IRJET- Optimization of Cycle Time by using Various Techniques: A Review
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The document reviews various techniques for optimizing manufacturing cycle times, which are affected by factors like machining conditions, human involvement, bottlenecks, and idle time. It discusses approaches like establishing machine performance capabilities, automating non-value added tasks, and focusing on eliminating sources of error to reduce cycle times. The goal is to optimize cycle times in cylinder block manufacturing to improve productivity, competitiveness, and ability to respond to customer demands.
![International Research Journal of Engineering and Technology (IRJET) e-ISSN: 2395-0056
Volume: 06 Issue: 05 | May 2019 www.irjet.net p-ISSN: 2395-0072
© 2019, IRJET | Impact Factor value: 7.211 | ISO 9001:2008 Certified Journal | Page 5482
a. Maintains and improves the capabilities
of the machine.
b. Eliminates judgment calls on which
machine to use.
c. Eliminates bottleneck.
d. Transforms operational expenditures
into investments in process.
e. Increases machine up-time.
f. Eliminates unnecessary movement of
parts.
g. Provides traceable documentation of the
machine and process capabilities.
Fig. 2- Predictive maintenance process [1]
2. Literature Review
Rawat. [1] Discussed the key considerations for defining
an effective productivity measurement. It also explores the
relationship between quality and productivity. They have
studied the parameter optimization or the present work
include the development of model for the measurement of
productivity for the manufacturing system. System
composed functioning independently in parallel, reliability
will be higher than reliability of each component.
BrkićI [2] In this survey, it has been shown that a modified
method of work sampling, with time components grouped
by factor analysis, is applicable not only in the domain of
capacity utilization observations, but also in investigating
PC in a metalworking industry with small-sized series,
using small alterations.
Proposals for further investigation include the application
and control of this method in other types of production,
such as assembly processes and processes in the textile
industry. Further analysis should be also oriented to the
issue of transport time, as well as further division of time
components of other stoppages, to isolate the most
significant ones.
R Muvunzia [3] the aim of the paper was to present a
model for predicting the cycle time in a hot stamping
process. An equation for the cooling time of the blank was
developed and validated using finite element analysis
simulation. The next phase of this research will involve
conducting physical experiments to validate the results
from the simulation.
Mrugalska [4] Lean production successfully challenged the
mass production practices to the production systems
focused on good quality products aimed at customers’
satisfaction, where everything that does not add value is
concerned to be waste and reduces Cycle Time. It can be
the answer to a great flexibility of production systems and
processes realizing complex products and supply chains.
In order to achieve it, it is advisable to introduce IT
integration of the production level with the planning level,
customers and suppliers by CPS. In the presented paper
the review of literature about lean production and
Industry was presented to show the possibility of linking
the approaches for minimizing overall time.
Shagluf [5] The goal of the original approach
demonstrated in this work is to reduce manufacturing
cycle time to the maximum, taking into account serial
production characterized by discontinuity and the
considerable amount of current assets needed for
financing the production process. This methodology is
based on designed models that, on one hand, respect
current technical-technological and manufacturing
documentation and, on the other, real production
constraints.
The results related to the identification of downtime
causes and losses measurement are of importance not
only for the cycle scheduling, but also for optimal
production planning.
K.Wavhal [6] the cycle time of any machining operation is
of great significance for any manufacturing industry. The
cycle time is affected by various parameters such as
machining conditions, human involvement, bottlenecks in
process, idle time etc. To reduce the cycle time, it is
necessary that all these parameters must be within
optimum limits. Various PPC techniques, automation of
machines, systematic sequencing of jobs and many other
methods can be applied to manufacturing process for
optimization of cycle time which in turns responsible for
improve productivity and efficiency of industry.
Toly Chen [7] Enhancing the competitiveness and
sustainability has been pursued by every semiconductor
manufacturer. A key to this is the production cycle time.
Shortening the production cycle time improves the
responsiveness to customer demands, and leads to
significant profits from yield improvement and cost
reduction. However, in the past, cycle time reduction is
usually unplanned owing to the lack of a systematic and
quantitative procedure. To tackle this problem, a
systematic procedure was established in this study for
planning cycle time reduction actions to enhance the
competitiveness and sustainability of a semiconductor
manufacturer. First, some controllable factors that are
influential to the job cycle time are identified.](https://image.slidesharecdn.com/irjet-v6i5716-191005061702/85/IRJET-Optimization-of-Cycle-Time-by-using-Various-Techniques-A-Review-2-320.jpg)
![International Research Journal of Engineering and Technology (IRJET) e-ISSN: 2395-0056
Volume: 06 Issue: 05 | May 2019 www.irjet.net p-ISSN: 2395-0072
© 2019, IRJET | Impact Factor value: 7.211 | ISO 9001:2008 Certified Journal | Page 5483
Subsequently, the relationship between the controllable
factors and the job cycle time is fitted with a BPN. Based
on this relationship, actions to shorten the job cycle time
can be planned. The feasibility and effectiveness of an
action have to be assessed before it is taken in the practice.
2.1 Findings from Literature Review:
After studying the above literature, we have found that,
i. Optimization of manufacturing cycle time
ii. The cycle time is affected by various parameters
such as machining conditions, human
involvement, bottlenecks in process, idle time etc.
iii. Lean production manufacturing to show the
possibility of linking the approaches for
minimizing overall time
iv. Improves the responsiveness to customer
demands, and leads to significant profits from
yield improvement and cost reduction
vi. To reduce the cycle time, it is necessary that all
these parameters such that machining conditions,
human involvement, bottlenecks in process, idle
time etc. must be within optimum limits
3. CONCLUSIONS
In this study, the effect of process parameters on the
response variables was investigated experimentally in
cylinder block manufacturing industry.
i. Identified of norms at Cylinder Block
Manufacturing machine shop
ii. Calculation of various major parameters to
achieve best production cycle time
iii. Evaluated actual time vs. estimated time study
iv. Analysis of past and present system
4. FUTURE SCOPE
Essential need to integrate the various methodologies and
approaches used in the cylinder block manufacturing
industry. Implementing the procedure of optimizing cycle
time to the kind of manufacturing production line can
increase number of output of products.
5. ACKNOWLEDGEMENT
Knowledge underlying this paper has been gained through
number of different research papers based on cycle time
optimization and various techniques related to it. The
authors thank the anonymous reviewers for the insights
on this study. We would also like to show our gratitude to
our institute Kolhapur Institute of technology’s college of
engineering Kolhapur for giving us opportunity to do
study on this paper.
REFERENCES
[1]Rogstad, Rogney S“Implementating Lean Manufacturing
Principles in Manufacturing Envionment”, International
Journal of Advanced Engineering Research and Studies
EISSN2249–8974.
[2] Stephen E. Smith, “Improve your machines and
manufacturing processes to increase your profits”, 2010.
[3] Leslie Kren, and Thomas Tyson, “Using cycle time to
measure performance and Control costs in focused
factories”, January, 2002.
[4] Measurement of aggregate and industry-level
productivity growth “Organization for Economic Co-
operation and Development (OCED)” Published in 2001.
[5] David N. Card, “The Challenge of Productivity
Measurement”, Pacific Northwest Software Quality
Conference, 2006.
[6] Ihsan Korkut, Mustafa Kasap, Ibrahim Ciftci, and Ulvi
Seker, “Determination of Optimum cutting parameters
during machining of AISI 304 austenitic stainless steel”,
23rd April, 2003.
[7] M. Albert, J. Ciurana, and C.A. Rodriguez,“Experimental
analysis of dimensional error vs. cycle time in high-speed
milling of aluminium alloy”, International journal of
machine tools & manufacture, 2007.](https://image.slidesharecdn.com/irjet-v6i5716-191005061702/85/IRJET-Optimization-of-Cycle-Time-by-using-Various-Techniques-A-Review-3-320.jpg)
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IRJET- Optimization of Cycle Time by using Various Techniques: A Review
- 1. International Research Journal of Engineering and Technology (IRJET) e-ISSN: 2395-0056 Volume: 06 Issue: 05 | May 2019 www.irjet.net p-ISSN: 2395-0072 © 2019, IRJET | Impact Factor value: 7.211 | ISO 9001:2008 Certified Journal | Page 5481 Optimization of cycle time by using various techniques: A Review Ajinkya Patil1, R.C.Bedasgaonkar 2 1M.Tech , Department of Mechanical-Production, KITCOEK, Kolhapur, Maharashtra, India 2Assistant Professor, Department of Mechanical Engineering, KITCOEK, Kolhapur, Maharashtra, India ---------------------------------------------------------------------***--------------------------------------------------------------------- Abstract - As industrialization has taken a great place in our world and also the competitiveness among industry is increasing day by day ,so every industry is in a way of manufacturing products of high quality at low cost with a priority of delivering product to customers in stipulated time span. Every industry uses a system to manufacture the product. Therefore, industry needs a manufacturing system which is capable to produce the high quality product in the minimum cycle time. This can be achieved by keeping the manufacturing system productivity high. Hence Productivity measurement is essential to measure the performance of the manufacturing system. In this present work we are developing the methodology to measure the productivity of cycle time reduction. Therefore, we are proposing a calculation for production cycle time by optimizing productive components of cylinder block component. Further the productivity is considered as one of the significant factor for performance measurement of manufacturing systems. The result shows that the proposed model can be useful in future studies target towards cycle time reduction in cylinder block manufacturing industries. Key Words: Optimizing productive, Cycle Time, Automation. 1. INTRODUCTION The demand placed by customers about mainly two things one is lead time and another one is price. Eliminating waste gives an advantage in both, and provides an opportunity for greater profits. There are three primary ways to eliminate waste: i. Establish machine performance capabilities before it begin making parts. ii. In process inspection. iii. Automate non value-added tasks such as tool setting and work piece set-up. Reduced cycle time can translate into increased customer satisfaction. Quick response companies can launch new products earlier, enter new markets faster, and meet changing demand. They can also offer their customers lower costs because quick response companies have streamlined processes with low inventory and less obsolete stock. If we automate machine set-up and machining processes, then it will reduce inspection costs. Also it helps to reduces machine downtime and create shorter lead times. Time-consuming set-up activities on CNC machines are i. Measurement of tool geometry. ii. Identifying and updating machine work offsets. iii. Cutting a second part. iv. Adjusting rough and finish tools to specification. v. Inspecting first-off parts to verify setup adjusting work offsets. vi. Repeating inspection of altered process parameters. Focusing on cycle time is a very effective way to eliminate waste and increase profits. Cycle time includes set-up time, parts movement time, inspection time, and rework time. It is well understood that the goods are created at lower costs. A good machine tool system concentrates on cycle time by eliminating the non-value-added activities. Fig. 1 illustrates a common example of the systematic impact of long cycle times. Fig. 1 - Systematic impact of long cycle time The mathematical expression for calculating cycle time is as follows, Cycle Time = ∑ (Setup Time + Machining Time) No. of final components Produced By minimizing the non-value-added activity (e.g. inspection, set-up, adjustments, tool breakage, etc.) we can maximize productivity and profits. Depicts five steps required to improve the capability of your machines. Five Steps for improvement of machine capability are i. Determine the accuracy as per need. ii. Establish a baseline. iii. Identify and rank the sources of error. iv. Eliminate or calibrate the errors. v. Establish a new baseline Fig. 2 provide a predictive maintenance process. It mainly includes following steps such as:
- 2. International Research Journal of Engineering and Technology (IRJET) e-ISSN: 2395-0056 Volume: 06 Issue: 05 | May 2019 www.irjet.net p-ISSN: 2395-0072 © 2019, IRJET | Impact Factor value: 7.211 | ISO 9001:2008 Certified Journal | Page 5482 a. Maintains and improves the capabilities of the machine. b. Eliminates judgment calls on which machine to use. c. Eliminates bottleneck. d. Transforms operational expenditures into investments in process. e. Increases machine up-time. f. Eliminates unnecessary movement of parts. g. Provides traceable documentation of the machine and process capabilities. Fig. 2- Predictive maintenance process [1] 2. Literature Review Rawat. [1] Discussed the key considerations for defining an effective productivity measurement. It also explores the relationship between quality and productivity. They have studied the parameter optimization or the present work include the development of model for the measurement of productivity for the manufacturing system. System composed functioning independently in parallel, reliability will be higher than reliability of each component. BrkićI [2] In this survey, it has been shown that a modified method of work sampling, with time components grouped by factor analysis, is applicable not only in the domain of capacity utilization observations, but also in investigating PC in a metalworking industry with small-sized series, using small alterations. Proposals for further investigation include the application and control of this method in other types of production, such as assembly processes and processes in the textile industry. Further analysis should be also oriented to the issue of transport time, as well as further division of time components of other stoppages, to isolate the most significant ones. R Muvunzia [3] the aim of the paper was to present a model for predicting the cycle time in a hot stamping process. An equation for the cooling time of the blank was developed and validated using finite element analysis simulation. The next phase of this research will involve conducting physical experiments to validate the results from the simulation. Mrugalska [4] Lean production successfully challenged the mass production practices to the production systems focused on good quality products aimed at customers’ satisfaction, where everything that does not add value is concerned to be waste and reduces Cycle Time. It can be the answer to a great flexibility of production systems and processes realizing complex products and supply chains. In order to achieve it, it is advisable to introduce IT integration of the production level with the planning level, customers and suppliers by CPS. In the presented paper the review of literature about lean production and Industry was presented to show the possibility of linking the approaches for minimizing overall time. Shagluf [5] The goal of the original approach demonstrated in this work is to reduce manufacturing cycle time to the maximum, taking into account serial production characterized by discontinuity and the considerable amount of current assets needed for financing the production process. This methodology is based on designed models that, on one hand, respect current technical-technological and manufacturing documentation and, on the other, real production constraints. The results related to the identification of downtime causes and losses measurement are of importance not only for the cycle scheduling, but also for optimal production planning. K.Wavhal [6] the cycle time of any machining operation is of great significance for any manufacturing industry. The cycle time is affected by various parameters such as machining conditions, human involvement, bottlenecks in process, idle time etc. To reduce the cycle time, it is necessary that all these parameters must be within optimum limits. Various PPC techniques, automation of machines, systematic sequencing of jobs and many other methods can be applied to manufacturing process for optimization of cycle time which in turns responsible for improve productivity and efficiency of industry. Toly Chen [7] Enhancing the competitiveness and sustainability has been pursued by every semiconductor manufacturer. A key to this is the production cycle time. Shortening the production cycle time improves the responsiveness to customer demands, and leads to significant profits from yield improvement and cost reduction. However, in the past, cycle time reduction is usually unplanned owing to the lack of a systematic and quantitative procedure. To tackle this problem, a systematic procedure was established in this study for planning cycle time reduction actions to enhance the competitiveness and sustainability of a semiconductor manufacturer. First, some controllable factors that are influential to the job cycle time are identified.
- 3. International Research Journal of Engineering and Technology (IRJET) e-ISSN: 2395-0056 Volume: 06 Issue: 05 | May 2019 www.irjet.net p-ISSN: 2395-0072 © 2019, IRJET | Impact Factor value: 7.211 | ISO 9001:2008 Certified Journal | Page 5483 Subsequently, the relationship between the controllable factors and the job cycle time is fitted with a BPN. Based on this relationship, actions to shorten the job cycle time can be planned. The feasibility and effectiveness of an action have to be assessed before it is taken in the practice. 2.1 Findings from Literature Review: After studying the above literature, we have found that, i. Optimization of manufacturing cycle time ii. The cycle time is affected by various parameters such as machining conditions, human involvement, bottlenecks in process, idle time etc. iii. Lean production manufacturing to show the possibility of linking the approaches for minimizing overall time iv. Improves the responsiveness to customer demands, and leads to significant profits from yield improvement and cost reduction vi. To reduce the cycle time, it is necessary that all these parameters such that machining conditions, human involvement, bottlenecks in process, idle time etc. must be within optimum limits 3. CONCLUSIONS In this study, the effect of process parameters on the response variables was investigated experimentally in cylinder block manufacturing industry. i. Identified of norms at Cylinder Block Manufacturing machine shop ii. Calculation of various major parameters to achieve best production cycle time iii. Evaluated actual time vs. estimated time study iv. Analysis of past and present system 4. FUTURE SCOPE Essential need to integrate the various methodologies and approaches used in the cylinder block manufacturing industry. Implementing the procedure of optimizing cycle time to the kind of manufacturing production line can increase number of output of products. 5. ACKNOWLEDGEMENT Knowledge underlying this paper has been gained through number of different research papers based on cycle time optimization and various techniques related to it. The authors thank the anonymous reviewers for the insights on this study. We would also like to show our gratitude to our institute Kolhapur Institute of technology’s college of engineering Kolhapur for giving us opportunity to do study on this paper. REFERENCES [1]Rogstad, Rogney S“Implementating Lean Manufacturing Principles in Manufacturing Envionment”, International Journal of Advanced Engineering Research and Studies EISSN2249–8974. [2] Stephen E. Smith, “Improve your machines and manufacturing processes to increase your profits”, 2010. [3] Leslie Kren, and Thomas Tyson, “Using cycle time to measure performance and Control costs in focused factories”, January, 2002. [4] Measurement of aggregate and industry-level productivity growth “Organization for Economic Co- operation and Development (OCED)” Published in 2001. [5] David N. Card, “The Challenge of Productivity Measurement”, Pacific Northwest Software Quality Conference, 2006. [6] Ihsan Korkut, Mustafa Kasap, Ibrahim Ciftci, and Ulvi Seker, “Determination of Optimum cutting parameters during machining of AISI 304 austenitic stainless steel”, 23rd April, 2003. [7] M. Albert, J. Ciurana, and C.A. Rodriguez,“Experimental analysis of dimensional error vs. cycle time in high-speed milling of aluminium alloy”, International journal of machine tools & manufacture, 2007.