Cycle Time Reduction Research Articles

Eliminating harmonic noise in vibroseis data through sparsity-promoted waveform modeling

Vibroseis acquisition, which uses slip sweep instead of traditional flip-flop acquisition, could significantly reduce cycle time and increase productivity. However, the vibroseis system suffers from harmonically distorted sweeps being used as correlation operators, thus causing sticky harmonic distortions in correlated data that cannot be eliminated by forerunning manipulations and hindering interpretation. We propose a novel method to separate the harmonic interferences from correlated vibroseis data by exploring the waveform diversity between useful reflections and harmonic interferences. Following the diverse time-frequency distribution patterns of useful signal components and harmonic interferences, two different redundant waveform dictionaries are constructed to sparsely model useful reflections and harmonic interferences. Then, an iterative thresholding algorithm is used to gradually separate harmonic interferences from useful reflections, with each successive iteration potentially extracting the most reliable waveform elements built up into the corresponding signal components. The processing results of synthetic and field data examples highlight the effectiveness of our method in eliminating harmonic noise without noticeable loss of useful reflections. Compared to the classic frequency-dependent attenuation method, our approach has a higher fidelity.

Aluminum Billets Heat Treatment Using Hot Flue Gas in Batch Homogenizing Preheating Furnace for Energy Efficiency and Cycle Time Reduction in Cast House

Aluminum Billets Heat Treatment Using Hot Flue Gas in Batch Homogenizing Preheating Furnace for Energy Efficiency and Cycle Time Reduction in Cast House

Improving Efficiency for Retail Warehouse Using Data Envelopment Analysis

Warehouse has an important role in supply chain management and has many complex activities that require special attention. This study aims to improve warehouse efficiency performance. Data Envelopment Analysis (DEA) method is employed to obtain the level of efficiency and benchmarking on five indicators, namely financial, productivity, utilization, quality, and cycle time along with five business processes in warehousing, i.e. receiving, put away, storage, order picking, and shipping. The decision making unit is a warehouse in four retailers in Yogyakarta province, in Indonesia. The input and output variables are selected based on the highest priority weight using the Analytical Hierarchy Process (AHP). The most important variable for receiving is productivity (receipt per man-hour), variable for put away is cycle time (put away cycle time), variable for storage is utilization (% location and cube occupied), variable for order picking is cycle time (order picking cycle time) and variable for shipping is productivity (order prepared for shipment per man-hour). The research results show that the benchmarking model with DEA can be used to increase warehouse efficiency performance by up to 22% by increasing receiving and shipping productivity, increasing storage utilization and reducing cycle time at put away and order picking.

Lean Approach for Waste Reduction in Production Line by Integrating DMAIC, VSM, and VALSAT Method (Study Case: Assembling Bracket Manufacturing Automotive Industry)

The automotive manufacturing industry is a manufacture that produces four-wheeled automotive accessories parts. One of the products is the audio unit and bracket. This research aims to reduce waste in production and reduce cycle time, affecting increasing production output to adapt it to customer needs. Waste identification by integrating lean six sigma, namely DMAIC, VSM, and VALSAT. Based on the analysis results, it was found that the four biggest wastes were motion, inventory, waiting, and process. After carrying out the repair activities, the cycle time decreased at station three from 704 seconds to 246 seconds, thereby increasing the capacity efficiency from 75% to 91 %.

Lean IT With Value Stream Mapping Analysis

Value Stream Mapping (VSM) is a useful tool for depicting the flow of materials and information in manufacturing and service processes. It is known as one of the most popular lean methods to identify bottlenecks, reduce cycle time, and improve current processes. Although VSM has been extensively used in manufacturing, there are limited studies that applied VSM in non-manufacturing environments. In this study, we present an application of VSM to improve Software Development Life Cycle (SDLC) process in an IT firm. The current process flows (as-is) are mapped to identify non-value-added activities as well as areas for improvement. Based on the analysis of the current state map, we propose recommendations, action plans, and a future state map (to-be-process). We estimate that, with the new process changes, IT project delivery time can be reduced from 210.5 days to 137.5 days – a 34.7% reduction in the software development life cycle process. This provides a powerful base for IT project management and enables the IT department to meet its expected project turnaround time.

Industrial‐scale vacuum casting with silicone molds: A review

AbstractVacuum casting (VC) of reactive polymer resins in silicone molds is one of the oldest rapid tooling methods. It is widely used in the industry for prototype and small‐series production of thermoset plastic parts. Despite its widespread use, its scientific exploration is still scarce compared to other prototyping methods, such as three‐dimensional (3D) printing. Compared to conventional 3D printing methods, a wide range of excellent material properties can be achieved, making it well suited for the production of functional prototypes and even final products. The properties of the thermosets are comparable to those of injection molding in terms of viable shapes, mold fidelity, and material properties. However, due to the high cycle time and limited service life of the molds, VC is rarely utilized for mid‐ or large‐series production. Here, we provide a comprehensive overview of the state of the art and recent advances in the field. The review also provides a detailed technical introduction to the mold production, the process flow, and the materials used. A particular focus is on the key challenges facing industrial‐scale VC today—how to reduce cycle time, and how to increase mold service life?

Genomic Selection: A Tool for Accelerating the Efficiency of Molecular Breeding for Development of Climate-Resilient Crops.

Since the inception of the theory and conceptual framework of genomic selection (GS), extensive research has been done on evaluating its efficiency for utilization in crop improvement. Though, the marker-assisted selection has proven its potential for improvement of qualitative traits controlled by one to few genes with large effects. Its role in improving quantitative traits controlled by several genes with small effects is limited. In this regard, GS that utilizes genomic-estimated breeding values of individuals obtained from genome-wide markers to choose candidates for the next breeding cycle is a powerful approach to improve quantitative traits. In the last two decades, GS has been widely adopted in animal breeding programs globally because of its potential to improve selection accuracy, minimize phenotyping, reduce cycle time, and increase genetic gains. In addition, given the promising initial evaluation outcomes of GS for the improvement of yield, biotic and abiotic stress tolerance, and quality in cereal crops like wheat, maize, and rice, prospects of integrating it in breeding crops are also being explored. Improved statistical models that leverage the genomic information to increase the prediction accuracies are critical for the effectiveness of GS-enabled breeding programs. Study on genetic architecture under drought and heat stress helps in developing production markers that can significantly accelerate the development of stress-resilient crop varieties through GS. This review focuses on the transition from traditional selection methods to GS, underlying statistical methods and tools used for this purpose, current status of GS studies in crop plants, and perspectives for its successful implementation in the development of climate-resilient crops.

Algorithms for Improving Speed and Accuracy of Automated Three-Dimensional Reconstruction With a Depth Camera Mounted on An Industrial Robot

Abstract Three-dimensional reconstruction technology is used in a wide variety of applications. Automatically creating accurate pointclouds for large parts with complex geometries usually requires expensive metrology instruments. We are interested in using low-cost depth cameras mounted on commonly available industrial robots to create accurate pointclouds for large parts automatically. Manufacturing applications require fast cycle times. Therefore, we are interested in speeding up the 3D reconstruction process. We present algorithmic advances in 3D reconstruction that achieve a sub-millimeter accuracy using a low-cost depth camera. Our system can be used to determine a pointcloud model of large and complex parts. Advances in camera calibration, cycle time reduction for pointcloud capturing, and uncertainty estimation are made in this work. We continuously capture pointclouds at an optimal camera location with respect to part distance during robot motion execution. The redundancy in pointclouds achieved by the moving camera significantly reduces errors in measurements without increasing cycle time. Our system produces sub-millimeter accuracy.

Implementation of Theory of Constraints To Improve Firm' Competitive Advantage: A Case Study in the Industrial Area of Bekasi, West Java Indonesia

To maintain its survival, the company needs to maintain its competitive advantage and make it a unique strategy. This study was conducted to examine and determine whether there is an effect of using the Theory of constraints (TOC) on competitive advantage. Six indicators measured the TOC: Timely delivery to the customer, eliminating raw materials, controlling operational costs and reducing wastage, reducing cycle times and reducing inventory, Rapid response, and additional production capacity without additional investment. The competitive advantage is measured by five indicators: price, quality, delivery dependability, product innovation, and time to market. 
 This study uses all manufacturing companies that use the TOC method. The samples of the research were 100 manufacturing firms in Bekasi Industrial Area, West Java, Indonesia. Based on the Partial Least Square used in analyzing the data, the result showed that the TOC positively influences competitive advantage.

Simple deterministic modeling can guide the design of breeding pipelines for self‐pollinated crops

AbstractGenetic gains delivered by plant breeding programs in the developing world must increase to deliver adaptation to a changing climate. Programs should be planned and optimized, with respect to gains per year and per dollar invested, as cyclic population improvement pipelines whose selection response is described by the breeder's equation (BE). We present a spreadsheet‐implemented model for the BE that includes operating costs. The model can be easily used to compare predicted selection response per cycle for different pipeline designs and resource allocation scenarios for self‐pollinated crops or hybrid crops that use inbred lines as parents. We modeled breeding programs that generate and select among F2– to F6–derived or doubled‐haploid (DH) lines, advance populations from one to three generations annually, and conduct agronomic testing in one to three stages during the main cropping season. Reducing cycle time is the most efficient method of increasing genetic gain under most circumstances. Although gains increase with increased population size and selection intensity, clear optima exist, in terms of the cost of a unit of gain, at relatively small population sizes and moderate selection intensities. Investments in reducing cycle length to three or even two years generate large increases in genetic gain and are more cost‐effective than increasing population size and standardized selection differential. High rates of genetic gain can be delivered by small breeding programs that complete cycles quickly.

Optimization of the Cooling of a Thermoplastic Injection Mold

In injection molding processes for thermoplastic parts, the polymer solidification phase in the molding cavity has a strong influence on the quality of the shaped parts and also on the process cycle time. Reducing cycle time is one of the major concerns for plastic injection industries. As cooling phase presents the most critical phase to get quality and cycle time of the part, the application of additive manufacturing (AM) technologies has been overcoming the limitations of traditional cooling system design. AM enables the construction of conformal cooling channels for higher cooling uniformity due to its almost unlimited freedom of design that can fulfil the desired functions in injection molding process equipment. The analysis of the heat transfer during the phase of cooling allows the investigation of the optimal positioning of the cold sources and their intensities. In this paper, a systematic approach is used to replace conventional channels in an injection molding tool with conformal cooling channels. A simulation is used to develop a numerical model that describes the heat transfer and predicts the cycle time of both the optimal and conventional designs. Finally, a numerical comparison is made between traditional and conformal cooling to demonstrate the beneficial effect on reducing the manufacturing cycle and enhancing part quality.

Cycle time reduction in multi-cavity injection mould through mould flow analysis and runner modification

Cycle time reduction in multi-cavity injection mould through mould flow analysis and runner modification

ОСОБЕННОСТИ ТЕХНОЛОГИИ И ПОЛИМЕРНЫЕ КОМПОЗИЦИОННЫЕ МАТЕРИАЛЫ ДЛЯ ИЗГОТОВЛЕНИЯ КРЫЛЬЕВ ПЕРСПЕКТИВНЫХ САМОЛЕТОВ (обзор

Today, the wings of Boeing 787, Airbus A350 aircraft are made by automated laying out of prepregs with subsequent autoclave molding. Boeing and Airbus plan to replace the 737 and A320 aircraft in the coming years, and new materials and technologies need to be developed to ensure the production of these aircraft in the amount of 100 pieces per month. To introduce new processes and materials, research is being carried out on the selection of a binder, reinforcing fillers, development of the vacuum impregnation process, curing and automation in order to increase reliability, speed up the process and reduce cycle time.

New composite fuselages manufacturing processes

The present document describes a new concept of composite fuselages manufacture, oriented towards the minimization of manufacturing costs through the generation of a monocoque fuselage structure, that allows to reduce the number of rivets and also the components joining operations, by means in addition of a process that avoids the use of molds, finally producing a lightweight and adaptable structure. The process in turn facilitates a high level of automation in the manufacture of composite fuselages and opens the door to a greater acceptance of this application in the aeronautical sector. The document outlines the design of the manufacturing process and the implementation of that particular production process for the manufacture of a real-scale concept demonstrator within the MTorres facilities, showing the reduction of the production cycle and the general manufacturing costs based on the simplification of the structural design and the integration of components into just one piece. Other additional variables that can benefit the reduction of costs and cycle times of the production process are also evaluated.

An Industry 4.0 Conceptual Model Proposal for Cable Harness Testing Equipment Industry

Nowadays, consumers search for organizations that can provide customized services at affordable prices. Therefore, it becomes essential for companies to meet those requirements by creating flexible and resilient production systems. Technological pathways such as industry 4.0 can represent a positive impact in the creation of those systems, through the integration of smart processes and technologies that can contribute to the automation of several activities within the shopfloor. Electrically controlled functions in passenger, commercial and special vehicles are becoming increasingly complex. If the signal and power cables were to be damaged, the vehicle’s operation would be affected, resulting in quality issues that can have a direct impact on safety, which can negatively affect the manufacturer’s reputation. Automotive manufacturers are thriving to achieve ever-growing mass customization, by offering a wide range of products, allowing for all clients to fulfill their needs. This scenario puts heavy pressure upon the cable harness industry, which must be as flexible as possible to supply all types of cables required by the automotive industry. This pressure is also extended to the enterprises that build test equipment for cable harnesses. In this context, the research group was able to plan an Industry 4.0 Network of Solutions that meets the requirements of the machining process of a cable harness testing equipment company, while compensating its flaws and optimizing it. The network is expected to promote the reduction of production cycle times in multiple activities, resulting in a production process that is expected to be more efficient and less prone to flaws.

Desarrollo de preformas para la fabricación de piezas estructurales de grandes dimensiones mediante la tecnología RTM para el sector aeronáutico

Resin Transfer Moulding Technology (RTM) is gaining attention on developing composite structural components for aeronautical industry, due to its high-cadence production, and as a consequence, a significant manufacturing cost reduction. This document describes the manufacturing of a composite fuselage frame oriented in dry reinforcement preform construction that, it’s one of the main factors that intervene in RTM process and has a direct influence on the component structural quality. It’s exposed the definition of an overlap strategy for dry Non-Crimp Fabric adaption on structural aeronautical components of large dimensions and implementation of such strategy for manufacture a real-scale demonstrator, exposing process time reduction base on a tooling design that facilitate the cycle time reduction. Simultaneously, it’s described a procedure to study the overlap influence at a dimensional and structural level and defects generation. Also, it’s exposed different overlap strategies for preform consolidation by commercial adhesives incorporation for fabrics and thermoplastic binders.

Electrical properties in polyester resins: comparison of the use of carbon nanotubes (CNT) and carbon black (CB)

This work presents a comparison in the production of electrical conductivity polyester resins by doping it with two types of carbonous fillers; carbon nanotubes (CNT) and carbon black (CB). These polyester resins are used to obtain electrical conductivity powder gel coat. This type of coating reduces cycle times in the manufacture of composites due to the fact that significantly decrease curing time of the gel coat and eliminate secondary operations for the application of the final coating in the composite. Electrical conductivity with different fillers content and percolation thresholds obtained in the simulation phase are detailed. The results obtained in the simulation are validated at the pilot plant level taking into account the influence of the loading percentage on the resin processing. Finally, a comparison between the results obtained with the different percentage of CNT and CB is made. The results of the simulation show that the value of the percolation threshold is much lower in the case of CNT (about 3% in the case of CNT versus 35% in the case of CB). The experimental results indicate the strong dependence of the electrical properties on the production process obtaining variations of up to two orders of magnitude in the experimental results using the same percentage of CNT but different type of polyester resin.

Design of additively manufacturable injection molds with conformal cooling

Additive manufacturing enables the production of intricate geometries including internal structures. This design freedom can be used advantageously to enhance heat transfer in injection molds by means of conformal cooling. The main goal is to reduce cycle times and to improve part quality through uniform cooling of the plastic products. This paper presents cooling design concepts for mold inserts. Their underlying approaches differ with respect to the shape and the cross-sectional geometries of cooling channels. Distinct inserts are additively manufactured by laser-based powder bed fusion (PBF-LB) of AISI 420 stainless steel. Experiments are carried out on a custom thermal test bench. Infrared thermography is used to examine the surface temperature, showing a reduction in cooling time by up to 41 % compared to conventional concepts. Additionally, the coolant flow is measured. The evaluation of the cooling characteristics reveal a critical trade-off between cycle time and uniformity of the surface temperature.

분류나무 기법에 기초한 공급사슬 회복성, 강건성, 민첩성과 공급사슬 성과의 평가

Purpose This study empirically analyzes the impact of three types of supply chain strategies(resilience, robustness, agility) for supply chain risk on supply chain performances. Methods We statistically measure the main types of supply chain strategies into resilience, robustness and agility using data collected by survey methods. SC strategies'' performance is evaluated by adopting general supply chain performances. In order to unveil more precise causality relationship between strategies and performance, we use classification tree technique in the field of data mining. Results The results reveal that all types of supply chain strategies are important for overall performances. In particular, regulating supply chain process for reducing cycle time is crucial for supply chain quality. Besides, meeting customer needs is essential for order fulfillment, recovering material logistics is for delivery speed, meeting customer needs is for partner satisfaction, and recovering material logistics is for independent delivery. Conclusion The findings of this study provide important empirical evidences on supply chain performances by each supply chain strategies with results supporting existing conceptual literatures.

Model development for the design of control strategies of the primary drying of lyophilization in vials

This paper proposes a development to reformulate the fundamental equations of primary drying into a linear-based representation to support control design. The model is expressed by transfer functions with variable gains that incorporate analytical relations derived from a phenomenological model. The time constants denote the dynamics of the heating/cooling and vacuum systems. Compared to fundamental equations, this approach simplifies the development and implementation of well-established control algorithms. The quality of the proposed representation is illustrated in the design of a control system using two different strategies: model predictive control and a feedback controller with proportional-integral action. The simulation case study allows assessing the performance of both designs with regard to cycle time reduction and robustness under parametric disturbances. Results evidence that the proposed model is detailed enough to provide accuracy in a simplified way, facilitating the implementation of in-line control strategies, which in turn enable significant reductions of drying time.