• Title/Summary/Keyword: Manufacturing & Facility Management

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Mobile Device NDF(No Defect Found) Cost Estimation (모바일 디바이스의 원인불명고장에 관한 비용 추정)

  • Lee, Jewang;Lee, Jungwoo;Han, Chang Hee
    • Journal of Korean Society of Industrial and Systems Engineering
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    • v.44 no.2
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    • pp.102-114
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    • 2021
  • NDF (No Defect Found) is a phenomenon in which defects have been found in the manufacturing, operation and use of a product or facility, but phenomenon of defects is not reproduced in the subsequent investigation system or the cause of the defects cannot be identified. Recently, with the development of the fourth industrial revolution, convergence of hardware and software technologies in various fields is spreading to products such as aircraft, home appliances, and mobile devices, and the number of parts is increasing due to functional convergence. The application of such convergence technologies and the increase in the number of parts are major factors that lead to an increase in NDF phenomena. NDF phenomena have a significant negative impact on cost, reliability, and reliability for both manufacturers, service providers and operators. On the other hand, due to the nature of NDF phenomena such as difficult and intermittent cause identification and ambiguity in judgment, it is common to underestimate the cost of NDF or fail to take appropriate countermeasures in corporate management. Therefore, in this paper, we propose a methodology for estimating NDF costs by the PAF model which is a quality cost analysis model and ABC (Activity Based Costing) technique. The methodology of this study suggests a detailed procedure and the concept to accurately estimate the NDF costs, using ABC analysis, accounting system information, and IT system data. In addition case studies have validated the methodology. We think this could be a valid methodology to refer to when estimating the cost of other parts. And, it is meaningful to provide important judgment information in the decision-making process based on quality management and ultimately reduce NDF costs by visualizing them separately by major variable factors.

Evaluation of the Level of Microbial Contamination in the Manufacturing and Processing Company of Red Pepper Powder (고춧가루 제조.가공업체의 시설 및 공정별 미생물학적 오염도 평가)

  • Woo, Hye-Im;Kim, Jong-Bae;Choi, Ji-Hee;Kim, Eun-Hye;Kim, Dong-Sul;Park, Kun-Sang;Kim, Eun-Jeong;Eun, Jong-Bang;Om, Ae-Son
    • Journal of Food Hygiene and Safety
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    • v.27 no.4
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    • pp.427-431
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    • 2012
  • This study was conducted to monitor and evaluate microbial contamination during manufacturing process in 6 red pepper powder factories. Red pepper powder samples were taken from manufacturing facilitates, working area and workers' hands to determine sanitary indicator bacteria (SIB) such as aerobic bacteria and coliform group as well as pathogenic indicator bacteria (PIB) such as Staphylococcus aureus, E.coli, Salmonella spp., Listeria monocytogenes, and Bacillus cereus. The results indicated that SIB in primary materials was detected as low as 3 log units and E.coil and Staphylococcus aureus of PIB were detected. After grinding process, aerobic bacteria, fungi, and coliform group increased 52% and 108%, respectively. In final products, PIB was not detected except for one found Staphylococcus aureus by which workers' hands were contaminated. Moreover, UV detectors in all the manufacturers were not able to reduce bacteria. Thus, this data suggest that a stringent safety management be needed to prevent cross contamination, and also reconsider effectiveness of facility.

Proposal of a Classification System of Checklists for Safety Management of On-Site Workers in Modular Construction (사례분석을 통한 모듈러 건축의 현장 작업자 안전관리 체크리스트의 분류 체계 제안)

  • Jun, Younghun;Kim, Kyoontai;Jeon, Eunbi
    • Korean Journal of Construction Engineering and Management
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    • v.22 no.6
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    • pp.120-130
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    • 2021
  • Recently, the government is reinforcing safety management at construction sites to prevent safety accidents in construction works, and the safety management plan of workers is an important situation. Meanwhile, modular construction is expected to be gradually expanded to middle and high-rise buildings, but active measures to ensure worker safety are insufficient. This study is a preliminary study of the development of a checklist for preventive worker safety management. The purpose of this study is to derive a checklist classification system for the safety management of workers in the field of modular construction by preceding studies, case analysis, and expert advisory opinions. The classification system consists of large categories of factory manufacturing, transportation, and on-site construction, and the sub-system consists of six sub-classes: foundation work, frame work, modular frame installation work, finishing work, and facility work. Among them, the sub-classification of modular frame installation work consists of 12 unit works, centering on module lifting and assembly module work, which are the main construction processes. And the classification system reflects the three main management factors and contents for defined safety management. It is expected that the research results of this study can contribute to efficient safety management at the modular construction site.

A Study on the Solution of Product Particle Attachment Problem using Practical TRIZ (실용 트리즈를 활용한 제품 Particle 부착 문제의 해결 방안 연구)

  • Kyu-Han Jeong;In-Kwang Song;Jang-Hee Lee
    • Journal of Practical Engineering Education
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    • v.15 no.1
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    • pp.209-221
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    • 2023
  • In the external inspection and packaging stages of products used in the semiconductor manufacturing process, there is a problem in which particles are adsorbed to the product itself or a carrying tool due to electrostatic discharge. This study presents a methodology that can improve the problem of adsorption of particles to a product by using a practical TRIZ technique. By applying the proposed practical TRIZ-based methodology, the problem was defined, and contradictions caused by product waiting time were derived. Among the derived contradictions, physical contradictions were set and the concept of 'space separation' was applied to derive solutions such as 'installation of Ionizer' and 'improvement of the layout of the workroom'. As a result of the experiment by applying 'Ionizer Installation' and 'Workroom Layout Improvement' derived through the application of practical TRIZ, it was confirmed that the particle adsorption problem that occurs during the waiting time of the product can be solved.Through this study, it is expected that workers, facility engineers, and technical engineers working at manufacturing processes will be able to effectively solve the problems they face through creative thinking and change of ideas by using practical TRIZ techniques, and contribute to innovative technology development and productivity improvement.

The Study on the Utilization of TPM program Affecting the Productivity Increase (TPM 프로그램의 활동요인이 경영성과에 미치는 효과)

  • Oh, Yon-Woo;Lee, Kee-Chai
    • Proceedings of the Korean Operations and Management Science Society Conference
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    • 2005.05a
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    • pp.969-974
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    • 2005
  • TPM program, which is a methodology for improving the management results through the management innovation activity of a company, has been widely introduced in the field of a service industry as well as a manufacturing industry. The main purpose of this study is to present the theoretical model by the relationship between active factors of TPM program and management results for a productivity increase, and to investigate the direct and indirect effects on the management of a company through a parametric study. A questionnaire survey of 300 companies that presently utilize the TPM program has been conducted. In order to verify the validity and the reliability of the contents of the questionnaire survey, a confirmatory factor analysis has been done. A frequency analysis has also been performed to examine the characteristics of the respondent. The factor analysis and the frequency analysis were done by using SAS Ver. 8.2, and the verification of a research model was done by using LISREL Ver. 8.52. The active factors of TPM in the research model consist of 'an independent preservation', 'an individual improvement', 'a planned reservation' and 'an education & training'. Among those active factors, the individual improvement and the education & training significantly influence on the facility efficiency and the organization and personnel management. The organization and personnel management has a greater influence on the management results. Therefore, the education and training for employes is most important for the improvement of the management results through TPM program, and the individual improvement activity is also important.

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A Contemplation on Measures to Advance Logistics Centers (물류센터 선진화를 위한 발전 방안에 대한 소고)

  • Sun, Il-Suck;Lee, Won-Dong
    • Journal of Distribution Science
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    • v.9 no.1
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    • pp.17-27
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    • 2011
  • As the world becomes more globalized, business competition becomes fiercer, while consumers' needs for less expensive quality products are on the increase. Business operations make an effort to secure a competitive edge in costs and services, and the logistics industry, that is, the industry operating the storing and transporting of goods, once thought to be an expense, begins to be considered as the third cash cow, a source of new income. Logistics centers are central to storage, loading and unloading of deliveries, packaging operations, and dispensing goods' information. As hubs for various deliveries, they also serve as a core infrastructure to smoothly coordinate manufacturing and selling, using varied information and operation systems. Logistics centers are increasingly on the rise as centers of business supply activities, growing beyond their previous role of primarily storing goods. They are no longer just facilities; they have become logistics strongholds that encompass various features from demand forecast to the regulation of supply, manufacturing, and sales by realizing SCM, taking into account marketability and the operation of service and products. However, despite these changes in logistics operations, some centers have been unable to shed their past roles as warehouses. For the continuous development of logistics centers, various measures would be needed, including a revision of current supporting policies, formulating effective management plans, and establishing systematic standards for founding, managing, and controlling logistics centers. To this end, the research explored previous studies on the use and effectiveness of logistics centers. From a theoretical perspective, an evaluation of the overall introduction, purposes, and transitions in the use of logistics centers found issues to ponder and suggested measures to promote and further advance logistics centers. First, a fact-finding survey to establish demand forecast and standardization is needed. As logistics newspapers predicted that after 2012 supply would exceed demand, causing rents to fall, the business environment for logistics centers has faltered. However, since there is a shortage of fact-finding surveys regarding actual demand for domestic logistic centers, it is hard to predict what the future holds for this industry. Accordingly, the first priority should be to get to the essence of the current market situation by conducting accurate domestic and international fact-finding surveys. Based on those, management and evaluation indicators should be developed to build the foundation for the consistent advancement of logistics centers. Second, many policies for logistics centers should be revised or developed. Above all, a guideline for fair trade between a shipper and a commercial logistics center should be enacted. Since there are no standards for fair trade between them, rampant unfair trades according to market practices have brought chaos to market orders, and now the logistics industry is confronting its own difficulties. Therefore, unfair trade cases that currently plague logistics centers should be gathered by the industry and fair trade guidelines should be established and implemented. In addition, restrictive employment regulations for foreign workers should be eased, and logistics centers should be charged industry rates for the use of electricity. Third, various measures should be taken to improve the management environment. First, we need to find out how to activate value-added logistics. Because the traditional purpose of logistics centers was storage and loading/unloading of goods, their profitability had a limit, and the need arose to find a new angle to create a value added service. Logistic centers have been perceived as support for a company's storage, manufacturing, and sales needs, not as creators of profits. The center's role in the company's economics has been lowering costs. However, as the logistics' management environment spiraled, along with its storage purpose, developing a new feature of profit creation should be a desirable goal, and to achieve that, value added logistics should be promoted. Logistics centers can also be improved through cost estimation. In the meantime, they have achieved some strides in facility development but have still fallen behind in others, particularly in management functioning. Lax management has been rampant because the industry has not developed a concept of cost estimation. The centers have since made an effort toward unification, standardization, and informatization while realizing cost reductions by establishing systems for effective management, but it has been hard to produce profits. Thus, there is an urgent need to estimate costs by determining a basic cost range for each division of work at logistics centers. This undertaking can be the first step to improving the ineffective aspects of how they operate. Ongoing research and constant efforts have been made to improve the level of effectiveness in the manufacturing industry, but studies on resource management in logistics centers are hardly enough. Thus, a plan to calculate the optimal level of resources necessary to operate a logistics center should be developed and implemented in management behavior, for example, by standardizing the hours of operation. If logistics centers, shippers, related trade groups, academic figures, and other experts could launch a committee to work with the government and maintain an ongoing relationship, the constraint and cooperation among members would help lead to coherent development plans for logistics centers. If the government continues its efforts to provide financial support, nurture professional workers, and maintain safety management, we can anticipate the continuous advancement of logistics centers.

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Start Point Detection Method for Tracing the Injection Path of Steel Rebars (철근 사출 궤적 추적을 위한 시작지점 검출 방법)

  • Lee, Jun-Mock;Kang, Dae-Seong
    • The Journal of Korean Institute of Information Technology
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    • v.17 no.6
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    • pp.9-16
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    • 2019
  • Companies that want to improve their manufacturing processes have recently introduced the smart factory, which is particularly noticeable. The ultimate goal is to maximize the area of the smart factory that performs the process of the production facility completely with minimal manual control and to minimize errors of reasoning. This research is a part of a project for unmanned production, management, packaging, and delivery management and the detection of the start point of rebars to perform the automatic calibration of the rollers through the tracking of the automated facilities of unmanned production. It must meet the requirement to accurately track the position from the start point to the end point. In order to improve the tracking performance, it is important to set the accurate start point. However, the probability of tracking errors is high depending on environments such as illumination and dust through the conventional time-based detection method. In this paper, we propose a starting point detection method using the average brightness change of high speed IR camera to reduce the errors according to the environments, As a result, its performance is improved by more than 15%.

A Study on the Safety of Carbon Manufacturing By-product Gas Emissions (카본제조 부생가스 배출 안전성에 관한 연구)

  • Joo, Jong-Yul;Jeong Phil-Hoon;Kim, Sang-Gil;Sung-Eun, Lee
    • Journal of the Korea Safety Management & Science
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    • v.26 no.1
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    • pp.99-106
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    • 2024
  • In the event of an emergency such as facility shutdown during process operation, the by-product gas must be urgently discharged to the vent stack to prevent leakage, fire, and explosion. At this time, the explosion drop value of the released by-product gas is calculated using ISO 10156 formula, which is 27.7 vol%. Therefore, it does not correspond to flammable gas because it is less than 13% of the explosion drop value, which is the standard for flammable gas defined by the Occupational Safety and Health Act, and since the explosion drop value is high, it can be seen that the risk of fire explosion is low even if it is discharged urgently with the vent stock. As a result of calculating the range of explosion hazard sites for hydrogen gas discharged to the Bent Stack according to KS C IEC 60079-10-1, 23 meters were calculated. Since hydrogen is lighter than air, electromechanical devices should not be installed within 23 meters of the upper portion of the Bent Stack, and if it is not possible, an explosion-proof electromechanical device suitable for type 1 of dangerous place should be installed. In addition, the height of the stack should be at least 5 meters so that the diffusion of by-product gas is facilitated in case of emergency discharge, and it should be installed so that there are no obstacles around it.

The Development of a Energy Monitoring System based on Data Collected from Food Factories (식품공장 수집 데이터 기반 에너지 모니터링 시스템 개발)

  • Chae-Eun Yeo;Woo-jin Cho;Jae-Hoi Gu
    • The Journal of the Convergence on Culture Technology
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    • v.9 no.6
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    • pp.1001-1006
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    • 2023
  • Globally, rising energy costs and increased energy demand are important issues for the food processing and manufacturing industries, which consume significant amounts of energy throughout the supply chain. Accordingly, there is a need for the development of a real-time energy monitoring and analysis system that can optimize energy use. In this study, a food factory energy monitoring system was proposed based on IoT installed in a food factory, including monitoring of each facility, energy supply and usage monitoring for the heat treatment process, and search functions. The system is based on the IoT sensor of the food processing plant and consists of PLC, database server, OPC-UA server, UI server, API server, and CIMON's HMI. The proposed system builds big data for food factories and provides facility-specific monitoring through collection functions, as well as energy supply and usage monitoring and search service functions for the heat treatment process. This data collection-based energy monitoring system will serve as a guide for the development of a small and medium-sized factory energy monitoring and management system for energy savings. In the future, this system can be used to identify and analyze energy usage to create quantitative energy saving measures that optimize process work.

A Survey of Sanitation Management Practices of School Food Ingredients Manufacturing Company Workers in Daegu and Gyeongbuk Province (대구.경북지역 학교급식 식재료 납품업체 생산직원의 위생관리 실태조사)

  • Kim, Yun-Hwa;Lee, Yeon-Kyung
    • Journal of the Korean Society of Food Science and Nutrition
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    • v.40 no.2
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    • pp.274-282
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    • 2011
  • The purpose of this study was to investigate factory workers' knowledge of sanitation management of school foodstuffs and sanitation practices. A questionnaire that identified employees' food safety sanitation management knowledge and practices was developed based on a review of literature. Subjects consisted of 221 factory workers employed at 34 factories in the Daegu and Gyeongbuk areas. Almost half of the factory workers were 40~49 years of age (45.7%), 34.8% had 1~3 years of work experience, 62.4% of the respondents received food safety education 1~2 times a month and 75.1% of the respondents were satisfied with sanitation education. However, the total score for factory worker sanitation knowledge was low: 4.63/9. Sanitation performance was self-evaluated using a Likert 5-point scale. The total mean score for the factory workers' sanitation performance was 4.63/5. Satisfaction level and the amount of sanitation education, application of sanitation knowledge, attitude regarding sanitation management, and sanitation management performance level were significantly high among workers employed in a HACCP certification facility (p<0.05). The difficulties were found to be sanitation management and the time to deliver food to schools. To instill a sense of duty and pride among workers and to ensure that the food suppliers provide best-quality school foodstuffs safely, school dietitians and factory managers must actively educate workers in safe food handling and sanitation.