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TECHNOLOGY
BASED
PRODUCTIVITY
IMPROVEMENTTECHNIQUES
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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.
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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.
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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.
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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.
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Good Companies
buy technology to improveprocesses, reduce lead times,boost quality, & increase
flexibility.Landmark Paper less Office, Ibd
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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.
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Tech Based Techniques For Producty
1. ComputerAided Design (CAD)
2. ComputerAided Manufacturing (CAM)
3. ComputerIntegrated Manufacturing (CIM)4. Robotics
5. Laser Technology
Contd
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Tech Based Techniques
6. Energy Technology
7. Group Technology
8. Computer Graphics
9. Maintenance Management10. Rebuilding Old Machinery
11. Energy- Conservation Technology
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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
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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...
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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.
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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
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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.
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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
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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.
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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
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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.
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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
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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
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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
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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.
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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.
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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.
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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
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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.
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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
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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
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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.
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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)
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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.
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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.
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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
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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.
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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
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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
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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.
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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
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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.
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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
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11. ENERGY CONSERVATION TECHNOLOGY
ECT also refer as Energy Mgmt
Purpose is to lower energyconsumption without lowering
quality or quantity.
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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.
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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)