This study aims at developing an improvement framework of warehouse processes by improving process cycle efficiency using lean six sigma (DMAIC) approach.
28 April 2021 in Journal of Industrial Engineering and Management
Purpose: This study aimed at implementing lean six sigma to evaluate the productivity and manufacturing waste in the production line of a paper companyMethodology/Approach: The study is a case study in nature. The method illustrates how lean six sigma (LSS) is used to evaluate the existing production process in a paper production company with focus on productivity and manufacturing waste. The study considered a real-time problem of customer’s dissatisfaction. The gathered data is based on machine functionality (up time, down time and cycle time); materials and labour flow at every process stages of the production line. The optimization of the production process was based on lean tools like value stream mapping, process cycle efficiency, Kaizen, 5S and pareto chartFindings: Based on lean six sigma application, it was discovered that the present production performance was below standard and more manufacturing wastes were generated. The present productivity and manufacturing wastes are reported as low process cycle efficiency (23.4 %), low takt time (4.11 sec), high lead time (43200sec), high number of products not conforming to six sigma values, high down time (32.64 %) and excess labour flow (33). After the implementation of the lean six sigma tools for certain period of time, there are lots of improvements in the production line in terms of all the parameters considered.Research Limitation/ Implications: The study has demonstrated an application of lean six sigma in the case of solving real-time problems of productivity and manufacturing wastes which have a direct implication on customer’s satisfaction. The lesson learned and implications presented can still be further modeled using some lean based software for validityOriginality/Value: The study has contributed to the body of knowledge in the field of LSS with focus to process based manufacturing, unlike most literature in the field concentrate more on discrete based manufacturing.
1 December 2020 in Advances in Science, Technology and Engineering Systems Journal
Friction Stir Welding (FSW) is a joining technique mostly used in aluminum alloys. The process includes multiple factors and control parameters, optimizing the quality of welds, enhancing efficiency, and reducing defects. This study examines different approaches used in FSW, such as the Taguchi method, Response Surface Methodology (RSM), Factorial Design (FD), numerical simulations and computational models, like Finite Element Analysis (FEA), Computational Fluid Dynamics (CFD), Artificial Neural Networks (ANN), and Genetic Algorithms (GA). The study also proposes the development of advanced simulation models and the integration of Artificial Intelligence (AI) for real-time process control.
The characterization of the morphology of the samples containing a homogenous mixtures of epoxy and graphene nanoplatelets (GNPs) produced by solution compounding and shear mixing techniques were carried out in this study. The research work is aimed at evaluation of the morphology in terms of crystallinity of the polymer nanocomposites using wide angle X-ray diffraction (WAXRD) and Scanning Electron Microscopy (SEM) in accordance with ASTM D3417. The nanoparticles were varied in 10, 20 and 30 % by weight fraction of the PNCs. Highly crystalline peaks at 2θ values of 20.3O, 24.46O and 23.80O for 10, 20 and 30 % GNP weight fractions respectively, were observed. These show significant improvements in the morphology of polymer nanocomposites with varying loading of graphene nanoplatelets. The nanocomposites have a characteristics microstructure dimensions comparable to critical length scale of physical phenomena that gives to the unique mechanical properties. The use of solution compounding coupled with high shear mixing as dispersion technique influences the morphology of the polymer nanocomposites positively, thus its suitability for light weight and high strength industrial applications in the automobile, electronics and aerospace industries.