Auslegung, Konstruktion und Fertigung von strömungsmechanischen Funktionsprototypen mittels Rapid Manufacturing

Bei der Fertigung von Funktionsbauteilen für Strömungsversuche spielt das Design und die Komplexität der Bauteilgeometrie eine wesentliche Rolle. Ziel der interdisziplinären Zusammenarbeit der Lehrstühle Strömungsmaschinen, Rechnereinsatz in der Konstruktion und Fertigungstechnik mit dem Rapid Technology Center (RTC) an der Universität Duisburg-Essen ist es, das Potenzial der additiven Fertigungsverfahren bei der Herstellung von Funktionsprototypen für strömungsmechanische Anwendungen effektiv zu nutzen. An verschiedenen, auf dieser Kooperation beruhenden, Best Practise Beispielen wird gezeigt wie das Laser-Sintern in die Prozesskette zur Herstellung von Laufrädern u. Ä. in unterschiedlichen Größenordnungen integriert werden kann. In diesem Zusammenhang werden auch die Vorüberlegungen (z. B. durch Simulation), Wechselwirkungen und Folgeprozesse, die mit dieser Fertigungstechnologie verbunden sind, aufgezeigt.

Klassifizierung der Methoden eines Ganzheitlichen Produktionssystems unter Berücksichtigung der Anforderungen indirekter Bereiche

Seit den 50er Jahren des Zwanzigsten Jahrhunderts erfährt das Konzept der schlanken Produktion stetig Erweiterungen und Renaissancen [Fau09]. Zielt das Ursprungskonzept noch überwiegend auf eine Effizienzsteigerung im Bereich der Fertigung ab, so werden im Rahmen eines Ganzheitlichen Produktionssystems verstärkt auch die indirekten Bereiche, wie z. B. Konstruktion, Forschung und Entwicklung, Planung oder Vertrieb einbezogen. Im folgenden Beitrag werden die Rahmenbedingungen eines Produktionssystems im indirekten Bereich dargestellt und Empfehlungen hinsichtlich einer strukturellen Erweiterung aktuell bestehender Ordnungsrahmen gegeben.

Schlanke Logistik im Druckmaschinenbau – Wechselwirkungen und Voraussetzungen

Die Bestandteile des Lean Thinking stellen für die moderne Produktion substantielle Prinzipien und Methoden für die Gestaltung effektiver wie auch gleichzeitig effizienter Systeme bereit. Ein unterstützendes Element bilden hier die Ansätze der Schlanken Logistik. Insbesondere die linienorientierte, variantenreiche Großserienproduktion im Automobilbau ist ein wesentlicher Treiber der Entwicklung. Die permanente Adaption auf mehrstufige Produktionssysteme, wie sie speziell im Druckmaschinenbau vorzufinden sind, erscheint dabei konsequent und sinnvoll. Der vorliegende Artikel stellt dabei wesentliche Voraussetzungen für die erfolgreiche Implementierung heraus und beschreibt die jeweiligen Interdependenzen. Schließlich werden ausgewählte Methoden mittels eines kennzahlenbasierten Messmodells anhand eines Fallbeispiels aus dem Druckmaschinenbau quantifiziert bewertet.

Ansätze zum Management der Additive Manufacturing Supply Chain

Da sich Additive Manufacturing (AM) von traditionellen Produktionsverfahren unterscheidet, entstehen neue Möglichkeiten im Produktdesign und im Supply Chain Setup. Die Auswirkungen der Aufhebung traditionellen Restriktionen im Produktdesign werden unter dem Begriff „Design for Additive Manufacturing“ intensiv diskutiert. In gleicher Weise werden durch AM Restriktionen im traditionellen Supply Chain Setup aufgehoben. Insbesondere sind die folgenden Verbesserungen möglich: Reduktion von Losgrössen und Lieferzeiten, bedarfsgerechte Produktion auf Abruf, dezentrale Produktion, Customization auf Ebene Bauteil und kontinuierliche Weiterentwicklung von Bauteilen. Viele Firmen investieren nicht selbst in die AM Technologien, sondern kaufen Bauteile bei Lieferanten. Um das Potential der AM Supply Chain mit Lieferanten umzusetzen, entstehen die folgenden Anforderungen an AM Einkaufsprozesse. Erstens muss der Aufwand pro Bestellung reduziert werden. Zweitens brauchen AM Nutzer einen direkten Zugang zu den Lieferanten ohne Umweg über die Einkaufsabteilung. Drittens müssen geeignete AM Lieferanten einfach identifiziert werden können. Viertens muss der Wechsel von Lieferanten mit möglichst geringem Aufwand möglich sein. Ein mögliche Lösung sind AM spezifische E-Procurement System um diese Anforderungen zu erfüllen

Finely Textured Lean Beef as an Ingredient for Processed Meats

Lean, finely textured beef (LFTB) is a lean product derived from beef-fat trimmings. Characterization of LFTB showed that, while it is high in total protein, the LFTB contains more serum and connective tissue proteins and less myofibrillar proteins than muscle meat. Because of the protein differences, LFTB has less functionality in processed meats, resulting in lower yields and softer texture. Appropriate use of sodium chloride, sodium tripolyphosphate, k-carrageenan, or isolated soy protein achieved desired stability and yields in frankfurters with FTLB. The softer texture may be used to advantage in high-protein, low-fat meat products where excessive toughness or firmness is often a problem.

In vitro precision of fit of computer-aided design and computer-aided manufacturing titanium and zirconium dioxide bars

OBJECTIVES Optical scanners combined with computer-aided design and computer-aided manufacturing (CAD/CAM) technology provide high accuracy in the fabrication of titanium (TIT) and zirconium dioxide (ZrO) bars. The aim of this study was to compare the precision of fit of CAD/CAM TIT bars produced with a photogrammetric and a laser scanner. METHODS Twenty rigid CAD/CAM bars were fabricated on one single edentulous master cast with 6 implants in the positions of the second premolars, canines and central incisors. A photogrammetric scanner (P) provided digitized data for TIT-P (n=5) while a laser scanner (L) was used for TIT-L (n=5). The control groups consisted of soldered gold bars (gold, n=5) and ZrO-P with similar bar design. Median vertical distance between implant and bar platforms from non-tightened implants (one-screw test) was calculated from mesial, buccal and distal scanning electron microscope measurements. RESULTS Vertical microgaps were not significantly different between TIT-P (median 16μm; 95% CI 10-27μm) and TIT-L (25μm; 13-32μm). Gold (49μm; 12-69μm) had higher values than TIT-P (p=0.001) and TIT-L (p=0.008), while ZrO-P (35μm; 17-55μm) exhibited higher values than TIT-P (p=0.023). Misfit values increased in all groups from implant position 23 (3 units) to 15 (10 units), while in gold and TIT-P values decreased from implant 11 toward the most distal implant 15. SIGNIFICANCE CAD/CAM titanium bars showed high precision of fit using photogrammetric and laser scanners. In comparison, the misfit of ZrO bars (CAM/CAM, photogrammetric scanner) and soldered gold bars was statistically higher but values were clinically acceptable.

Direct and Indirect Measures of Capacity Utilization: A Nonparametric Analysis of U.S. Manufacturing

We measure the capacity output of a firm as the maximum amount producible by a firm given a specific quantity of the quasi-fixed input and an overall expenditure constraint for its choice of variable inputs. We compute this indirect capacity utilization measure for the total manufacturing sector in the US as well as for a number of disaggregated industries, for the period 1970-2001. We find considerable variation in capacity utilization rates both across industries and over years within industries. Our results suggest that the expenditure constraint was binding, especially in periods of high interest rates.

Input Aggregation in Models of Data Envelopment Analysis: A Statistical Test with an Application to Indian Manufacturing

A problem frequently encountered in Data Envelopment Analysis (DEA) is that the total number of inputs and outputs included tend to be too many relative to the sample size. One way to counter this problem is to combine several inputs (or outputs) into (meaningful) aggregate variables reducing thereby the dimension of the input (or output) vector. A direct effect of input aggregation is to reduce the number of constraints. This, in its turn, alters the optimal value of the objective function. In this paper, we show how a statistical test proposed by Banker (1993) may be applied to test the validity of a specific way of aggregating several inputs. An empirical application using data from Indian manufacturing for the year 2002-03 is included as an example of the proposed test.

Are Indian Firms too Small? A Nonparametric Analysis of Cost Efficiency and Industry Structure of Indian Manufacturing

In this paper we use the 2004-05 Annual Survey of Industries data to estimate the levels of cost efficiency of Indian manufacturing firms in the various states and also get state level measures of industrial organization (IO) efficiency. The empirical results show the presence of considerable cost inefficiency in a majority of the states. Further, we also find that, on average, Indian firms are too small. Consolidating them to attain the optimal scale would further enhance efficiency and lower average cost.

Does the Presence of Surplus Labor Hinder Production in Indian Manufacturing?

Input congestion occurs at a given input bundle when the assumption of free disposability of inputs does not hold and an increase in input leads to a decline in output. In this paper we employ the nonparametric method of Data Envelopment Analysis (DEA) to examine the question on input congestion with respect to labor, using state level data from the Annual Survey of Industries for the period 1986-87 through 1999-2000. When the standard assumption of strong disposability is relaxed for the labor inputs, the nonparametric analysis of state-level data from Indian manufacturing shows considerable measure of labor input congestion. While in selected states congestion comes from non-production workers as well, the principal source of labor congestion is production labor. There is no evidence that the problem of labor congestion has become less severe during the post-Reform years. It appears that market forces without any major institutional changes in enforcement of labor discipline cannot eliminate congestion.

Surplus Labor in Indian Manufacturing: Evidence from the Annual Survey of Industries

In this paper we analyze state level data for total manufacturing constructed from the Annual Survey of Industries for the period 1986-2000 using the nonparametric method of Data Envelopment Analysis (DEA). We assess the extent of surplus labor in the manufacturing sector in the individual states in India. The study also investigates whether the same states show the maximum incidence of surplus labor every year in the sample period and if there any evidence that the extent of surplus labor in manufacturing has been reduced or eliminated in the post-reform era. Our study shows the presence of considerable measure of surplus labor in all of the years in a majority of the states. Things have worsened rather than improved after the reform. Also, the regional distribution of surplus labor has remain fairly unchanged with the same states performing inefficiently both before and after the reform.

Die runzliche Mark-Erbse, Mac Lean's Little Gem

von Kunstgärtner C. Pfeiffer

A descriptive and exploratory analysis of occupational injuries at a chemical manufacturing facility

A retrospective study of 1353 occupational injuries occurring at a chemical manufacturing facility in Houston, Texas from January, 1982 through May, 1988 was performed to investigate the etiology of the occupational injury process. Injury incidence rates were calculated for various sub-populations of workers to determine differences in the risk of injury for various groups. Linear modeling techniques were used to determine the association between certain collected independent variables and severity of an injury event. Finally, two sub-groups of the worker population, shiftworkers and injury recidivists, were examined. An injury recidivist as defined is any worker experiencing one or more injury per year. Overall, female shiftworkers evidenced the highest average injury incidence rate compared to all other worker groups analyzed. Although the female shiftworkers were younger and less experienced, the etiology of their increased risk of injury remains unclear, although the rigors of performing shiftwork itself or ergonomic factors are suspect. In general, females were injured more frequently than males, but they did not incur more severe injuries. For all workers, many injuries were caused by erroneous or foregone training, and risk taking behaviors. Injuries of these types are avoidable. The distribution of injuries by severity level was bimodal; either injuries were of minor or major severity with only a small number of cases falling in between. Of the variables collected, only the type of injury incurred and the worker's titlecode were statistically significantly associated with injury severity. Shiftworkers did not sustain more severe injuries than other worker groups. Injury to shiftworkers varied as a 24-hour pattern; the greatest number occurred between 1200-1230 hours, (p = 0.002) by Cosinor analysis. Recidivists made up 3.3% of the population (23 males and 10 females), yet suffered 17.8% of the injuries. Although past research suggests that injury recidivism is a random statistical event, analysis of the data by logistic regression implicates gender, area worked, age and job titlecode as being statistically significantly related to injury recidivism at this facility. ^

Assessment of occupational exposures to organic chemicals in a plastics manufacturing facility

The objective of this dissertation was to design and implement strategies for assessment of exposures to organic chemicals used in the production of a styrene-butadiene polymer at the Texas Plastics Company (TPC). Linear statistical retrospective exposure models, univariate and multivariate, were developed based on the validation of historical industrial hygiene monitoring data collected by industrial hygienists at TPC, and additional current industrial hygiene monitoring data collected for the purposes of this study. The current monitoring data served several purposes. First, it provided information on current exposure data, in the form of unbiased estimates of mean exposure to organic chemicals for each job title included. Second, it provided information on homogeneity of exposure within each job title, through the use of a carefully designed sampling scheme which addressed variability of exposure both between and within job titles. Third, it permitted the investigation of how well current exposure data can serve as an evaluation tool for retrospective exposure estimation. Finally, this dissertation investigated the simultaneous evaluation of exposure to several chemicals, as well as the use of values below detection limits in a multivariate linear statistical model of exposures. ^