Cycle Time Reduction Research Articles

A Study on mPPO Development and Injection Molding Process for Lightweight Stack Enclosure of FCEV

The automobile industry is focused on eco-friendly vehicles with the goal of carbon neutrality (Netzero), and vehicle weight reduction is essential to achieve high fuel efficiency for driving performance and distance compared to internal combustion engines. This is important for the light-weight stack enclosure of FCEV. Moreover, mPPO needs to be developed with injection molding for the replacement of existing material (aluminum). For this purpose, this study develops mPPO and presents it through physical property tests, predicts the injection molding process flow system for stack enclosure production, proposes injection molding process conditions to secure productivity, and verifies conditions through mechanical stiffness analysis. As a result of the analysis, the runner system with pin-point gate and tab gate's sizes are proposed. In addition, injection molding process conditions were proposed with the results of cycle time 107.627 s and reduced weld lines. As a result of the strength analysis, it can withstand the load 5933 kg. Therefore, it is possible to reduce weight and material costs using the mPPO existing manufacturing process with existing aluminum, and it is expected that there would be effects, such as reducing the production cost by securing productivity through reducing cycle time.

Ebola optimization search algorithm for the enhancement of devops and cycle time reduction

Ebola optimization search algorithm for the enhancement of devops and cycle time reduction

Process Design for Manufacturing Fiber-Reinforced Plastic Helical Gears Using a Rapid Heating and Cooling System

In this study, a lightweight fiber-reinforced plastic (FRP) helical gear was fabricated to investigate the potential application of FRP in automobile parts that require high loads and reduced noise. High-performance aramid FRP processed using the wet-laid method was used in the tooth region, and SCR420 steel was used in the inner hub region. A hot-forming system that combines rapid induction heating and water channel cooling methods was developed to reduce the cycle time. The cooling water flow conditions were analyzed to precisely control the mold temperature. Additionally, a rotating extraction system was developed to mitigate the extraction difficulty owing to the helix angle to the extraction direction. Using the innovative hot-forming system developed in this study, a helical gear without any process-induced defects was fabricated with a significantly reduced cycle time. The performance of the gear was successfully estimated using gear durability, torsional strength, and motion noise tests. The use of FRP materials offers significant potential to realize lightweight components; however, certain challenges related to their properties that may limit their application must be addressed on a case-by-case basis.

Quantitative analysis of the effects of incorporating laser powder bed fusion manufactured conformal cooling inserts in steel moulds over four types of defects of a commercially produced injected part

The introduction of additively manufactured conformal cooling inserts in steel moulds for plastic injection is becoming a recommended standard. Fine adjustment of the temperatures in the mould has demonstrated potential to reduce cycle times and to increase production volumes. Within this context, the present article explores the historical production data of a commercially produced part, before and after the incorporation of an L-PBF conformal cooling insert, to analyse what is the quantitative real effect on the efficiency of the production runs. The article analyses the change in the global rejection rates, and its effect over four different product defect types, i.e.: optical (surface), part integrity (bubbles, transparency, geometry), incomplete fill-in (interior), and breakages during extraction. The results demonstrate a specific decrease on the average appearance (from 20.53% to 13.48%; reduction of 7.05%) and variability (standard deviation from 14.16% to 6.81%; reduction of a 7.35%), of the global scrap rates, and a significant decrease in the scrap rates generated by optical defects and extraction part breakages. The article also characterises the former and the new processes by adjusting two distribution functions (Pareto Type-I and Weibull) and compares different estimates for the global expected scrap rates in past and future production runs.

Condition Monitoring of Additively Manufactured Injection Mould Tooling: A Review of Demands, Opportunities and Potential Strategies.

Injection moulding (IM) is an important industrial process, known to be the most used plastic formation technique. Demand for faster cycle times and higher product customisation is driving interest in additive manufacturing (AM) as a new method for mould tool manufacturing. The use of AM offers advantages such as greater design flexibility and conformal cooling of components to reduce cycle times and increase product precision. However, shortcomings of metal additive manufacturing, such as porosity and residual stresses, introduce uncertainties about the reliability and longevity of AM tooling. The injection moulding process relies on high volumes of produced parts and a minimal amount of tool failures. This paper reviews the demands for tool condition monitoring systems for AM-manufactured mould tools; although tool failures in conventionally manufactured tooling are rare, they do occur, usually due to cracking, deflection, and channel blockages. However, due to the limitations of the AM process, metal 3D-printed mould tools are susceptible to failures due to cracking, delamination and deformation. Due to their success in other fields, acoustic emission, accelerometers and ultrasound sensors offer the greatest potential in mould tool condition monitoring. Due to the noisy machine environment, sophisticated signal processing and decision-making algorithms are required to prevent false alarms or the missing of warning signals. This review outlines the state of the art in signal decomposition and both data- and model-based approaches to determination of the current state of the tool, and how these can be employed for IM tool condition monitoring. The development of such a system would help to ensure greater industrial uptake of additive manufacturing of injection mould tooling, by increasing confidence in the technology, further improving the efficiency and productivity of the sector.

Optimizing the Gas Carburization Process: Strategies for Reducing Total Cycle Time

Abstract: This case study presents the results of an experiment designed to reduce the total cycle time of the gas-Carburizing process for AISI 8620 steel. By optimizing process parameters such as carburizing temperature, soaking time, and carbon potential, the effective case depth was significantly improved. Previous research has indicated that optimizing the duration of the boost/diffusion stages and carbon potential in the carburizing process can lead to a 25% reduction in total process time [1].Our study showed that it is possible to achieve a reduction in total cycle time of up to 21%, leading to cost savings for heat treatment companies while also promoting a safer environmental outcome

Reduction in cycle time for a rapid polymerase chain reaction diagnostic test at the point of care

Rapid testing facilitates safe and effective diagnosis, but the true speed of the process is the time from collection of a sample to delivery of an accurate and reliable test result - 'end-to-end' time. Transport, unpacking and relaying of information can extend this time considerably beyond the minimum laboratory turnaround times as stipulated by PCR testing protocols. This study aimed to minimise time needed to ascertain SARS-CoV-2 status prior to treatment in a UK Dental Hospital using a novel, mobile, direct to polymerase chain reaction (PCR) workflow. Process flow analysis and PDSA (Plan, Do, Study, Act) cycles for rapid continuous improvement were employed in a service improvement programme. Primerdesign™ q16 rapid PCR instruments and PROmate® COVID-19 direct assays were used for molecular testing. We showed a reduction in real-world end-to-end time for a diagnostic test from 240min to 85min (65% reduction) over a 4-week period. New rapid technologies have become available that reduce analytical time to under 90min, but the real-world clinical implementation of the test requires a fully integrated workflow from clinic to reporting.

Cycle time reduction through a novel view planning concept for hybrid white light interferometry-based inspection

Inspecting large areas with a white light interferometer is time-consuming. To shorten inspection times, additionally, a coarser sensor can be used in a preceding step to identify possible defects. These are afterwards accurately measured with the white light interferometer. Often, several points of interest can be grouped and scanned with a single white light interferometer measurement. Grouping approaches found in the literature show potential for further improvement. In this paper, a novel algorithm for view planning concerning a two-step inspection is presented. Respective literature is reviewed and discussed. Afterwards, the functionality of the algorithm is demonstrated through an example and its performance is evaluated based on comparison to other solutions. The approach generates results that are promising for reducing inspection times further than other approaches.

Intelligent feedrate optimization using a physics-based and data-driven digital twin

Intelligent manufacturing machines envisioned for the future must be able to autonomously select process parameters that maximize their speed while adhering to quality specifications. Accordingly, this paper proposes a framework and methodology for using a physics-based and data-driven digital twin of a feed drive to maximize feedrate while respecting kinematic and contour error limits. To correct for inaccuracies introduced by unmodeled dynamics and disturbances, the data-driven model is updated on-the-fly using sensor feedback. Experiments on a 3-axis CNC machine tool prototype are used to demonstrate up to 35% cycle time reduction without violating error tolerances compared to the status quo.

Design and Manufacturing of Robotic Arm for Industrial Applications

Design and Development of Automation of Loading and Unloading to machine fixture” This Setup involves the use of automation solution to reduce operator fatigue and increase efficiency. Industries in the recent day concentrating on CNC machineries for mass production by replacing conventional lathes to improve productivity, but loading and unloading of job carried over by manual, However Present work, machine tool manufacturer are coming with solutions including automatic loading and unloading to reduce the fatigue of labour and reduce cycle time and increasing productivity. Productivity Improvement on a Production by Automatic Loading and Unloading of Component includes analysis and detailed study of manufacturing process including loading and unloading methods of components on a machine. Present work aims at improving the productivity of components on a CNC Fixture. Here emphasis is placed upon improving the existing time-consuming methods.

Defect detection for large-series automated fibre placement using a neural network-assisted machine vision approach

Tailored reinforcement structures from carbon fibre-reinforced thermoplastics show high potential for minimizing material volume, wall thickness and overall lightweight potential in plastic parts. Integrating small amounts of carbon fibre unidirectional tape material in injection-molded parts has the ability to maximize lightweight potential. Through a novel manufacturing approach developed by AZL, automated fibre placement becomes viable in large-series manufacturing by reducing cycle times down to 5 seconds. Therefore reliable, defect-free manufacturing becomes vital for economic competitivity. In this paper, a novel approach for defect detection using computer vision in combination with neural networks is developed and analysed for applicability in large-series manufacturing. Different occurring defects during processing are detected and classified. Subsequently, classification accuracy is analysed in regard to the predefined defect classes.

Mathematical model of quantitative assessment of stability of heterogeneous of computer networks in the conditions of the propagation of the influence of a logical obstacle on the basis of the percolation theory

The trends of recent years, especially with the beginning of the aggression of the Russian Federation against Ukraine, testify to the significantly increasing requirements for increasing the efficiency of the management processes of state authorities, with a significant reduction in the management cycle time. At the same time, increasing the efficiency of task performance is impossible without the introduction of modern information technologies into work at all levels of state administration, and, as a result, the formation of a single information space. The article examines the peculiarities of the construction of modern automated control systems, which require the construction of territorially distributed, at the same time, heterogeneous (heterogeneous) computer networks, which must ensure the availability and reliability of the transmission of the necessary information, including in the conditions of the spread of the influence of logical interference (intentional — cyber-attacks on the part of hackers and unintentional actions of the user, system administrator, etc.), which in turn affect the creation of a single information space. Developed approaches to ensure the stability of heterogeneous computer networks that, in turn, use the equipment of Internet service providers in conditions of external and internal destabilizing factors. A mathematical model for assessing the stability of heterogeneous computer networks of critical purpose, under the influence of logical interference, is proposed. At the same time, the theory of percolation is used as a theoretical basis. This approach makes it possible to take into account the lack of reliable information about the stability indicators of network components that belong to various Internet service providers (not under the control of state administration bodies). Computer modeling based on the proposed mathematical model indicates an increase in the efficiency of the computer network as a whole.

The possibilities of improving the human-machine co-operation in semi-automatic production process

Nowadays, modern production processes are undergoing intensive technological development, according to Industry 4.0 and Industry 5.0 assumptions. Despite the separate differentiation and numbering of these terms, the assumptions of the two approaches do not contradict each other. Industry 5.0 is a type of an extension of the drive for the highest possible degree of integration of automated systems (along with the pillars assumed in Industry 4.0) by finding a place where humans prove to be irreplaceable and their needs are identified as the most essential, central aspect. This leads to the implementation of semi-automated processes in which the cooperation between human and machine is the key. The paper presents an analysis and the results of the studies performed in company that produces vehicle control systems in automotive. The research includes quarter-a-year of studies and observation of production process. The studies aimed identifying waste in production process and proposing improvement methods, with particular reference to automated operations. Implementation of proposed improvements was mainly based on re-programming automated systems, but also on adding new process of cleaning brakes, that allowed to reduce the number of scrapped parts. Moreover, the implicated solutions allowed to achieve reduction of production process cycle time, financial savings and risk of the defects.

Project management model of motor vehicle development with consideration of built-in quality concept requirements

Problem of long timeframes of new car model development cycle due to excessive testing process of numerous vehicle prototypes is specified. Positive example of solving the problem using digital twin, computer modelling and virtual testing technologies in Formula 1 is given. Positive effect of virtual verification and validation during the development process on built-in product quality and development cycle time reduction is indicated. Existing project management V-models in automotive and information technology industries are reviewed and analyzed. State standards and methodologies of project management, lean manufacturing and digital twin development are reviewed. The improvements based on project life cycle, project management processes and product life cycle are enumerated and explained. Improved V-shaped project management model is described and visualized. The proposed model positive effects are described: it allows to increase the level of built-in vehicle quality, shorten its development cycle timeframes while providing the connection between project management and product development processes.

Modulation of Arm Swing Frequency and Gait Using Rhythmic Tactile Feedback.

Due to the neural coupling between upper and lower limbs and the importance of interlimb coordination in human gait, focusing on appropriate arm swing should be a part of gait rehabilitation in individuals with walking impairments. Despite its vital importance, there is a lack of effective methods to exploit the potential of arm swing inclusion for gait rehabilitation. In this work, we present a lightweight and wireless haptic feedback system that provides highly synchronized vibrotactile cues to the arms to manipulate arm swing and investigate the effects of this manipulation on the subjects' gait in a study with 12 participants (20-44 years). We found the developed system effectively adjusted the subjects' arm swing and stride cycle times by significantly reducing and increasing those parameters by up to 20% and 35%, respectively, compared to their baseline values during normal walking with no feedback. Particularly, the reduction of arms' and legs' cycle times translated into a substantial increase of up to 19.3% (on average) in walking speed. The response of the subjects to the feedback was also quantified in both transient and steady-state walking. The analysis of settling times from the transient responses revealed a fast and similar adaptation of both arms' and legs' movements to the feedback for reducing cycle time (i.e., increasing speed). Conversely, larger settling times and the time differences between arms' and legs' responses were observed due to feedback for increasing cycle times (i.e., reducing speed). The results clearly demonstrate the potential of the developed system to induce different arm-swing patterns as well as the ability of the proposed method to modulate key gait parameters through leveraging the interlimb neural coupling, with implications for gait training.

Supermarket and Water Spider Concept for Improving Door Sub-Assembly Productivity

This research is based on a case study at the door sub-assembly area of a German car manufacturer in Indonesia. The door sub-assembly area is responsible for assembling doors to be supplied to the specific station in assembly line that will assemble the finished doors to the car. The area had a problem in supplying the doors to the main assembly line on time. This means, the cycle time of door sub-assembly is higher than that of the assembly line. After observation, the factor that greatly contributes to the high cycle time can be identified, which is motion waste. Therefore, a unique approach is offered to overcome the situation, which involves re-designing work system and work area. The approach is to implement new working system by adopting lean tool water spider to significantly reduce motion waste. In the end, the initial and after condition will be contrasted to see the improvement made by this research. The results of this study could give the company several benefits: improved working efficiency of workers, reduced cycle time in door assembly and reduced fatigue of workers.

Effects of Common FDM Printing Parameter on Tensile Strength and Material Consumption: A short review

Fused deposition modelling (FDM), a form of additive manufacturing (AM) is a process that constructs product similar to that of material extrusion is a radically growing modern manufacturing approach that efficiently reduces cycle time during product development with minimal losses. Despite the minimal losses, developing FDM products with high mechanical strength entails high material consumption and longer print time making it cost inefficient. Therefore, this paper reviews several existing works to identify common printing parameters significant to improving tensile strength and material consumption of FDM printed products. Additionally, it is expected that isolating these significant parameters could benefit future research by providing direction for possible printing parameter optimization.

APPLICATION OF RECEIVABLE DYNAMIC BRAKING TO INCREASE THE PRODUCTIVITY OF A LIFTING SKIP INSTALLATION

The work solves an actual technical problem — increasing the productivity of the mine skip installation by shifting the lift cycle of the skip loading. The aim of the work is to provide a theoretical and experimental study of the electric drive according to the scheme of the asynchronous valve cascade (AVK) to reduce the cycle time of the lifting skip installation.
 The task of the work is the development of an economical electric drive according to the scheme of an asynchronous valve cascade for mine skip lifting installations. To increase the productivity of the lifting installation, an automated electric drive according to the scheme of an asynchronous valve cascade is proposed. Calculated and constructed static and mechanical characteristics of the cascade for engine and regenerative braking modes. The structural diagram of the cascade is given, on the basis of which the speed diagram is constructed. Industrial tests of the electric drive according to the cascade scheme were carried out on an operating mine skip unit. It is proven that the proposed scheme will ensure a reduction in the lifting cycle time of the skip installation and an increase in productivity by 3...5 %.
 The developed electric drive system is recommended for the modernization of existing mine skip lifting installations equipped with a relay-contactor control scheme.

Using patient flow analysis with real-time patient tracking to optimize radiation oncology consultation visits

PurposeClinical efficiency is a key component of the value-based care model and a driver of patient satisfaction. The purpose of this study was to identify and address inefficiencies at a high-volume radiation oncology clinic.Methods and materialsPatient flow analysis (PFA) was used to create process maps and optimize the workflow of consultation visits in a gastrointestinal radiation oncology clinic at a large academic cancer center. Metrics such as cycle times, waiting times, and rooming times were assessed by using a real-time patient status function in the electronic medical record for 556 consults and compared between before vs after implementation of the PFA recommendations.ResultsThe initial PFA revealed four inefficiencies: (1) protracted rooming time, (2) inefficient communications, (3) duplicated tasks, and (4) ambiguous clinical roles. We analyzed 485 consult-visits before the PFA and 71 after the PFA. The PFA recommendations led to reductions in overall median cycle time by 21% (91 min vs 72 min, p < 0.001), in cumulative waiting times by 64% (45 min vs 16 min; p < 0.001), which included waiting room time (14 min vs 5 min; p < 0.001) and wait for physician (20 min vs. 6 min; p < 0.001). Slightly less than one-quarter (22%) of consult visits before the PFA lasted > 2 h vs. 0% after implementation of the recommendations (p < 0.001). Similarly, the proportion of visits requiring < 1 h was 16% before PFA vs 34% afterward (p < 0.001).ConclusionsPFA can be used to identify clinical inefficiencies and optimize workflows in radiation oncology consultation clinics, and implementing their findings can significantly improve cycle times and waiting times. Potential downstream effects of these interventions include improved patient experience, decreased staff burnout, financial savings, and opportunities for expanding clinical capacity.

Sustainable Manufacturing through Systematic Reduction in Cycle Time

The lean manufacturing strategy is used to eliminate waste, improve quality, reduce time and costs, and enhance operational efficiency. This paper explores the method of systematic cycle time reduction for sustainability (environmental, social, and economic) through the lens of the theory of constraints. This paper uses a case study method in support of a developed method of systematic cycle time reduction. The findings suggest that reduction in cycle time results in improved sustainability performance. Results also demonstrate that sustainability performance can be improved with low investment and without compromising working conditions of any manufacturing operation.