innovation Knowledge (MPIK) acquisition paradigm is presented, including knowledge units and a knowledge network. Further, a MPIK network-driven structured process problem-solving and heuristic innovation design method was explored. Subsequently, a knowledge-driven heuristic design system for machining process innovation was integrated in the Computer-Aided Process Innovation (CAPI) platform. Finally, a case study involving specific process problem-solving and innovation scheme design for micro-turbine machining was studied to validate the proposed approach.

Evolution of Robust Manufacturing Process in Machining of DC Motor Commutator Using Complementing Problem Solving Tools

2015 ◽  
Vol 766-767 ◽  
pp. 1183-1189
Author(s):  
A.J. Jagadeesan ◽  
L. Karunamoorthy ◽  
N. Arunkumar
Keyword(s):  
Problem Solving ◽  
Contact Surface ◽  
Process Design ◽  
Manufacturing Process ◽  
Real Root ◽  
Physical Mechanism ◽  
Complete Removal ◽  
Mechanism Analysis ◽  
Root Cause ◽  
Combined Use

Machining the mica insulation in commutator to provide under cut in the surface of contact with the carbon brush is a vital process related to the life of the product. Complete removal of mica in the contact surface is essential and this requires complex sensing and positioning of the thin mica layer during machining. This study revealed improving the sensing and positioning technologies is not adequate and evolved a robust product-process design to overcome the real root cause of variations in the manufacturing process. Combined use of orthogonal array, Shainin technique, physical-mechanism analysis, relations-diagram and evaporating-cloud method complemented the problem solving approach in gaining knowledge and evolving robustness.

Root cause and vibration analysis to increase veneer manufacturing process efficiency: a case study on an industrial peeling lathe

2021 ◽  
Author(s):  
Víctor Tuninetti ◽  
Ricardo Alzugaray ◽  
Jorge González ◽  
Marian Valenzuela ◽  
Andrés Jaramillo ◽  
...  
Keyword(s):  
Manufacturing Process ◽  
Vibration Analysis ◽  
Process Efficiency ◽  
Root Cause
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