Thietbidinhvithongminh

Tag: process

Lean Process: The Problem With 5S

Posted on by master

Although 5S is generally considered to be one of the fundamental building blocks in a lean process, it is also, in my experience, easily misinterpreted and poorly implemented. By exploring the problems with 5S, maybe we can address some of the underlying issues and produce better results in the future.

What is 5S?

5S is a term used to describe workplace practices aimed at improving visual control in a factory and helping to reduce waste. The name 5S itself is based on the 5 Japanese words for the stages of the process which all start with the letter S. They are:

Seiri (Sort)

Seiton (Set In Order)

Seiso (Shine)

Seiketsu (Standardise)

Shitsuke (Sustain)

The five stages of 5S

Sort

The aim of this stage is to verify what is needed to complete the job based on the standard work. Anything that is not required should be red tagged and removed from the area. Material or tools that are used infrequently should also be removed and identified for local storage (ie not directly in the work area).

Common problems at this stage include:

Not removing all unnecessary items (material, tools etc) from the work area.

Not designating a red tag area.

Not completing the red tags and/or documenting what was removed.

Not getting approval to remove red tagged items from all 3 shifts.

Not having an independent adjudicator to settle any disagreements.

Tips to avoid these problems:

Train all operators in 5S and its benefits.

Designate a safe area, large enough to store all of the anticipated red-tagged items.

Explain the importance of completing the tags for recording purposes.

Designate one team member to control the red tag area. They should not allow anything into the area unless it is tagged properly.

Give all operators across shifts a chance to review what has been tagged.

When a disagreement occurs, don’t compromise: if in doubt, move it out! That said, respect that this is somebody’s workplace and apply reasonable judgement when it comes to personal possessions. Better to allow them to feel like a part of the change than to disengage them completely.

Set

During the set phase of a 5S implementation, the team find locations for all of the remaining items after the red tagging. Anything that is left has been deemed necessary to do the job and therefore needs a storage location.

Common problems at this stage include:

Not adhering to ergonomic design principles.

Not locating each part in the optimal position.

Not making it easy to return parts to their location.

Not using visual management principles.

Tips to avoid these problems:

Adhere to ergonomics guidelines.

Locate parts based on frequency of use. The more frequently it is used, the closer at hand it should be.

Utilise spring balancers for tools, so the operator can just let go to return it to it’s location.

Use labelling, colour coding and shadow boards to help any operator identify where things go.

Shine

The third phase of 5S is shine. This is where …

Read more

Mapping an Industrial Manufacturing Process

Posted on by master

The term “mapping an industrial manufacturing process” sounds quite complex, but is not really hard to explain. In short it is where a floor plan is made of a manufacturing facility showing the direction that an item or items are assembled to make a finished product.
The task begins when a draftsman or drafter draws a layout of the building used to create a product. Then, to give the layout definition, all the isles, machines, presses, and work stations are drawn on the plan.
Once this is completed, arrows similar to treasure maps you read about as a child, are placed on the plan to show the various steps from start to finish of the completed product Importance Of Service Marketing Ppt as it moves from one section of the plant to another. Sometimes notes are shown on the layout explaining the actual process instructions for the workers reference.
Some of the most involved manufacturing process drawings are in industries like automotive or furniture plants. In the automotive industry, the flow process usually starts with the unibody or frame of the car or truck. And then the different parts like the seats, steering wheel, windshield, wheels and axles, hood, etc. are all placed on the vehicle until it rolls off the assembly line. With the furniture industry the piece always starts with the wooden frame, then the springs, next the padding, the upholstery, then finally the packaging.
In short, this type of drawing makes it easier to keep up with what is going on in a manufacturing Types Of Manufacturing Process plant. It is also used to plan out new additions to the process or processes.…

Read more

Patio Umbrellas – Manufacturing Process

Posted on by master

Modern umbrellas are generally made by a hand-assembly process. Quality control and material choices occur throughout the manufacturing operation. Rain protective units that telescope into a length of a couple feet are the most recent innovations in umbrella Manufacturing Strategies In Supply Chain. The differences between a stick umbrella and a collapsible umbrella is that the collapsible uses a two piece shaft that telescopes into itself, and an extra set of runners along the top of the umbrella. The manufacturing operation can be broken up into eight simple steps. The process generally starts with the production of the main support pole. This vital part of the unit is made from wood, aluminum or fiberglass. Depending on what size the umbrella canopy is will change the diameter of support pole that is needed. On smaller six-foot umbrellas, a 1 A� inch diameter pole is sufficient whereas with a larger nine-foot umbrellas, a 1 A� to 2 inch diameter pole is used to create a stronger structure to prevent damage. The types of wood used range from Rowan wood from Asia, to a higher grade Marenti Hardwood. Higher quality materials will last longer and are great for any commercial setting at a hotel, restaurant or country club as well as your backyard.
The next step in the process is to attach the support ribs (support arms). The support ribs run underneath the canopy or top of the umbrella. The ribs are then attached to the main support pole, locking in or being connected into a top notch to create a secure and strong connection point for durability. New modern innovation has created fiberglass ribs that are made of 100% fiberglass to allow the support arms to flex, preventing any damage that may occur from high winds. This feature is becoming increasingly more popular through the commercial and residential users. The ability to have this commercial quality available to the residential user prevents any What Is A Heavy Industry frustration from support ribs being broken by wind saving the customer time and more importantly, money. The next main point in the process is the creation of the top or canopy. Having many different options including but not limited to Polyester, Spun Poly, Olefin, Solution-dyed Acrylic, Pacifica and the most popular, Sunbrella fabric. Each of these fabrics offers different colors and qualities. Read about the different descriptions of these fabrics with the patio umbrella buying guide. This information is provided by our experts to inform the consumer on the different types that are available to help them choose the best one to fit their personal needs.
The very tip, above the canopy is the finial (top cap). The finial is used to secure the canopy fabric to the main support pole. If the finial is broken or not used, the user will run the risk of the fabric flying up and off the support ribs. The finial is generally constructed from a hard plastic or metal (depending on the type of umbrella) and …

Read more

Knowing Some Basic Steps in the PCP Manufacturing Process

Posted on by master

The printed circuit board (PCB) is generally used to interconnect the electronic components of any electronic gadgets such as television, cell phones, computers or hard drives Porter’S Five Forces Starbucks by applying conductive pathways from copper sheets onto a non-conductive substrate. PCB is also referred to as etched wiring board (EWB) or printer wiring board (PWB).
PCB’s are inexpensive and easy to use. Although it requires a lot of layout and designs, still you can guarantee that the cost is much cheaper compared Getting An Electrical Apprenticeship to other types of boards offered in the market. In fact, the manufacturing of PCB’s is much cheaper and faster for large volume production.
Things to Consider in the PCB Manufacturing Process
The printed circuit board manufacturing (PCBM) involves sophisticated series of operation and complex processing steps to produce single or multilayered printed circuit board. The manufacturing process can be either through mechanical, chemical, electrical or optical in nature. However, always keep in mind that though PCB emits limited pollution, still the process could produce significant amount of chemicals that could not only affect the body but also environment. Materials to be used in the PCB manufacturing process should be checked and considered before going through the actual process. The overall output of the PCB could be affected when materials to be used are not checked eagerly especially in the boarding process.
Steps in the PCB Manufacturing Process
The very first step in building PCB is to set up the materials, process and requirements that meet with the client’s specifications about the board design.
The next step is the transferring of data. This process involves transferring of the data for a coating onto the etch film placed on the conductive copper layer.
Next is etching. This process exposes the copper and some parts unprotected by the etch resist film to an element that gets rid of the unprotected copper, which makes the protected copper traces and pads in place.
Another process is the drilling. This process drills off the holes for the protection of the board through some applications. During the process, another drilling would be used for the same purpose of protection.
The next step in the PCB manufacturing is platting. This process is the actual application of copper plating onto the traces, pads and drilled through the holes that were made during the drilling process.
Next to that is masking. This process is the application of protective masking materials over the bare traces so that the whole PCB is coated and protected.
The last phase is the finishing. This process is the coating of pad areas around the thin layer of the solder to organize the board for the reflow soldering process.
Best Way to Find PCB Manufacturing Companies
The fastest way to search for PCB manufacturers is through the Internet. You can see dozens of companies that offer manufacturing of PCB. You can also get more details and information about a certain PCB provider so you will have high chances …

Read more

Manufacturing Juices and Other Acidic Beverages – What Pasteurization Process is Right For You?

Posted on by master

Ever since Louis Pasteur discovered that harmful organisms could be killed off by applying heat to wine, pasteurization has been one of the most important operations in manufacturing food, dairy, beer, juice, and all beverages. There are a number of different methods of pasteurization and it’s important to understand these. I will seek to explain as clearly as possible these methods in the following few paragraphs.
Continuous VS. Manufacturing Engineer Degree Batch (VAT):
Simply put, batch pasteurization involves heating a large amount (or batch) of the liquid all at once to about 145 degrees Fahrenheit for 30 minutes. It’s kind of like heating water in a pot on your stove, but on a much larger scale. The temperature and hold time varies depending on the liquid’s acidity. Specific guidelines are prescribed by the FDA for each industry. One very important form of pasteurization that could fall into this category is tunnel pasteurization. Tunnel pasteurization involves filling and capping the liquid into glass bottles or aluminum cans prior to pasteurization. The liquid, bottle, and cap are then heated to around 160 degrees Fahrenheit for 20 minutes or so. This process is often used by beer, tea, and energy drink companies whose flavor system can vary greatly with the amount of time their product cooks, or in the case of cans; it’s the easiest way to avoid any contamination. Other than those reasons, batch pasteurization has largely been replaced by Continuous pasteurization.
Continuous pasteurization has numerous advantages over VAT pasteurization including less time, fewer sanitation variables, and energy savings. The name “continuous” is given to this process because only a part of the batch (anywhere from 5-100 gallons per minute) is pasteurized continually as it flows through a heat exchange. Continuous pasteurization is achieved using either a plate heat exchanger or tubular heat exchanger. Plate is used often with the pasteurization of milk and non pulpy liquids. If the liquid is thick, pulpy, or fibrous, as many juices are, a tubular heat exchange is used to avoid blockage in the system and burning. The heating medium is either water or steam.
Defining HTST, UP, UHT, Flash Pasteurization, and Hot Fill
Within continuous pasteurization there are a number of different processes. You’ve probably heard of HTST (high temperature short time,) Ultra pasteurization, and Ultra-high temperature sterilization. Each of these forms of pasteurization has a different temperature and hold time. For HTST pasteurization, the temperature is typically 165 degrees to 180 degrees Fahrenheit. The hold time is anywhere from 3 to 15 seconds. Ultra pasteurization ranges from 190 degrees and 212 degrees Fahrenheit with hold times of 1 to.01 seconds. UHT sterilization is 280 degrees for 2 seconds. The shelf life and flavor of the liquid can be affected depending on which process is used.
With either of these processes a “Flash Pasteurization” can be achieved if the liquid is immediately passed through a second heat exchange prior to bottling, cooled to ambient temperature, and filled cold in an aseptic environment. This is often …

Read more

Manufacturing Juices and Other Acidic Beverages – What Pasteurization Process is Right For You?

Posted on by master

Ever since Louis Pasteur discovered that harmful organisms could be killed off by applying heat to wine, pasteurization has been one of the most important operations in manufacturing food, dairy, beer, juice, and all beverages. There are a number of different methods of pasteurization and it’s important to understand these. I will seek to explain as clearly as possible these methods in the following few paragraphs.
Continuous VS. Manufacturing Engineer Degree Batch (VAT):
Simply put, batch pasteurization involves heating a large amount (or batch) of the liquid all at once to about 145 degrees Fahrenheit for 30 minutes. It’s kind of like heating water in a pot on your stove, but on a much larger scale. The temperature and hold time varies depending on the liquid’s acidity. Specific guidelines are prescribed by the FDA for each industry. One very important form of pasteurization that could fall into this category is tunnel pasteurization. Tunnel pasteurization involves filling and capping the liquid into glass bottles or aluminum cans prior to pasteurization. The liquid, bottle, and cap are then heated to around 160 degrees Fahrenheit for 20 minutes or so. This process is often used by beer, tea, and energy drink companies whose flavor system can vary greatly with the amount of time their product cooks, or in the case of cans; it’s the easiest way to avoid any contamination. Other than those reasons, batch pasteurization has largely been replaced by Continuous pasteurization.
Continuous pasteurization has numerous advantages over VAT pasteurization including less time, fewer sanitation variables, and energy savings. The name “continuous” is given to this process because only a part of the batch (anywhere from 5-100 gallons per minute) is pasteurized continually as it flows through a heat exchange. Continuous pasteurization is achieved using either a plate heat exchanger or tubular heat exchanger. Plate is used often with the pasteurization of milk and non pulpy liquids. If the liquid is thick, pulpy, or fibrous, as many juices are, a tubular heat exchange is used to avoid blockage in the system and burning. The heating medium is either water or steam.
Defining HTST, UP, UHT, Flash Pasteurization, and Hot Fill
Within continuous pasteurization there are a number of different processes. You’ve probably heard of HTST (high temperature short time,) Ultra pasteurization, and Ultra-high temperature sterilization. Each of these forms of pasteurization has a different temperature and hold time. For HTST pasteurization, the temperature is typically 165 degrees to 180 degrees Fahrenheit. The hold time is anywhere from 3 to 15 seconds. Ultra pasteurization ranges from 190 degrees and 212 degrees Fahrenheit with hold times of 1 to.01 seconds. UHT sterilization is 280 degrees for 2 seconds. The shelf life and flavor of the liquid can be affected depending on which process is used.
With either of these processes a “Flash Pasteurization” can be achieved if the liquid is immediately passed through a second heat exchange prior to bottling, cooled to ambient temperature, and filled cold in an aseptic environment. This is often …

Read more

Process Mapping and How To Get The Most Out Of It

Posted on by master

Process mapping, as the term indicates is a work flow diagram which is adopted to bring forward a clearer understanding of a process or a series of processes. It refers to the strategic act of defining every single action of production. This can be very helpful in understanding the systems and procedures that are already in place. It also helps in understanding the existing short comings in order to make improvements to them. It would be appropriate that all persons involved in the business of production also be involved in Process Mapping.

If the intentions are to make an improvement in the work place, one should first of all know the system; what works and what needs improvement. One should be familiar with the ‘as is’ condition prior to making any changes. Process maps are more than just knowing how a system works. Before attempting to improve the work area one should be thorough with the system itself.

These are a potent set of tools that in the right and competent hands can unlock opportunities to do the following things:-

Eliminate non-value added activities

Increase efficiency

Expand service capabilities

Reduce cycle time

Minimize dependencies

Gain buy-in and organizational support for change

Simplify work flow.

Earlier ‘Process Mapping’ was also known as ‘flow charting’. However, this term was routinely used for software development. When organizational work is flowcharted, a broader set of tools appropriate for business workflow can illuminate the multiple views of process performance. These set of tools comprise Process Mapping.

To acquire the maximum benefit from process mapping, one has to use the right set of tools. The oft quoted saying, ‘If all you have is a hammer, everything looks like a nail’ applies to Process Mapping too. If one always makes the use of block diagrams to indicate how work flows, one might miss the other opportunities of business performance (who, where and why). Successful process mapping begins with choosing the right tool from your multi-faceted tool kit. Each tool has its own pros and cons, and should be used appropriately. Each technique involves certain aspects of a process, and it’s only by a trial and error method that the right tool can be found for the problem. The following are the methods to illustrate your process:-

System maps-formal and informal

Top down chart

Block diagram-logic flow-left to right

Block diagram-responsibility matrix

Block diagram-cycle vs. process

Flow process chart

Work flow diagram(Basic flow chart)

Swim lane or development chart(deployment maps or cross functional flow charts)

State change chart

These system charts are very handy and useful when evaluating Learn About Tech Industry the systemic interplay between the various processes.

Each tool is better or worse to illustrate parts of your process, and to find gaps that you have found in your process analysis. There are seven critical dimensions which would help in giving depth to your analysis, and greater meaning to your images. They are:-

Who

What

When

Where

Whether

What degree (How much),and

What frequency Horizontal Restraint …

Read more

Gold Chains and the Manufacturing Process

Posted on by master

It is seldom that one can pass a jeweller’s window and not gaze in fascination at the beautiful wares on offer. The gold chains glint beneath the lights, tempting the purchaser with a lustrous glow that is particular only to gold itself. We don these expensive decorative items, but offer little thought to how they come into being.
Gold chains begin life in a very different form to what we purchase in the high-end jewellery store. South Africa, the United States of America and Australia are What Is The Major Industries In Indonesia the largest gold producers in the world, in that order. In the United States, most gold is obtained above the ground, in what is referred to as open pit mining.
Believe it or not, geologists are called upon to do land surveys and by use of such tools as geochemistry and state of the art satellite surveys, they determine where an ore deposit might Industrial Production Investopedia be found. Computer graphics are used to design the layout of the mine long before any physical steps are taken. Once all the necessary permits are obtained, things begin to progress.
Samples of the gold ore are extracted and examined to determine the quality and metallurgical characteristics. Depending on the rock type and quality of the ore, the broken rocks will either be sent to an area for processing low grade or high grade ore. Low grade ore is broken into smaller pieces and set to percolate in a diluted cyanide solution, which dissolves the gold. This solution is then collected.
High grade ore is generally ground into powder in a specialized mill and then undergoes one of three processes. It may either be heated to 1,000 degrees Fahrenheit, burning off all the sulphide and carbon, before being passed on to the leaching circuit, where it is dissolved with a cyanide solution. Alternatively, it may go directly to the leaching circuit or it is oxidized to separate the gold from other minerals.
Activated carbon is then used to leach the gold from the cyanide solution. The next step in the process is to strip the gold from the carbon in a specialized process. The gold containing solution is then put through an electrolytic process and the gold is then melted into gold bars. The gold bars are then sent to a refinery where the refining process renders them 999.9% pure.
The gold is then put through a process of annealing (heating and then quenching) as it is put through a rolling mill, stretching it out into gold wire. It is this gold wire that is purchased by the gold smith or gold manufacturer. Gold chains are either handmade or mass produced.
The goldsmith then works the gold wire into the desired shaped rings by use of a specialized set of tools that decides the shape of each individual ring. The individual rings are annealed to ensure that there are no breaks in the links. The fire scale is removed by …

Read more

Automated Assembly Is an Effective Automated Manufacturing Process

Posted on by master

Automated assembly comes in various shapes and sizes depending on the types of products that require assembly. Assembly is a core work effort in the automated manufacturing process. Automated assembly contributes benefits to the automated manufacturing process and should be optimized to fit in with the other processes that have to be done in the manufacturing operation. Setting Up Industries There are four basic types of automated assembly that can be included in the automated manufacturing process. These are single work cell, flexible, synchronous, and non-synchronous automation. The optimum application of any one of these assembly types will have to be dictated by the configuration of manufacturing that will be used in concert with the assembly.
Single work cell automated assembly, as a part of the automated manufacturing process, performs the entire assembly of a product in a single work cell. This operation is best applied in high-volume manufacturing that requires for products with a small number of parts to be assembled to complete a given unit. This unit, once assembled, can be a finished product or it can be a sub-assembly that will be included in further assembly to build a finished product. In a lot of cases the single work cell automated assembly process can be just one part of several such work cells that build sub-assemblies for the production of other finished parts.
Synchronous automated assembly can be set up in the automated manufacturing process in either rotary, sometimes called circular, in-line, or carousel configurations. Any of these configurations requires that all the movement from work cell to work cell in the assembly process keep moving continuously. If any part of the assembly process breaks down or stops then all the processes in assembly will stop. There is no in-process inventory with this process. This type of set up is very effective for high-speed automated assembly because of its non-stop nature. The process runs as fast as the character of the machines and the parts will allow. Synchronous automation usually is used to assemble small, lightweight parts.
Non-synchronous automated assembly is a manufacturing operation that allows for the movement of products from one work cell to another at different rates. If there is a lot of time required for the completion of one step in the assembly process, and other steps in the process are performed at different rates, then this is the type of assembly automation that can be used very effectively. There may be some accumulation of in-process products at different points in the assembly process. The production rates for the non-synchronous assembly processes are inherently slower than the rates provided by synchronous processes. These slower processes have more flexibility in the types and sizes of products that can be assembled, so they are used in many more instances than synchronous assembly automation. The fact that in-process products can be accumulated between work cells allows these assembly processes to keep working in some areas if other parts of the process have stopped. The configuration of …

Read more

Benefits of the Industrial Automation Process and Control System

Posted on by master

When rugged data acquisition and monitoring is needed in a variety of industrial applications, automation can provide many benefits. The technology is especially helpful in marine and offshore applications, where feedback signals, logic and switching functions can all be automated.
Automation utilizes information technologies and control systems to improve dependability and productivity. Machine automation processes can help to increase efficiency and consistency beyond a level that is possible with human effort. Automation goes one level above mechanization. While this streamlined process offers human technicians equipment to physical support to their regular tasks, the automation process decreases the need for Genetic Industry human labor altogether. Depending on the industrial function, consistency and creation time can see a substantial increase. Optimizing drive systems to through robotic automation and control technologies can assist the manufacturing to be more efficiency and accurate.Today, energy efficiency in industrial processes is becoming more and more relevant. As energy costs continue to rise, automation can help work to decrease these costs.
Another benefit of automation includes an improvement in overall product quality. The use of automated systems also reduces the amount of time from beginning to end during the physical operations process. It provides benefits in instances where a high degree of accuracy and consistency are required. Automation can also replace the need for human workers in tasks where difficult physical labor is required. Robotic engineering can perform tasks that are simply beyond scope of human beings. Systems can be customized to ideal production without having to worry about human capital and the inherent limitations that go with it, such as physical endurance and mental concentration.
Most importantly, it can also replace the need for human workers in dangerous environments. This is especially beneficial in marine and offshore applications. Automated systems can withstand dangerous work environments and work around hazardous substances. By removing workers from these unsafe areas, and assigning them in more challenging operating and programming jobs, industrial automation improves quality of life and protects the company from costly insurance claims.
Robotic automation can also help to reduce costs. It not only can cut down on labor costs, but also can also reduce operation time and handling time significantly. It essentially allows workers to take on higher-level jobs in the Industrial Engineering Ppt automated processes. Fully integrated automation systems can provide piece of mind in knowing that not only is production efficient and reliable, but that tasks are being performed safely without putting employees at risk.…

Read more