Reliability management of machine tool technology: a case study of current practice

Considerable attention has been given in the literature to identifying and describing the effective elements which positively affect the improvement of product reliability. These have been perceived by many as the 'state of the art' in the manufacturing industry. The applicability, diffusion and effectiveness of such methods and philosophies, as a means of systematically improving the reliability of a product, come in the main from case studies and single and infra-industry empirical studies. These studies have both been carried out within the wider context of quality assurance and management, and taking reliability as a discipline in its own right. However, it is somewhat of a surprise that there are no recently published findings or research studies on the adoption of these methods by the machine tool industry. This may lead one to construct several hypothesised paradigms: (a) that machine tool manufacturers compared to other industries, are slow to respond to propositions given in the literature by theorists or (b) this may indicate that a large proportion of the manufacturers make little use of the reliability improvement techniques as described in the literature, with the overall perception that they will not lead to any significant improvements? On the other hand, it is evident that hypothetical verification of the operational and engineering methods of reliability achievement and improvement adopted in the machine tool industry is less widely researched. Therefore, research into this area is needed in order to explore the 'state of the art' practice in the machine tool industry. This is in terms of the status, structure and activities of the operation of the reliability function. This paper outlines a research programme being conducted with the co-operation of a leading machine tool manufacturer, whose UK manufacturing plant produces in the main Vertical Machining Centres (VMCs) and is continuously undergoing incremental transitions in product reliability improvement.

Setting parameters in MRP for the effective management of bought-out inventory in a JIT assembly environment

In recent years, UK industry has seen an explosive growth in the number of `Computer Aided Production Management' (CAPM) system installations. Of the many CAPM systems, materials requirement planning/manufacturing resource planning (MRP/MRPII) is the most widely implemented. Despite the huge investments in MRP systems, over 80 percent are said to have failed within 3 to 5 years of installation. Many people now assume that Just-In-Time (JIT) is the best manufacturing technique. However, those who have implemented JIT have found that it also has many problems. The author argues that the success of a manufacturing company will not be due to a system which complies with a single technique; but due to the integration of many techniques and the ability to make them complement each other in a specific manufacturing environment. This dissertation examines the potential for integrating MRP with JIT and Two-Bin systems to reduce operational costs involved in managing bought-out inventory. Within this framework it shows that controlling MRP is essential to facilitate the integrating process. The behaviour of MRP systems is dependent on the complex interactions between the numerous control parameters used. Methodologies/models are developed to set these parameters. The models are based on the Pareto principle. The idea is to use business targets to set a coherent set of parameters, which not only enables those business targets to be realised, but also facilitates JIT implementation. It illustrates this approach in the context of an actual manufacturing plant - IBM Havant. (IBM Havant is a high volume electronics assembly plant with the majority of the materials bought-out). The parameter setting models are applicable to control bought-out items in a wide range of industries and are not dependent on specific MRP software. The models have produced successful results in several companies and are now being developed as commercial products.

Using a simulation model for capacity management

A simulation model has been constructed of a valve manufacturing plant with the aim of assessing capacity requirements in response to a forecast increase in demand. The plant provides a weekly cycle of valves of varying types, based on a yearly production plan. Production control is provided by a just-in-time type system to minimise inventory. The simulation model investigates the effect on production lead time of a range of valve sequences into the plant. The study required the collection of information from a variety of sources, and a model that reflected the true capabilities of the production system. The simulation results convinced management that substantial changes were needed in order to meet demand. The case highlights the use of simulation in enabling a manager to quantify operational scenarios and thus provide a rational basis on which to take decisions on meeting performance criteria.

Do educators need educating?

Actual text: I was recently at the Spanish College of Optometry biennial conference and attended a meeting of contact lens lecturers from around Spain and Portugal. We discussed various ideas, mainly about how to share good practice and improve standards. What came to my mind was ‘is there a blueprint for training trainers?’ Well probably not but there are many things that we need to acknowledge such as the way students learn for example. Many educators themselves were taught by lecturers who would write on a blackboard or use acetate on an overhead projector, then came the 35 mm slide era followed by the Powerpoint era. More recently there is a move towards a much more integrated approach of various teaching methods. At my university our contact lens and anterior eye lectures generally follow a format where a narrated Powerpoint lecture is uploaded onto our internal virtual learning environment. This narrated version of the slides is designed to give the didactic element of the topic. The students listen to that before attending an interactive seminar on that topic. The seminar is also recorded so that students can listen to that afterwards. The seminar is designed to give additional information, such as case reports, or to clarify key points or for live demonstrations. It is a good way of doubling the contact time with the students without imposing further on an already packed formal timetable as the students can work in their own time. One problem that we noticed with this approach was that attendance can vary. If the students feel that they will gain something from the interactive seminar then they are more likely to attend – exam tips usually win them over! At the Spanish meeting the educators decided that they wanted to have regular meetings. The industry colleagues in attendance said that they were happy to help but could not necessarily give money, but they could offer meeting rooms, pay for lunch and evening meals. They even said that that they were happy to host meetings and invite other companies too (except to manufacturing plants). In the UK the British Committee of Contact Lens Educators (BUCCLE) meets for one day on three occasions in the year. The American Optometric Contact Lens Educators (AOCLE) meets annually at a three day event. Both these organisations get some help from industry. BUCCLE usually has one of its meetings at a university, one at a company training centre/manufacturing plant/national headquarters and one meeting the day before the BCLA annual conference. BUCCLE usually has its pre-BCLA meeting in conjunction with the International Association of Contact Lens Educators (IACLE). So when educators meet what would they discuss; well probably the focus should be on education rather than actual contact lens knowledge. For example sharing ideas on how to teach toric lens fitting would be better than discussing the actual topic of toric lenses itself. Most universities will have an education department with an expert who could share ideas on how to use the internet in teaching or how to structure lectures or assessments etc. In the past I have helped with similar training programmes in other countries and sharing good practice in pedagogy is always a popular topic. Anyone who is involved in education in the field of contact lenses should look at the IACLE web page and look out for the IACLE World Congress in 2015 in the days preceding the BCLA. Finally, IACLE, AOCLE and BUCCLE all exist as a result of generous educational grants from contact lens companies and anyone interested in finding out more about should refer to their respective web pages.

Development of a knowledge sharing framework for improving the testing processes in global product development

As identified by Griffin (1997) and Kahn (2012), manufacturing organisations typically improve their market position by accelerating their product development (PD) cycles. One method for achieving this is to reduce the time taken to design, test and validate new products, so that they can reach the end customer before competition. This paper adds to existing research on PD testing procedures by reporting on an exploratory investigation carried out in a UK-based manufacturing plant. We explore the organisational and managerial factors that contribute to the time spent on testing of new products during development. The investigation consisted of three sections, viz. observations and process modelling, utilisation metrics and a questionnaire-based investigation, from which a proposed framework to improve and reduce the PD time cycle is presented. This research focuses specifically on the improvement of the utilisation of product testing facilities and the links to its main internal stakeholders - PD engineers.

Desenvolvimento de indicadores enzimáticos inteligentes para monitoramento da qualidade de alimentos

A dificuldade em conhecer o histórico de temperatura de um alimento, desde sua produção até o consumo, torna difícil prever sua verdadeira vida-útil. O uso de indicadores de tempo e temperatura (ITT) pode ser uma alternativa inovadora empregada para garantir a validade de produtos de forma dinâmica. Assim, este trabalho visa desenvolver novos indicadores enzimáticos de tempo e temperatura para monitorar a qualidade de alimentos perecíveis durante o seu processamento e armazenamento, baseados na reação de complexação entre o amido e o iodo (azul), e na posterior atuação de uma enzima amilase sobre esse complexo, para causar uma redução da intensidade da cor azul a uma taxa dependente do tempo e da temperatura de armazenagem. Os sistemas inteligentes propostos possuem versatilidade de atuação em função do tipo e quantidade de amilase empregada. Desta forma, foi utilizada uma amilase termoestável para a formulação de um indicador inteligente de processamento, utilizado para o controle de tratamentos térmicos industriais (pasteurização);e uma amilase termosensível na formulação de um indicador de armazenamento, empregada para o controle das condições de temperatura durante a cadeia de frio de produtos perecíveis. Na elaboração dos ITT de processamento foram realizadas simulações em laboratório e testes em planta fabril, os quais avaliaram diferentes concentrações de amilase termoestável nos protótipos de ITT quando submetidos as condições de tempo e temperatura de pasteurização. Os resultados evidenciaram que a resposta de cor dos indicadores foi visualmente interpretada, como adaptável à medição usando equipamentos, apresentando boa reprodutibilidade em todas as condições estudadas. O ITT contendo 6,5 % de amilase termoestável (penzima/pamido) foi aquele cujo resultado melhor se adequou à utilização na validação de cozimento de presunto. Nesta condição, o protótipo anexado à embalagem primária do produto indicou o processo de pasteurização de forma fácil, precisa e não destrutiva. Já durante o desenvolvimento do ITT de armazenamento foram realizadas simulações em laboratório, testes em planta fabril e ponto de venda, os quais avaliaram o uso de diferentes concentrações de amilase termosensível nos protótipos de ITT quando submetidos a diversas condições de cadeia de frio. Os resultados evidenciaram que devido à possibilidade de definir a vida-útil destes protótipos variando as concentrações de enzima termosensível, os indicadores podem ser facilmente adaptados para controlar as condições de temperatura durante a cadeia de diversos alimentos perecíveis. O protótipo contendo 60 % de amilase termosensível (penzima/pamido) foi aquele cujo resultado melhor se adequou à utilização no controle da cadeia avícola. Assim, o ITT indicou visualmente o histórico de tempo e temperatura de produtos à base de frango de forma fácil e precisa. Os resultados obtidos na avaliação das percepções dos consumidores frente ao emprego de indicadores inteligentes em embalagens alimentícias mostraram que o uso de ITT é uma inovação receptiva, com consequente aceitação e intenção de compra elevada pela população brasileira. Assim, com este trabalho espera-se contribuir efetivamente para que o conceito de embalagens inteligentes possa ser aceito comercialmente e que sejam estabelecidas no Brasil normas que regulamentem seu uso, conferindo benefícios à conservação de grande variedade de alimentos.

Riesgo biomecánico y dolor lumbar en operarios y personal administrativo en una fábrica de jabón en Bogotá 2016

Introducción: El dolor lumbar y los desórdenes músculo esqueléticos comprometen la salud y la calidad de vida de los trabajadores, pueden poner en riesgo el futuro laboral de las personas. bjetivo: Estimar la prevalencia de dolor lumbar y los posibles factores biomecánicos asociados en el personal operativo y administrativo en una empresa manufacturera de jabón en Bogotá, en el año 2016 Metodología: Estudio de corte transversal donde se evaluó el riesgo biomecánico y la prevalencia del dolor lumbar en personal administrativo (138) y operativo (165); se utilizó como instrumento el ERGOPAR validado en España. Se revisó la asociación utilizando la prueba Chi Cuadrado de Pearson, con un nivel de significación α 0.05 Resultados: 303 trabajadores de una empresa manufacturera de jabón en Bogotá, donde predominó el género masculino (51,82%) y la población adulta media entre 30-39 años (57,42%). La prevalencia del dolor lumbar en la población fue de 61,39% (186). La edad no se asoció estadísticamente al dolor lumbar. Se encontró asociación estadística entre el síntoma dolor lumbar y extensión de cuello (p=0,05 OR1.95 IC 1.33-2.88), así como con agarrar o sujetar objetos (p= 0,036. OR 2.3 IC 1.59-3.51) y con las exigencias físicas laborales (p= 0.001 OR 1.99 IC 1.31-3.02). Conclusiones: La población estudiada presentó una alta prevalencia de dolor lumbar, con predominio en personal que realiza labores operativas, y del género femenino. La adopción de posturas de extensión del cuello y la sujeción o agarre de objetos son factores asociados directamente con la aparición de lumbalgia.

Use of medicinal plant in the manufacturing of energetic cookies

Many nutrients provide energy and regulate physiological processes linked to exercise. This work aimed at using medicinal plant in the manufacturing of energetic cookie. An evaluation of microbiological and physicochemical stability was made within 180 days of the fabrication of the product. Sensorial analysis was performed in all stages with untrained tasters. The results were statistically tested. The evaluation of ergogenic effect of the product used the maximum volume of oxygen index as a parameter through the cooper track test (12 minutes) with 7 voluntaries. The participants received the consent form. This study was approved by the local ethics committee (N° CAAE - 0009.0.313.000-08). It was observed good stability for physicochemical and microbiological parameters. As for sensorial analysis there was a predominance of scores 6 to 8, characterizing good acceptance. It was verified increase in VO2 max after the intake of the cookies with or without the medicinal plants. However, the product with the medicinal plants presented a bigger value, 35.47 VO2 max mL/(kg.min)-1. The fraction of carbohydrate and the presence of medicinal plants can be considered as nutritional ergogenic substances. The lipid fraction favor the energetic aspect of the product. The proposed product presented energetic and ergogenic effect.

Direct support and general support maintenance repair parts and special tools lists (including depot maintenance repair parts and special tools lists) : crushing and screening plant, diesel engine driven, semitrailer MTD, 35 ton per hour capacity, Army model 2A-2A, NSN 3820-00-878-4285, Iowa Manufacturing Company model 2A-2A, primary unit, Army model 2A2PRIM ...

Includes index.

Organizational maintenance repair parts and special tools lists : crushing and screening plant, diesel engine driven, semitrailer MTD, 35 ton per hour capacity, Army model 2A-2A, NSN 3820-00-878-4285, Iowa Manufacturing Company model 2A-2A, primary unit, Army model 2A2PRIM, NSN 3820-00-851-6728, Iowa Manufacturing Company model 2A-2B and secondary unit Army model 2A2SEC ...

Includes index.

Direct support, general support, and depot maintenance manual : crusher, jaw, diesel engine driven, semitrailer mounted, 35 ton per hour capacity (Iowa Manufacturing Company model 2A-2A), FSN 3820-851-6728, component of crushing and screening plant, diesel engine driven, FSN 3820-878-4285.

"May 1968."

Direct support, general support, and depot maintenance manual : crusher, screening unit, diesel engine driven, semitrailer mounted, 35 ton per hour capacity (Iowa Manufacturing Company model 2A-2B), FSN 3820-938-7942, component of crushing and screening plant, diesel engine driven, FSN 3820-878-4285.

"June 1968."

Operator and organizational maintenance manual : crusher, jaw, diesel engine driven, semitrailer mounted, 35 ton per hour capacity (Iowa Manufacturing Company model 2A-2A), FSN 3820-851-6728, component of crushing and screening plant, diesel engine driven, FSN 3820-878-4285.

"September 1970."

Is the post-reform growth of the Indian manufacturing sector efficiency driven? Empirical evidence from plant level data

It is generally believed that the structural reforms that were introduced in India following the macro-economic crisis of 1991 ushered in competition and forced companies to become more efficient. However, whether the post-1991 growth is an outcome of more efficient use of resources or greater use of factor inputs remains an open empirical question. In this paper, we use plant-level data from 1989–1990 and 2000–2001 to address this question. Our results indicate that while there was an increase in the productivity of factor inputs during the 1990s, most of the growth in value added is explained by growth in the use of factor inputs. We also find that median technical efficiency declined in all but one of the industries between 1989–1990 and 2000–2001, and that change in technical efficiency explains a very small proportion of the change in gross value added.

Toxicity and recalcitrant compound removal from bleaching pulp plant effluents by an integrated system: anaerobic packed-bed bioreactor and ozone

Effluents originated in cellulose pulp manufacturing processes are usually toxic and recalcitrant, specially the bleaching effluents, which exhibit high contents of aromatic compounds (e.g. residual lignin derivates). Although biological processes are normally used, their efficiency for the removal of toxic lignin derivates is low. The toxicity and recalcitrance of a bleached Kraft pulp mill were assessed through bioassays and ultraviolet absorption measurements, i.e. acid soluble lignin (ASL), UV(280), and specific ultraviolet absorption (SUVA), before and after treatment by an integrated system comprised of an anaerobic packed-bed bioreactor and oxidation step with ozone. Furthermore, adsorbable organic halides (AOX) were measured. The results demonstrated not only that the toxic recalcitrant compounds can be removed successfully using integrated system, but also the ultraviolet absorption measurements can be an interesting control-parameter in a wastewater treatment.