Journal of Industrial Mechanics (e-ISSN: 2582-1067)

Productivity Enhancement of Wire Drawing through Root Cause Analysis (RCA)

Sanjay Singh — 2016-11-13

Productivity enhancement has become an important goal for improving the production performance in many manufacturing industries. We have attempted to present productivity enhancement by improving the method of production and reducing the downtime of machine. Our main work highlights the maintenance and productivity improvement with the help of root cause analysis of wire drawing process in context with steel wires which are used in manufacturing of tires. So, here in this paper we provide knowledge of root cause analysis by using the why- why analysis tool to identify the origin of failure of machines for enhancing the productivity of steel wires. It provides a deep knowledge about the process, failure, methodology and overall details of wire drawing to improve the productivity and performance.

Productivity Enhancement through Value Stream Mapping in an Graphite Electrode Industry: A Case Study

F Ujjainwala — 2016-09-13

Value stream mapping is a lean tool which is used to gather all the information at the production shop. It comprises all the necessary process and time consumed in performing those processes. It also includes the time which is associated with the production process but does not help in value addition. Such processes are known as non-value added activities. In any organization it is necessary to eliminate or at least minimizing this non value added activities. Such activity consumes both resources and time but does not helps in value creation of the product. This will result in higher waiting times, which will finally results into the dissatisfaction of the customer. Value stream mapping is very much simple and effective tool to locate all activities performed during the production, whether they are value added activities or non-value added activities. To do so time observations are made associated with all the performed processes. Time observation is made with the help of stopwatch. Repeated time measurement is done to eliminate any kind of error. After calculating time consumed in all activities standard time are calculated. On the preparation of the decided time current state guide is drawn for the whole fundamental offices. For the time of perceptions it was once confirmed that the plant has defective configuration which comes about into unnecessary development of the item. This outcomes into better lead time. It was furthermore watched that there was once absence of inspiration among the numerous representatives. This result into declination inside the generation cost of the association. This makes hazard for the gathering in the buyer situated business sector.It was suggested to make necessary changes in plant layout and to give training and motivation to the employees. 5-S was implemented which results into reduction in lead time. In this work productivity was improved by modification in plant layout, 5-S implementation and provision of proper guidance, motivation and training to the employees.

Finite Element Simulation of Thermal Field in Double Wire Welding

Bharat Mudgal — 2016-11-26

in this paper, the thermal area of double wire welding is simulated by the use of ANSYS software program. Simulation consequences were proven that the total warmness input (E) is the maximum huge parameters to trade the price of t8/5; by means of the imply of rationally controlling the percentage of the front arc warmness enter (E1) within the overall warmness enter (E) and as it should be deciding on double wire spacing (L), it's miles powerful way to get the double wire welding thermal cycle. by using the manner of simulation, it's miles viable to control the thermal input in the double welding wires and to manipulate the temperature subject and cooling fee that are fundamental for the final joint satisfactory, it is excellent significance guidance to optimize the double wire welding process parameters.

Analysis of Process Parameters in Wire EDM with NITINOL Shape Memory Alloy using Multi Objective Grey Relational Grade

P.A.Phadtare — 2016-10-15

The position of traditional machining process are taken by non-traditional machining processes because of increasing demands of high surface finish and machining of complex shape geometries,. Wire EDM is one of the non-traditional machining processes. Surface roughness and material removal rate are of most importance in the field of machining processes. This paper gives brief description of the Grey relational theory and Taguchi optimization technique, in order to optimize the cutting parameters in Wire EDM for NITINOL shape memory alloy. The objective of optimization is to attain the minimum surface roughness and the best surface quality along with that higher material removal rate. In this present study NITINOL shape memory alloy is used as a work piece, brass wire of 0.25mm diameter used as a tool, orthogonal array has been used. The input parameters selected for optimization Peak current, pulse on time, pulse off time, wire feed, and wire tension,also other parameter are kept constant. For each experiment material removal rate and surface roughness was determined. With the help of multi objective optimization technique grey relational theory, the optimal value is obtained for material removal rate and surface roughness and by using Taguchi optimization technique. Additionally, the analysis of variance (ANOVA) is used for identifying the most affecting parameter factor.

Closed Loop Univariate System For Single Input And Single Output (SISO)

Vaibhavi upadhyay — 2016-12-14

the precept difficulty of this thesis is to evaluate manage loop overall performance the usage of minimal variance manage by FCOR set of rules in a convenient way via the use of only normal running data and comparing the outcomes with an gift set of rules (named PINDEX). only by way of the usage of figuring out a performance aspect of the feed-again control loop the controller general performance might be assessed, even from heaps of manipulate loops in way industries. minimum variance is the benchmark which suggests attainable minimum variance against the actual variance of the control mistakes. A average overall performance index has been described because the ratio of minimal variance to real variance. where, a overall performance index value close to 1 shows excellent manipulate a cost close to 0 shows negative manipulate. The performance index is always bounded between zero to1. The performance index calculation set of rules changed into implemented using MATLAB. A dynamic simulation looks at turned into executed using Aspen HYSIS for producing manner facts and also by using SIMULINK. Numerous cases consisting of noise corruption, stiction and oscillation were added and the aftermath turned into studied and analyzed. Commercial information from an Ammonia plant (SAFCO) turned into also analyzed. All of the outcomes are in comparison with previously advanced algorithm. This thesis will assist to define a very easy however effective way to detect performance of the controller in technique structures.