• Journal of Korean Society of Industrial and Systems Engineering
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• v.39 no.1
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• pp.130-139
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• 2016

The purpose of this paper is to analyze the problems and the sources of defective products and draw improvement plans in a small plastic boat manufacturing process using TOC (Theory Of Constraints) and statistical analysis. TOC is a methodology to present a scheme for optimization of production process by finding the CCR (Capacity Constraints Resource) in the organization or the all production process through the concentration improvement activity. In this paper, we found and reformed constraints and bottlenecks in plastic boat manufacturing process in the target company for less defect ratio and production cost by applying DBR (Drum, Buffer, Rope) scheduling. And we set the threshold values for the critical process variables using statistical analysis. The result can be summarized as follows. First, CCRs in inventory control, material mix, and oven setting were found and solutions were suggested by applying DBR method. Second, the logical thinking process was utilized to find core conflict factors and draw solutions. Third, to specify the solution plan, experiment data were statistically analyzed. Data were collected from the daily journal addressing the details of 96 products such as temperature, humidity, duration and temperature of heating process, rotation speed, duration time of cooling, and the temperature of removal process. Basic statistics and logistic regression analysis were conducted with the defection as the dependent variable. Finally, critical values for major processes were proposed based on the analysis. This paper has a practical importance in contribution to the quality level of the target company through theoretical approach, TOC, and statistical analysis. However, limited number of data might depreciate the significance of the analysis and therefore it will be interesting further research direction to specify the significant manufacturing conditions across different products and processes.

• Journal of Life Science
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• v.16 no.6
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• pp.938-941
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• 2006

Continuous fermentation process for the production of soluble glucan using mutant Agrobacterium sp. ATCC31750 has been developed in this research. When the concentration of soluble glucan was higher than 6 g/l, the viscosity of the fermented broth was too high and it needs complex separation process to separate from culture broth. Mathematical models which describe the cell growth and glucan production was developed and they kinetic parameters were estimated with experimental data. They are used for the optimization of continuous fermentation process and calculate optimal dilution rate for easy separation of glucan 4 g/l. With continuous fermentation, glucan production rate was increased 1.8 times more than that with batch fermentation.

• Journal of Computational Design and Engineering
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• v.3 no.1
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• pp.53-62
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• 2016

The current trends of product customization and repair of high value parts with individual defects demand automation and a high degree of flexibility of the involved manufacturing process chains. To determine the corresponding requirements this paper gives an overview of manufacturing process chains by distinguishing between horizontal and vertical process chains. The established way of modeling and programming processes with CAx systems and existing approaches is shown. Furthermore, the different types of possible adaptions of a manufacturing process chain are shown and considered as a cascaded control loop. Following this it is discussed which key requirements of repair process chains are unresolved by existing approaches. To overcome the deficits this paper introduces repair features which comprise the idea of geometric features and defines analytical auxiliary geometries based on the measurement input data. This meets challenges normally caused by working directly on reconstructed geometries in the form of triangulated surfaces which are prone to artifacts. Embedded into function blocks, this allows the use of traditional approaches for manufacturing process chains to be applied to adaptive repair process chains.

• Corrosion Science and Technology
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• v.23 no.2
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• pp.131-138
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• 2024

This paper introduces Primetals Technologies' Through-Process Optimization (TPO) Services and Through-Process Quality Control (TPQC) System, which integrate domain knowledge, software, and automation expertise to assist steel producers in achieving operational excellence. TPQC collects high-resolution process and product data from the entire production route, providing visualizations and facilitating quality assurance. It also enables the application of artificial intelligence techniques to optimize processes, accelerate steel grade development, and enhance product quality. The main objective of TPO is to grow and digitize operational know-how, increase profitability, and better meet customer needs. The paper describes the contribution of these systems to achieving operational excellence, with a focus on quality assurance. Transparent and traceable production data is used for manual and automatic quality evaluation, resulting in product quality status and guiding the product disposition process. Deviation management is supported by rule-based and AI-based assistants, along with monitoring, alarming, and reporting functions ensuring early recognition of deviations. Embedded root cause proposals and their corrective and compensatory actions facilitate decision support to maintain product quality. Quality indicators and predictive quality models further enhance the efficiency of the quality assurance process. Utilizing the quality assurance software package, TPQC acts as a "one-truth" platform for product quality key players.

• Journal of Technology Innovation
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• v.6 no.1
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• pp.187-214
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• 1998

This paper tries to examine the effectiveness of inventory reduction to the productivity increase and the impact of production environments on its effectiveness utilizing the Profit Impact of Market Strategy (PIMS) Database from the Strategic Planning Institute, a large data set that covers a variety of manufacturing activities from the early 1970s to late 1980s. The empirical results of this paper support the robustness of the principle of "Lean Production" or JIT system (also referred to as "Stockless Production"). We also find that the overall environment in which manufacturing strategic business units operate is an important factor in determining the different degrees of effectiveness of the work-in process (and raw materials) invertory reductions. In particular, we find that the effectiveness of the work-in process reduction varies according to the position in the product life cycly as well as the complexity and characteristics of the production processes.roduction processes.

• Proceedings of the Korea Society for Simulation Conference
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• 2000.11a
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• pp.28-33
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• 2000

This article describes the application of discrete event simulation in a process industry (coffee manufacturing) as a daily production-scheduling tool. A large number of end products (around 300), sporadic demand, and limited shelf life of coffee (90 days) make it difficult to generate feasible production schedules manually. To solve this problem an integrated system was developed incorporating discrete event simulation methodology into scheduling process. The integrated system is comprised of two components: a scheduling program and a simulation model. The scheduling program is used to generate daily schedules for roasting, grinding, and packing coffee. The simulation model uses the generated schedules to simulate the production of coffee and regenerates a modified production schedule. In this paper, each of the components will be described in detail, evaluated in terms of performance factors, and validated with a set of real production data. Although this article focuses on a specific system, we will share our experiences and intuitions gained and encourage other process industries to develop simulation-based scheduling tools.

• Proceedings of the Korean Society for Noise and Vibration Engineering Conference
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• 2002.05a
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• pp.509-514
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• 2002

This paper studies on the noise reduction for a small automobile DC Motor (a window motor) using the 6 sigma process. The application of 6 sigma process suggested reliable and valuable statistical data for the quality of the DC motor at the production line. In the measurement step in 6 sigma process, the FMEA(Failure Mode Effect Analysis) were used for the detection of noise sources. The application of 6 sigma process gave not only the improving method for the quality of the DC motor but also the confidence of improvement itself since it was done on the basis of the test results for a number of DC motors at the production line. Consequently the 6 sigma process was proved very effective for the noise reduction at the production line.

• IE interfaces
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• v.16 no.1
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• pp.111-116
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• 2003

Business integration has been considered as one of the most critical success factors that enable the firms to gain competitive edges. Despite this trend, it has also been found among not a few companies that the activities that should be functionally tied with are performed even independently. In this study, an integrated model of production planning and inventory has been developed. Computerization of the production planning activities is proposed and implemented. We also proposed the reasonable inventory levels of each item using historic data of the items, which are composed of safety stock from the given fill-rate, operating stock from the production patterns, and reserved stock from the production planning. This study has helped the firm to have clearer job definition of the related processes, to tightly control the inventory by setting and tracing the reasonable fill rates for every product, and to quickly respond to the market changes through the computerized production planning process.

• Fashion & Textile Research Journal
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• v.18 no.6
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• pp.776-786
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• 2016

This study intends to suggest production process of circular knitted jackets and dimensional change data of finished clothes after washing. the study provides pattern design method of circular knitted jackets by applying dimensional change. By doing so, the purpose of this study is to increase production efficiency through accurate order in consideration of loss amount of the fabrics in production. With the three fabric materials selected, this study investigated dimensional change of circular knitted jackets after sewing and washing by varying the parts to be attached to padding cloth and with or without inner lining. As for the fabric F-C (including the spandex, thicker and weightier than the other two fabrics), front width shrunk by 4.6%, which showed the biggest shrinkage among the jackets made of test fabrics. Then it suggested design methods of circular knitted jacket patterns to which dimensional change is applied according to materials, and analyzed the amount of fabric required for production by comparison of the materials. When using the fabric F-C without inner lining, there is big dimensional change and more than double amount of fabric is required. It is expected that the research results will be a basic data for pattern design and production process of circular knitted clothing.

• Industrial Engineering and Management Systems
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• v.15 no.4
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• pp.403-431
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• 2016

The objective of this study is to integrate the business, maintenance and production processes of a manufacturing system by incorporating errors. First, the required functions are estimated according to the historical data. The system activities are simulated by Visual SLAM software and the required outputs are obtained. Several outputs including lead times in different dimensions, total cost and production rates are computed through simulation. Finally, data envelopment analysis (DEA) is utilized in order to select the best option between the defined scenarios due to the multi-criteria feature of the problem. This is the first study in which the lead times, cost and production rates are simultaneously considered in the integrated system imposed of business, maintenance and production processes by incorporating errors. In the current study, the major bottlenecks of the system being studied are identified and suggested different strategies to improve the system and make the best decision.