technology based productivity

7/30/2019 Technology Based Productivity

1/46

1

TECHNOLOGY

BASED

PRODUCTIVITY

IMPROVEMENTTECHNIQUES


2/46

2

What is Technology ??

Is Applied Science

Is a way of doing things

Is systems & artifacts incorporating

knowledge of physical and social worlds

which affect societys activities &

organizations.


3/46

3

MANAGEMENT SYSTEMS Vs.

TEHCHNOLOGY

Labor specialization accompanied by

mechanization is answer to economic growthand productivity.

Rate of productivity growth is largely a function

of changes in real capital relative to labor andextent of Technology.


4/46

4

It is a mistake to attribute Japanssuccess to technology alone and a

bigger mistake to consider technology

to be the only answer to improved U.Squality and productivity.


5/46

5

Technology is automation &mechanization, machines and computers,

and semiconductors and new inventions,

but the term has a much broadermeaning. It is a means of transforming

inputs in to outputs.


6/46

6

Good Companies

buy technology to improveprocesses, reduce lead times,boost quality, & increase

flexibility.Landmark Paper less Office, Ibd


7/46

7

Technology includes

methods, procedures, & techniques

which enable this transformation both

machines & methods

No one can argue convincingly against

the use of the hardware side oftechnology to improve both quality &

productivity.


8/46

8

Tech Based Techniques For Producty

1. ComputerAided Design (CAD)

2. ComputerAided Manufacturing (CAM)

3. ComputerIntegrated Manufacturing (CIM)4. Robotics

5. Laser Technology

Contd


9/46

9

Tech Based Techniques

6. Energy Technology

7. Group Technology

8. Computer Graphics

9. Maintenance Management10. Rebuilding Old Machinery

11. Energy- Conservation Technology


10/46


11/46

11

1. COMPUTERAIDED

DESIGN (CAD)Design of:

a) products, processes, or systems with help

of computer.

b) Component parts, subassemblies, &products in mfg- oriented cos.

Deal in complex geometry & three-

dimensional internal parts.

Aircraft industry Pioneer to useas PI tool.

Contd


12/46

12

COMPUTERAIDED DESIGN (CAD)

Few Examples In Design

-Automobile chassis, engine parts, & suspension

parts,machine tools,

-Circuit configuration in PCB in for electronic

products.

-Facilities to minimize unnecessary movements of

materials, people, & products.

-Evaluate physical interaction betweenman/workplace (in AC cockpits, truck cabs,

passenger vehicles, cranes, forklifts)

Contd...


13/46

13

CAD-Examples. Contd ..

Computer parts & subassemblies

Military Hardware, Electronic Calculator, Machine Tool

press working tools & dies Molds for investment casting

electric motors, Design of earth-moving equipment,bridges

CAD replaces manual design of

drafting with interactive computer,with Pen.


14/46

14

Advantages of CAD

1. Speedy Evaluation of Alternatives.Designer questionsWhat IF scenario (toCost if I cut weight & volume)

Impact on physical properties if modifydesign?

2. Error Reduction. Because CAD relieves

designer of need to make tedious, timeconsuming decisions & reducescomputations, fewer errors are made.

Contd


15/46

15

Advantages of CAD

3. Minimization of Risk in Functioning.

Possible uses can be evaluated ahead of time,

avoiding possible failures.

4. High Rate of Return on Investment.

where Taskrepetitive, complex & time-

consuming in nature, CAD is highly useful,

with the ROR10:1 to 50:1.


16/46

16

2. COMPUTER-AIDDED

MANUFACTURING (CAM)

Use of a computer to design & control

mfg process. It replaces many manual design

& control functions in manufacturing.

Examples

Assembly-line balancing

Machine sequencing & loading.

Parts scheduling


17/46


18/46

18

CAM contd..

CAM recent development than CAD

Most cases-inseparable, so referred to as

combination as CAD/CAM.

Integration avoids reconstructing, reformatting,

reentering, & reproducing the data that arecommon to all corporate operations.


19/46

19

PROBLEMS IN CAM

Lack of in-house computer knowledge.

High initial cost

Inability to verify adequate rate of return of

investment

Unavailability of appropriate software

Contd


20/46

20

Problems in CAM. cont.

Inadequate training from the vendor

Questionable hardware reliability Fear of computerization

ButCAM technique may prove useful toimprove both partial & total productivities.


21/46

21

ADVANTAGES OF CAM

1. Improved Utilization of ResourcesWell-managed plants15 & 30 % of timewaiting for parts, tool, & supervisorsinstruction.

Reduced idle time-better scheduling thesethings.

2. Lower Inventory Costs,

JIT (Kanban) system of inventory Toyota usesCAM, savings due to reduced inventory costs-made Toyota highly price competitive.

Contd


22/46

22

ADVANTAGES OF CAM. CONT..

GEs CAM & Engg Council survey of 300 orgdistribution of Primary Benefits of CAD/CAM:

56 % to productivity,

25 % to quality17 % reduction to cycle time,

2 % improvement to meeting contractualrequirement

CAD/CAM design//drafting/mfg process time cutby 5 times


23/46

23

3. COMPUTER-INTEGRATED

MANUFACTURING (CIM)A fully integrated CAD/CAM system that provides

computer assistance from marketing to product

shipment.

FunctionsOrder entry, bill of material processing, shop floor

control (assembly automation,testing and process

automation) inventory control, design

automation,(drafting, design and simulation)& Mfgplanning (process planning, routing, tool design and

parts programming). See Diagram


24/46

24

CIM contd

Design Automation- drafting, design & simulation:

Manufacturing planning, including process planning,routing & rating, tool design.

Parts Programming& shop floor control- numerical

control, assembly automation, testing, & processautomation.


25/46

25

4. ROBOTICS

is rapidly developing technology - uses robots.

An industrial robot is a reprogram-able

multifunctional manipulator designed to movematerial, parts, tools, or specialized devices,through variable programmed motions toaccomplish a variety of tasks.

It, is a general-purpose automation device. Amechanical arm rather than a mechanicalhuman being.

Contd.


26/46

26

ROBOTICS

Three basic components: manipulator, powersupply, & control system..

Not just sit-alone units.can be integrated withother devices & machines in automated orflexible mfg systems.

Robotics technology improve partial & total

productivities, as there is some natural liking ofrobots.


27/46

27

ADVANTAGES OF ROBOT

1. Work 03 shifts, round clock,uninterrupted, no overtime.

2. Perform difficult tasks-handling heavyparts, hot melt slabs, poisonous,radioactive, hazardous chemical.

3. Improve quality by consistency in mfg

operations.4. Save substantially on wages, salaries, &

fringe benefits.

Contd


28/46

28

ADVANTAGES OF ROBOT Contd..

5. Overcome shortage of blue-collar workers6. Integrate CAD/CAM, automated guided

vehicle systems, FMS for integrated, auto

mfg facilities. (FIAT PLANT).

7. Improvement in partial & total

productivities.

Die-casting operation, robots increased

production by 10 percent & cut rejects by 15percent.


29/46

29

Robots in Industry

1. Spot Welding

2. Spray painting

3. Arc welding

4. Grinding/debarring5. Material handling (loading & conveyance)

6. Machine loading/unloading

7. Assembly (e.g., assembling steering locks)

Contd


30/46

30

Robots in Industry (contd..)

8. Inspection (checking container labels,inspecting parts, gauging)

9. Fish farming (feed and Breed)

10. Fire fighting (where heat & smoke wouldprevent the deployment of firefighters withconventional equipment).

11. Fish farming (feed & monitor fish)

12. Die casting13. Filling /sealing/packaging/gluing/gasketing

14. Warehousing

Contd


31/46

31

Robots in Industry contd

14. Cake making & decorating

15. Nuclear reactor operation

16 restaurant operations (e.g. making sushi).17 Casting (Pouring hot metal into molds,

inserting parts into furnaces)

18 Cutting /machining

19 Polishing/surface preparation

In Japan, Robots accepted more readily than in

most EU.


32/46

32

ROBOTIC CLASSIFICATIONS

BY CONFIGURATION Cartesian- coordinate

Robot

Cylindrical coordinate

robot Polar (spherical

coordinate) robot.

Revolute (jointed arm)

robot.

BY FUNCTION Programmable servo

controlled, continuous-

path.

Programmable, servocontrolled, point to

point.

Programmable, non-

servo robots, point topoint.

Mechanical transfer

devices (pick & place)


33/46


34/46

34

LASSER TECHNOLOGY (LT)

Laser-assisted inspectionlasers will be

used in machining.

LT in conjunction with fiber optics for

comm purposes.

Tremendous savings potential with laser.

Initial cost of laser technology is relativelyhigh.


35/46

35

6. Energy Technology (ET)

Use of New Sources of Energy.

Use ofchemical energy, solar energy,geothermal energy, & hydrogen energy.

Considerations must be taken into account.

Economics of production & distribution ofthe energy

Effect on environmental, ecological, &social aspects of system

Rate of depletion & rate of replenishment(if any) of the energy resource.


36/46

36

7. Group Technology (GT)

GT is a rapidly developing productivityimprovement technique - have a significantimpact on development of totally integratedmfg facilities & FMS.

Organization & planning production parts intobatchessome similarity in (a) geometry & (b)processing sequence.

Aims at a detailed classification & grouping ofparts by size.

Contd


37/46

37

Group Technology (GT) Contd

Shape, nature of operation to be performed,design tolerances, & the setup time required.

Small-Batch Productionloss of production

time due to many machine setups.

75 percent of all machined parts are produced

in small-batch manufacture.

Need to minimize machine setup times in small

batch manufacture - GT is very effective wayof doing so.


38/46

38

8. COMPUTER GRAPHICS (CG)

A rapidly developing technique.

Computer-aided design (CAD) & CAM known

application of CG.

Business Executives use, simple Bar Charts,

Histograms, Frequency Distribution Diagrams, Pie

Charts, & other simple tools of business analysis.

Contd


39/46

39

ADVANTAGES OF COMPUTER

GRAPHICS

1. Ease in creating, modifying, & storing thedrawing of an object.

2. The ability to rotate an object in three

dimensions to study complex work settings.3. Minimization (& if used properly, elimination)

of duplication of data on the physical,chemical metallurgical, & or aesthetic

characteristics of an object.

Contd


40/46

40

CG Contd.

4. Virtual elimination of costly storage ofpaper drawing or paintings.

Initial investments-graphics terminals &

software,

Productivity is concerned, the time for

designing, drawing & reproducing is

considerably reduced. Thus HumanProductivity is bound to improve.


41/46

41

9. MAINTANANCE MGT (MM)

MM & Rebuilding old machinery, energy-conservation Tech - three approaches to

productivity improvement in term of plant &

equipment rather than new technology.

MM is formalized approach to maintaining thecurrently available machinery & equipment to

help them function according to the

maintainability & reliability characteristics.

Contd


42/46

42

MM Cont

Effective means of cutting down maintenancecosts & increasing human productivity, fixedcapital productivity, & energy productivity, inmost cases.

In light metal working & fabric-producingplants, maintenance employees may account

4 percent of workforce.

In processing plants, heavy industry, & plantswith complex eqpt, maintenance personnelcan represent up to 40 percent.


43/46

43

10. REBUILDING OLD MACHINERY

Modifying the existing machinery & their tooling,

instead purchase brand-new machinery.

Greater the initial cost of machine being remodeled, the

greater are the savings in fixed capital input.

Many large companies have own machine-building

department to remodel very methodically.

Contd


44/46

44

11. ENERGY CONSERVATION TECHNOLOGY

ECT also refer as Energy Mgmt

Purpose is to lower energyconsumption without lowering

quality or quantity.


45/46

45

ECT.. CONT

ETC Deals with :

Decision & performance of energy audits

Economic analysis of energy related projects

Design & effectiveness of monitoring

Redesign of existing products & processes

Identifies potential areas of energy savings

Develops Energy conservation measures for each area

Implements conservation procedures

Monitors their progress

Reports human, material, capital, energy & other expense

inputs to productivity engineering deptt.


46/46

46

ECT.. Contd

Potential Areas for Energy Saving are:

Material-handling equipment

Lighting of unnecessary areas

Air-conditioning & heating equipment

Motors, boilers etc

Entrances & exits from air-conditioned areas

Car pools

Energy control for machinery Pollution at the source (causing clean up

problems else where)

technology based productivity

Documents