Cost effectiveness of production control systems

This thesis deals with the problems associated with the planning and control of production, with particular reference to a small aluminium die casting company. The main problem areas were identified as: (a) A need to be able to forecast the customers demands upon the company's facilities. (b) A need to produce a manufacturing programme in which the output of the foundry (or die casting section) was balanced with the available capacity in the machine shop. (c) The need to ensure that the resultant system enabled the company's operating budget to have a reasonable chance of being achieved. At the commencement of the research work the major customers were members of the automobile industry and had their own system of forecasting, from which they issued manufacturing schedules to their component suppliers, The errors in the forecast were analysed and the distributions noted. Using these distributions the customer's forecast was capable of being modified to enable his final demand to be met with a known degree of confidence. Before a manufacturing programme could be developed the actual manufacturing system had to be reviewed and it was found that as with many small companies there was a remarkable lack of formal control and written data. Relevant data with regards to the component and the manufacturing process had therefore to be collected and analysed. The foundry process was fixed but the secondary machining operations were analysed by a technique similar to Component Flow Analysis and as a result the machines were arranged in a series of flow lines. A system of manual production control was proposed and for comparison, a local computer bureau was approached and a system proposed incorporating the production of additional management information. These systems are compared and the relative merits discussed and a proposal made for implementation.

Biomass production in short rotation effluent-irrigated plantations in North-West India

This study estimates above-ground biomass in high density plantations of six important semi-arid tree species at Palwal (70 km from Delhi) irrigated with secondary treated sewage water at the rate of 0, 25, 50 and 100% of daily net evaporation potential (EP). In 2.5 y old plantations (plant spacing, 2 m x 2 m for single stem species and 2 m x 1 m for multi-stem species), Melia azedarach showed fairly high biomass production (38.4 t/ha) followed by Ailanthus excelsa (27.2 t/ha). Order of biomass production (kg / tree) was: Eucalyptus tereticornis (24.1) > A. excelsa (21.8) > M. azedarach (12.6) > Populus deltoides clone G 48 (8.3) > Alstonia scholaris (6.6)> Pongamia pinnata (3.7). Survival of plants after 2.5 y ranged from 25.2% in P. deltoides to 71.7% in P. pinnata, and had a significant effect on biomass production per unit area. ANOVA shows that levels of irrigation (0 - 100%) did not have statistically significant effect on plant growth. Correlation between diameter and biomass was found highly significant (p< 0.01) with R2 nearing to 1.

Solid biofuel production by mechanical pre-treatment of brewers' spent grain

The brewing industry produces large amounts of by-products and wastes like brewers' spent grain (BSG). In Germany, each year approximately 2.1 million tonnes of BSG are generated. During the last years conventional routes of BSG utilization face a remarkable change, such as the decline in the demand as animal feed. Due to its high content of organic matter energetic utilization may create an additional economic value for breweries. Furthermore, in the recent past breweries tend to shift their energy supply towards more sustainable concepts. Although, a decent number of research projects were carried out already, still no mature strategy is available. However, one possible solution can be the mechanical pretreatment of BSG. This step allows optimized energy utilization by the fractionation of BSG. Due to the transfer of digestible components, such as protein, to the liquid phase, the solid phase will largely consist of combustible components. That represents an opportunity to produce a solid biofuel with lower fuelnitrogen content compared to only thermal dried BSG. Therefore, two main purposes for the mechanical pre-treatment were determined, (1) to reduce the moisture content to at least 60 % (w/w) and (2) to diminish the protein content of the solid phase by 30 %. Moreover, the combustion trials should demonstrate whether stable processes and flue gas emissions within the legal limits in Germany are feasible. The results of the mechanical pre-treatment trials showed that a decrease of the moisture and protein content has been achieved. With regard to the combustion trials inconsistent outcomes were found. On the one hand a stable combustion was realized. On the other hand the legal emission levels of NOx (500 mgm -3) and dust (50 mgm-3) could not be kept during all trials. The further research steps will focus on the optimization of the air/fuel ratio by reducing the primary and secondary air conditions. Copyright © 2014,AIDIC Servizi S.r.l.