Plan Production Map Book Sections 4

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Lean Production

To start off with, what is lean production? One definition of lean production is; a manufacturing performance improvement approach and philosophy that emphasizes the minimization of the amount of all the resources (including time). It involves identifying and removing non-value-adding activities in design, production, supply chain management, and dealing with the customers. Put simply it's a way to cut costs by taking away/minimizing time consuming activities. Note that implementing lean production is difficult.

The lean manufacturing history is thought to stem from the research Ford carried out in 1986 on Toyota, the business strategies implemented reduced production times, giving lower costs per unit, but it also gave an increase to quality. The lean manufacturing success of Toyota sparked the beginning of a new production method.

A common mistake among students is to identify lean production with Just in Time (JIT), although it is a part of it, it is not the basis of the production method. When/if a business decides to become a lean producer there and 4 principles they must apply for the lean strategy to work:

Lean quality
Lean design
Lean people management
Lean component supply

Lean Design

The first of the lean techniques involves assessing and improving upon product development, or product modifications, so that the firm can quickly and efficiently adapt to the changing business environment. Computer aided design (cad software) is one of the most flexible and quickest method for firms to design new products quickly, and transfer new product ideas from the conception stage to the market, this can lead to first mover advantage. First mover advantages include such things as; A high, if not 100% market share in the product, brand loyal customers (since they can see you as the first, therefore the best) and allows the business to establish a foot-in-the-door effect, which is needed to focus customers on their specific product when the copy firms move in.

When lean companies look for speedy product development and launch, time-based management plays a crucial role. Time-based management is, essentially, minimizing the time between product design and product launch. It looks for the areas in the business where simultaneous engineering can take place (decision trees are a good example of this) which cuts costs by saving time and money.

Lean quality

Quality is an expensive area for business organisations, but there are greater costs when ignoring quality. Bad quality can lead to bad publicity, a poor brand image and a great loss of customer loyalty. On the human resource side of things, one of the best ways to increase quality is by training the employees in all aspects of the production, making them multi skilled and making them feel more empowered giving greater motivation. The importance of quality will also be reflected throughout a firm's culture. Quality techniques include quality circles and kaizen groups: using both of these would be the best way to bring in ideas from employees, this brings greater employee motivation and productivity.

Lean people management

What is people management? People management is simply as it says, a way in which people involved in and outside the business are treated and used. Lean producers will aim to fully utilize all the skills and ideas of their workers. They will attempt to ensure that all their workers are fully trained and multi skilled in the businesses production methods. Empowerment and delegation are key to lean people management and they therefore create participation schemes to enable staff to contribute their ideas and experiences. This not only makes them feel valued, but also benefits the firm by getting ideas from experienced workers. This delegation of decision-making power makes workers feel more involved and, therefore, more committed to the business objectives of the firm. Motivation is key to productivity and therefore lower costs.

Lean Component supply

Just-in-time (JIT) is a system of stock management that involves only requesting a new supply of materials once there is a definite need. This is the moment students say 'Good, JIT, I know all about that.' But, in addition to understanding the benefits of JIT such as: saving money on space and insurance and removing the risk of holding stocks that may become damaged or obsolete (as with food), the opportunity costs also need to be considered. The firm will no longer be able to benefit from bulk-buying discounts (economies of scale) or be able to respond immediately to a customer order. The conditions necessary for JIT to work also have to be recognised. The firm must have reliable suppliers who are able to supply on demand with a short delivery time. Proximity is always good and accessibility is also important for a quick supply and delivery.

Conclusion

To summarize, the key aspects of lean production students should know that: Lean production is expensive, there are high start up costs and it cannot be applied to every business, most economies of scale advantages are lost and it can take a long time for the workforce to adapt to a such a change and some employees may reject the changes.

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Tips on Low Cost Invention Prototyping and Small Volume Production Runs

Introduction

The purpose of this article is to provide an outline on techniques that can be used to prototype an invention and make a small volume production run. This article will not cover the techniques in detail. There are multiple resources available online for each of the techniques mentioned in the article. Rather this article will show how to combine the techniques to produce a prototype and multiple copies. By using these techniques or variations, an inventor or entrepreneur would be able to make a prototype and multiple copies. In addition, by using the techniques I outlined in a previous article I wrote on low costs packaging and inventor or entrepreneur would be able to make a fairly complete product that could be test marketed or presented to a potential licensee.

Limitations

First some warnings about the techniques outlined below. They are rather labor intensive. Not hard physical work per se, but it does require learning and developing new skills. Further, the number of copies that can be made using silicone molds varies and is dependent on the geometry of the components being molded. Typically the lifetime of a silicone mold varies from as few as 25 copies to several hundred. Another factor is how much care is taken in extracting the components. The rougher the mold is treated the shorter its life.

In addition, these techniques are not practical for making intricate prototypes such as complex mechanical devices. These techniques are more suited to making prototypes composed of a few parts (1 to 3) with either a single component or where multiple components are glued together.

Finally care must be taken in selection of suitable casting material. Be sure to use materials that are safe for the prototypes application. Do not use toxic materials especially in any prototype to be used in the handling of food or by children.

Making the Prototype Pattern

The pattern is the initial prototype and will be used to make the molds to create copies. The techniques that can be used to make an initial prototype include but are not limited to those outlined below. Use any method that will yield a usable pattern. Please do not feel limited to this list of techniques. Feel free to be as creative in coming up with a method to make the pattern as you were in coming up with the idea.

Sculpting

One way to make a prototype pattern is to sculpt the shape in wax, clay or other suitable sculpting material. The problem with wax or clay is that they are either brittle (wax) or deformable (clay). Some clay can be fired, heated, so that they are no longer deformable. However brittleness is still a problem. There some sculpting materials such as Magic-Sculpt (available at Tap Plastics) that remains pliable for a couple of hours and then cures to rock hardness. In order to produce the desired shape sculpting tools are usually required. Sources for these tools are easily found on the Web.

Carving

Another technique very similar to sculpting is carving. A pattern could be whittled out of wood for example. However if the material is porous, the surface will have to be sealed using a suitable surface treatment such as a sealer or primer. To make the carving job easier an electrically powered rotary tool can be used. As with sculpting, sources for the tools and techniques associated with carving are easily found on the Web.

Rapid Prototyping

Generally to use a rapid prototyping technique a Computer Aided Design (CAD) three dimensional model is required. This model is exported to a suitable file format such as a stereolithographic file. The file is then read by a computer automated machine that makes the part. The processes are either additive or subtractive. In an additive process material is added by solidifying or fusing material. A computer controlled laser may solidify a liquid by a photochemical process or adherence of solid material by sintering or fusing. The part's position is also computer controlled. These processes are called by a variety of names such as SLA (stereolithography), SLS (selective laser sintering) and FDM (fused deposition modeling). More information can be found at the following site http://en.wikipedia.org/wiki/Stereolithography.

An example of a subtractive process is computer numerical controlled machine tooling (CNC). In this case the computer controlled machine tool removes material to form the parts.

There are numerous companies offering prototyping services. In fact, many SLA companies have Web sites where the CAD model can be uploaded, a price quoted, parts ordered and purchased via a credit card payment. The process is almost completely automated. However, there is a check done on the uploaded file to confirm the intentions of the customer. Sometimes there are problems with the file. On the other hand, the CNC process has a much lower level of automation. A program has to be written for the part model and stock material has to be loaded into the machine. The program may be generated by software but as before a check is required to confirm intentions and fidelity of the file.

Silicone Molds

After a prototype pattern is finished a silicone mold can be made using room temperature vulcanization (RTV) process. Most of the RTV materials are non toxic and are easy to use. Further silicone molds can take temperatures up to around 500 degrees Fahrenheit and can be use to cast low temperature casting metals such as pewter. Since there are numerous sources on the Web that provide instruction on the technique it will not be covered here. Materials for RTV molding are available on the Web and through Tap Plastics. However the following pointers are offered. First use gloves not just to keep the materials off your hands but also to keep finger prints off the prototype pattern. The molding material is able to produce extremely fine surface detail. If a finger print were on the pattern it could pick it up and it would appear on all your copies. Second, the material is very fluid so make sure your mold frames are well sealed. In addition, pay attention to the parting lines of your mold - where the mold comes apart to remove the casting. Make sure there are no areas where the silicone rubber can flow to trap the part. For example, the handle of a cup would require that the mold would part on a plane through the center of the cup and parallel to the handle. There would be handle impressions on both sides of the parted mold showing a profile of the cup and handle.

Depending on the prototype pattern it may be possible to make a one piece mold that is completely open on one side. This type of mold is usually used for low temperature casting metals. For a two piece mold be sure and use mold release on the first part before casting the second. If this step is neglected the first and second halves will fuse together and tarp the prototype pattern. Also for the two part mold make sure not to forget to place the spews and a fill port. Spews are vents that allow trapped gases to escape and the mold is filled until the resin flows out of them. When the casting is set and the mold is parted the spews and the fill port will leave a column that has to be cut off. Therefore be sure to place them where it is easy to touch up the surface. The spews need to go on the highest portion of the pattern so that air is not trapped in the mold. Spews and the inlet can be made by sticking rods vertically on to the prototype pattern and hold them in place with a supporting structure connected to the mold frame. In an adhesive is used be sure that it will not interfere with the curing of the silicone molding material.

Use mold release liberally on the relevant surfaces of the prototype pattern and all surfaces of the spews and fill port. This is important to make sure that the castings can be removed and to prolong the life of the mold.

To prevent the formation of bubbles on the surface of the prototype pattern, paint the surface being molded with the molding material. To keep bubbles from forming in the body of the mold, pour the silicone compound slowly and try to thin out the molding compound over the lip of the pouring container to burst bubbles already in the material. It is very difficult not to introduce bubbles while mixing. Usually a vacuum degassing chamber is used to remove the bubbles. However, with enough care the bubbles should not be a problem for most prototype patterns.

Finally for a complex three dimension casting consider a bottom up approach. That is, support the prototype pattern using the top of the molding frame and fill the frame up to its surface. The pattern needs to be securely held in place or it may float. As with the spews and fill spout make sure that whatever supporting structure is put in place does not irreparably mar the surface of the casting.

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An overview of gas production Metrics

Few people who use gas in their daily life of the gas production metrics used to measure the quality of gas deliberately placed on the market for end-user consumption. In each area, where you use an existing process and there is an exit, whether it is material or not, the data for measuring actual results against what you want, too. These measures will be quantified by numbers, and often called key performance indicators or metrics.

The gas --Production, has seen one of these things is in exploration. Significant amount when money is invested in order to find the best and richest resources of gas, which is oil. These are then gathered and gas installations are located, where is the actual implementation. Among the costs of exploration, are not transformed in a statement that a large amount of investment lost, as another should be done.

Once the exploration is successful, it is too late. There must be an equitable distribution orAllocation of resources, including financial resources, personnel and distribution of tasks. Infrastructure must be built, which means a further significant investment, must take place. These are then identifying the number of oil wells, to be productive against the financial performance compared to quantify the total investment.

Another thing as a metric for production of gas used is the development and actual production. Capital expenditures included in the identificationDevelopment plans for the wells and the gas plant. The costs for other resources are also taken in, and they are drilling, personnel, facilities and equipment. Investment measured the metric is real, the allocation of resources. This includes the development of expenditure.

The ability of professionals who are working for the gas plant is also part of the metric. Human knowledge and skills are always indicators, such as running a business. In addition to these, their decisionsis a significant business impact. Incompetent for the job will cost someone has lost a considerable amount of money. He lost only a marginal error in the society to convert a fault and money always remarkable. In fact, every error as a defect. The degree of control is also measured to see how effective the management of the business away. In essence, read the full functionality of professionals.

There are virtually hundreds of metricsmeasured and quantified to see the overall efficiency of a gas plant. From one department to another, almost the same metrics, adjustments, however, are less applicable, depending on the nature of the investment segment. From a general point of view, all aspects considered. These include refining or oil. These parameters also to ensure the marketing of the produce to see the product. The process was also measured to verify that it is still effective. Some processes can be eliminated in order toto accelerate and stop in front of existing procedures with the technology changes. That is to say that the parameters of gas production, and not with the basics, is virtually infinite.

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