Prioritization and ranking of lean practices: a case study

PurposeThe paper aims to identify, prioritize and rank lean practices in the context of an Indian automotive component manufacturing organization using interpretive ranking process (IRP) and interpretive structural modeling (ISM) approaches.Design/methodology/approachLean practices are identified from the literature. Then, two hierarchical models were are developed using two distinct modeling approaches – ISM and IRP with expert opinions from an Indian automotive component manufacturing organization to analyze the contextual relationships among the various lean practices and to prioritize and rank them with respect to performance dimensions.FindingsIn the study, the hierarchical structural models are developed using ISM and IRP approaches for an Indian automotive component manufacturing organization. In ISM-based modeling, lean practices can be categorized into five levels. Top priority should be given to the motivators followed by value chain, system/technology and organization centric practices. IRP model shows the dominance relationship among the various lean practices with respect to performance dimensions.Practical implicationsThe models are constructed from the organizational standpoint to evaluate their impact to the implementation of lean manufacturing. The study leverages the organizations to prioritize limited resources as per the hierarchy. Managers get the inter-linkages and ranking of various lean practices, which leads to a better perspective for the effective implementation of lean. The structural models also assist management to assign proper roles to employees/departments for effective lean implementation.Originality/valueThere is hardly any structural model of lean practices in the literature for clustering, prioritizing and ranking of lean practices. The study fills this gap and develops the hierarchical models of lean practices through IRP and ISM approaches for an Indian automotive component manufacturing organization. The results from both approaches are compared for illustrating the benefits of one over the other.

Energy and Carbon Emission Efficiency Prediction: Applications in Future Transport Manufacturing

The long-term impact of high-energy consumption in the manufacturing sector results in adverse environmental effects. Energy consumption and carbon emission prediction in the production environment is an essential requirement to mitigate climate change. The aim of this paper is to evaluate, model, construct, and validate the electricity generated data errors of an automotive component manufacturing company in South Africa for prediction of future transport manufacturing energy consumption and carbon emissions. The energy consumption and carbon emission data of an automotive component manufacturing company were explored for decision making, using data from 2016 to 2018 for prediction of future transport manufacturing energy consumption. The result is an ARIMA model with regression-correlated error fittings in the generalized least squares estimation of future forecast values for five years. The result is validated with RSS, showing an improvement of 89.61% in AR and 99.1% in MA when combined and an RMSE value of 449.8932 at a confidence level of 95%. This paper proposes a model for efficient prediction of energy consumption and carbon emissions for better decision making and utilize appropriate precautions to improve eco-friendly operation.

Planar Micro-Positioning Device Based on a 3D Digital Electromagnetic Actuator

In this paper, a novel micro-positioning device based on a 3D digital actuator is presented. The proposed system allows realizing planar motions of micro-objects, which could be implemented in several applications where micro-positioning tasks are needed such as micro-component manufacturing/assembly, biomedicine, scanning microscopy, etc. The device has three degrees of freedom, and it is able to achieve planar motions of a mobile plate in the xy-plane at two different levels along the z-axis. It consists of a hexagonal mobile part composed of a permanent magnet that can reach twelve discrete positions distributed between two z-axis levels (six at each level). Two different approaches are presented to perform positioning tasks of the plate using the digital actuator: the stick-slip and the lift-mode approaches. A comparison between these two approaches is provided on the basis of the plate displacement with respect to different current values and conveyed mass. It was observed that for a current of 2 A, the actuator is able to displace a mass of 1.15 g over a distance of 0.08 mm. The optimal positioning range of the planar device was found to be ±5.40 mm and ±7.05 mm along the x- and y-axis, respectively.

Development of a Novel Hybrid Thermoplastic Material and Holistic Assessment of Its Application Potential

Τhe development of a novel hybrid thermoplastic prepreg material enabling the fabrication of next-generation recyclable composite aerostructures produced by affordable, automated technologies is presented in the present work. The new hybrid material is produced using automated equipment designed and developed for this reason. A preliminary assessment of the application of the new material is made to obtain material properties related to its processability as well as to its strength. A typical aeronautical flat skin panel has been identified and produced using an autoclave-based process in order to assess the potential of the new material for producing aircraft structural parts. Moreover, a newly developed holistic index is implemented to enable a more holistic comparison of the suitability of the materials used for the panel production. The aspects considered for the material comparison are the quality, the environmental footprint, and the cost. The results of the study pointed out that the hybrid thermoplastic material that has been developed represents a viable manufacturing option from an industrial point of view and that its implementation in structural component manufacturing leads to clear cost and environmental advantages.

Implementation of Strategic Structure By Integrating Flexible Manufacturing System With Green Technology for Enhancement of Productivity And Quality Of Product

The worldwide advancements of new innovations are developing at a touchy rate, yet associations are embracing more gradually henceforth, serious promoting society and incorporated supervisory crews are required in an organization to exploit new advances. Adaptable assembling innovations are seen by organizations to be a significant component Exceeding competitiveness and seriousness. Notwithstanding, dominating in the present market isn’t easy and straightforward like the procurement of fresh improvement. So as to accomplish more of advantages, the structural framework associations will combine to ensure that the execution of innovation should lead to the normal benefits. Hence, a structure that encourages flexible manufacturing system companies deciding the prerequisites of the FMS reception, with the correct blend of green technology and vital components is required. The study examines particular dimensions of green manufacturing Index Applicability and FMS such as Information technology, planning, flexible automation techniques. The outcome will determine the major substantiate to establish and strengthen the value of product with superior performance, Using the findings the research will suggests the implication and adoption for further research. It would definitely enhance the performance in any industrial organisation with economic growth. This Research aims to report the findings of an exploratory work by integrating Green Manufacturing and flexible Manufacturing system techniques to generate new strategies which can be further administered in an industrial organization and sectors such as component manufacturing, automobile parts and processing sectors.

Temperature Cycling Study of Aerosol-Jet Printed Conductive Silver Traces in Printed Electronics

Aerosol-Jet Printing (AJP) provides a new method for electronic component manufacturing. Understanding the reliability of electronics printed using the AJP process is essential to take full advantage of this technology and realize its industrial potential. In the current study, we have designed and tested AJP printed samples and conducted failure analysis of those samples that have exhibited early failures. Failures first occurred in the short traces that connect the main traces to the silver pads, due to local stress-raisers caused by local geometric features in the printing geometry. Thermal-Mechanical Finite-Element-Modeling (FEM) has been performed to analyze the cyclic history of thermo-mechanical stress distribution and plastic strain distribution.

STUDY OF MATERIALS AND WELDING USED IN THE CONSTRUCTION OF RACKS FOR STORAGE OF FUEL ELEMENTS AT NUCLEAR PLANTS

This paper showed the technological innovations and the necessary requirements for the welding of ASTM A240 TP316L Austenitic Stainless Steel in the construction of racks used in the storage of Fuel Elements inside nuclear power plants. It presents the development of welding processes using coated electrode, SMAW and as addition metal rods EAS 2-IG / ER 308L. This study is divided into two stages, the preparation of technical documentation and the development of methods and manufacturing processes used in the qualification of welding processes. A sequence was outlined based on real situations used by nuclear component manufacturing companies, meeting the physical and mechanical properties required by the nuclear classification standards and their regulations. The results showed that the welding processes were satisfactory, that the destructive and non-destructive tests showed that there was no discontinuity in the surface and defects in the volume of the welding and that, in the present study, safety in the project for the operation of a Nuclear Power Plant was demonstrated.

Influence of manufacturing errors of bearing components on rotational accuracy of cylindrical roller bearings

Understanding the influence of bearing component manufacturing errors and roller number on the rotational accuracy of rolling bearings is crucial in the design of high precision bearings. The rotational accuracy of an assembled bearing is dependent upon roller number and manufacturing error of the bearing components. We propose a model for calculating the rotational accuracy of a cylindrical roller bearing; we experimentally verified the effectiveness of the model in predicting the radial run-out of the inner ring proposed in the previous paper in this series. We sought to define the key contributing factors to the rotational accuracy by studying both the influence of the coupling effect of the roller number and the influence of the manufacturing errors in the inner raceway, outer raceway, and rollers on the motion error. The model and results will help engineers choose reasonable manufacturing tolerances for bearing components to achieve the required rotational accuracy.