Mass Production System Research Articles

Impact of Lean Manufacturing Practices on Clothing Industry Performance

Most of the Indian clothing Industry follows mass production system are so called Progressive Bundling System (PBS). This typical system creates high amount of non-value added activity, longer production lead time due to higher Work in progress (WIP). Which in turn affects smooth production flow. In this research the researcher approached to address the cited problems with various lean manufacturing tools such as VSM, cellular layout, Single piece flow, and kaizen at ABC clothing Ltd, India. The current state VSM map was developed by mapping all the information and product flow at ABC towards the selected product line. This includes machine cycle time, inventory, setup time, and information flow such as how customers place the order. The current state of Value stream mapping (VSM) for mentioned the product was studied and the target areas of improvement were identified to eliminate the process wastages revealed by current state map at ABC. The future state VSM is designed by incorporating cellular layout, Single piece flow, Kaizen.

English

Soil insects are a major source of crop loss in tropical, subtropical and temperate zones. Many soil insecticides are either/or highly toxic to humans, have serious other non-target effects, or are a banned from use nationally or internationally. An alternative strategy is the use of beneficial (entomopathogenic) nematodes as they are well-adapted to the soil environment and non-toxic. However, the establishment of locally adapted mass production systems for beneficial nematodes requires considerable technological development effort and time. We therefore analyzed the design of 16 in-vitro semi-solid, 3 in-vivo and 2 combined in-vitro + in-vivo nematode production factories from Rwanda, Switzerland, PR China, DPR Korea, to provide an understanding of the rationale behind factory site selection, as well as external and internal factory designs. The factories should, regardless of the production method, consist of at least six rooms in one building. Their allocation depends on the work-flow, insulation of cultures and storage, as well as on separations to avoid cross-contaminations. Our findings propose optimal standard designs for nematode mass production factories and give insight into steps for planning their establishment. This information will be vital to support the dissemination of such technologies to other locations in-country, or to new countries, with the ultimate aim to more safely control soil pests.   Key words: Biological pest control, entomopathogenic/ entomoparasitic nematodes, technology transfer/exchange, East Africa, East Asia.

Nanomaterials for Functional Textiles and Fibers.

Nanoparticles are very interesting because of their surface properties, different from bulk materials. Such properties make possible to endow ordinary products with new functionalities. Their relatively low cost with respect to other nano-additives make them a promising choice for industrial mass-production systems. Nanoparticles of different kind of materials such as silver, titania, and zinc oxide have been used in the functionalization of fibers and fabrics achieving significantly improved products with new macroscopic properties. This article reviews the most relevant approaches for incorporating such nanoparticles into synthetic fibers used traditionally in the textile industry allowing to give a solution to traditional problems for textiles such as the microorganism growth onto fibers, flammability, robustness against ultraviolet radiation, and many others. In addition, the incorporation of such nanoparticles into special ultrathin fibers is also analyzed. In this field, electrospinning is a very promising technique that allows the fabrication of ultrathin fiber mats with an extraordinary control of their structure and properties, being an ideal alternative for applications such as wound healing or even functional membranes.

Development of a continuous roll-to-roll processing system for mass production of plastic optical film

This paper reports a highly effective method for the mass production of large-area plastic optical films with a microlens array pattern based on a continuous roll-to-roll film extrusion and roller embossing process. In this study, a thin steel mold with a micro-circular hole array pattern is fabricated by photolithography and a wet chemical etching process. The thin steel mold was then wrapped onto a metal cylinder to form an embossing roller mold. During the roll-to-roll process operation, a thermoplastic raw material (polycarbonate grains) was put into the barrel of the plastic extruder with a flat T-die. Then, the molten polymer film was extruded and immediately pressed against the surface of the embossing roller mold. Under the proper processing conditions, the molten polymer will just partially fill the micro-circular holes of the mold and due to surface tension form a convex lens surface. A continuous plastic optical film with a microlens array pattern was obtained. Experiments are carried out to investigate the effect of plastic microlens formation on the roll-to-roll process. Finally, the geometrical and optical properties of the fabricated plastic optical film were measured and proved satisfactory. This technique shows great potential for the mass production of large-area plastic optical films with a microlens array pattern.

A somatic embryogenesis–based system for the production of fluted pumpkin (Telfairia occidentalis Hook. f.) planting materials

Fluted pumpkin (Telfairia occidentalis Hook. f.) is traditionally propagated by seeds, which have low viability after pod harvest, low percentage germination, and poor root development and often germinate during storage. The competition between use of seeds for consumption and propagation causes scarcity of propagules, necessitating development of more efficient propagation systems. Efficient protocols were developed for the induction of somatic embryos (SEs) and conversion into plantlets using cotyledons from mature zygotic embryos. This study evaluated the effects of 2,4-dichlorophenoxyacetic acid (2,4-D) and kinetin (25 combinations) on the induction of SEs, and of indole-3-acetic acid (IAA), 2,4-D, and kinetin (7 combinations) on conversion of SEs into plantlets. Significantly more SEs (381.7; p < 0.01) were obtained on medium with 0.5 mg l−1 2,4-D and 0.1 mg l−1 kinetin than from the other 24 treatments after 4 wk of cotyledon culture. All SEs were obtained through an intermediary callus. For the production of SE-derived plantlets, treatments with 0.01 mg l−1 IAA and 0.02 mg l−1 kinetin resulted in significantly more shoots and roots than other treatments (p < 0.001 for each) and gave 100% conversion of SEs to plantlets. The mean numbers of roots and shoots on this treatment were 3.7 and 1.3, respectively, and the mean shoot length was 2.2 cm. The plantlets had broad leaves and good vigor, similar to the parent cultivar. Nearly all plantlets (98–100%) survived acclimatization. The production of SEs from cotyledons and the high rate of conversion into quality plants will allow development of a mass production system for Telfairia planting material to meet the increasing demand for this crop.

Nineteenth-Century Telegraphy: Wiring the Emerging Urban Corporate Economy

Nineteenth-century telegraphy had a vital integrative role in the intersecting and mutually constituted developments of American industrialization, urbanization, and mediatization. Previous work by Tarr, Finholt, and Goodman1 focused on the internal activities of business, fire, and police institutions in American cities. Here, I move beyond their approach in relating telegraphy to broader infrastructural developments of national-level urban industry and modern mass media in the late nineteenth century and the rise of dominant, networked urban commercial, industrial, financial, and media centers. By radically accelerating the mobility of information and capital, telegraphy significantly reduced barriers of distance to industry, commerce, news and advertising, and state and military interventions. Owing to its commercial ownership in the USA, telegraphy privileged business over public use in comparison to Western Europe. Its enduring effects were its integrative functions in the development of a large-scale, urban-centered, largely private system of mass production, mass media, mass culture, and mass consumption.

An Architect′s Adaptation to the Mass Production System: A. Quincy Jones′s Tract Houses

AbstrctThis study identifies an architect′s interpretation of the mass production system, and the public responses in the housing market, through the works of A. Quincy Jones. He provides an extraordinary example, in being successful in his efforts to envision professional architectural designs respecting the principles developed by mass builders. He proposed the post-and-beam system, and variations of the minimum plan in the plan layout, as the discipline in his guidebook. While his adoption of the post-and-beam system originated from criticism of the mass builders′ houses following the regional modern architects, the methodology for layout planning was apparently based on the standardized guidance of the Federal Housing Administration. In his actual projects, the consistency of the structural system and the flexible application of the minimum plan showed a significant difference with those of mass builders. In particular, the modification of the minimum plan resulted in more attractive spatial experiences for the masses, with an open kitchen centered on the family living space. His post-and-beam structural system was also effective, in visualizing the connection between inside and outside space for outdoor living spaces. His architectural effort in considering the mass housing market envisioned ideal family living spaces for the public, with the application of modern architectural disciplines to the mass production housing market.

Conversion of organic wastes into fly larval biomass: bottlenecks and challenges

The large volume of organic wastes and by-products produced every year usually generates environmental problems, such as water, air and soil contamination and it can be also a focus for pathogen dispersion. Sustainable waste management strategies should be developed, that can favour the value of the organic waste instead of its disposal. A sustainable strategy would be the use of the organic waste as substrate for intensive production of insect biomass. The insects associated with manure and organic waste can play a key role for the sustainable valorisation of organic waste streams as high add value products as they could be used as feed. This review is an overview of the research related with intensive insect farming of saprophagous dipteran species (flies) on manure and other organic wastes and the by-products obtained after the process. Using dipterans as recyclers of waste means that the mass-production systems of these organisms have to be efficient and competitive with other recycling systems. This review describes the possibilities of the dipterans to become active agents in waste management systems and, at the same time, an important resource of protein for feed and the main aspects and bottlenecks that have to be improved in order to achieve competitive insect farming.

Development of hybrid process for double-side flexible printed circuit boards using roll-to-roll gravure printing, via-hole printing, and electroless plating

A hybrid process including roll-to-roll (R2R) gravure printing, via-hole printing, and electroless plating was investigated for the creation of a double-side flexible printed circuit board (FPCB). A R2R gravure process with an Ag seed layer that includes front- and back-side printing with a polyimide film at the center was investigated. The gravure-printed Ag pattern was laser drilled for high accuracy. A via hole was filled with a low-viscosity Ag ink using the drop-casting method. In addition, an electroless Cu plating process was performed to increase the conductivity of the printed circuit. The interconnection performance was confirmed from the resistance values obtained using a feed-through test and microscopic images. To evaluate the reliability of the FPCB, a cyclic bending motion test was performed; stable electrical performance was observed even after 400,000 cycles. The results obtained in this study suggest that the proposed hybrid process for double-side FPCBs is viable for a mass production system.

A comprehensive electric field analysis of cylinder-type multi-nozzle electrospinning system for mass production of nanofibers

Electrospinning is the commonly used method for fabrication of micro/nano fibers due to simple setup and intuitive understanding of mechanism. In laboratory scale, single or dual nozzle systems are mainly used to conduct specific experiments and use simple electric power connections and it has uncomplicated electric field distributions. An industrial scale mass production of micro/nano fiber is an essential prerequisite for price competitiveness. For the first time in South Korea, we developed a novel upward cylindrical-type electrospinning system and the study demonstrates the comprehensive electric field simulations of multi-nozzle system and practical test results of the electrospinning system.

Theorizing media production: the poverty of political economy

This article argues that the Political Economy of Communication (PEC) has generally failed to develop theories of media production. Such theory as exists has been heavily influenced by accounts of mass production and flexible specialization in Hollywood. Hollywood film production has been viewed as paradigmatic of media production in general, in the same way as Ford was for manufacturing, and these theories continue to influence accounts of production across media and cultural industries. The article tests the mass production/flexible specialization paradigm against both the evidence of the Hollywood case and Ford’s mass production system. An alternative paradigm, the theory of craft media production, is also examined. The article then attempts to show how applying organization theory and media economics can provide a more convincing explanation of media production and of the Hollywood case. Finally, the article briefly attempts to show how we might develop rich theoretical explanations of media production by exploring the relationships between economic, organizational and media-specific cultural elements.

EXPRESSED/LATENT NEEDS FOR CO-CREATIVE FASHION PRODUCTS

Customization systems have incarnated the notion of co-creation and provided a wide variety of customized products which fit individual customers’ needs. However, most customized fashion items are no more than modified products based upon existing products and, therefore, satisfy only expressed needs. In contrast, mass-production systems can offer more innovative fashion items satisfying latent needs, though they may not fit individual needs in detail.To investigate the relationship between the type of market orientation (responsive vs. proactive market orientation) and the type of production system (mass-production vs. customization systems), we conduct a consumer survey regarding four types of fashion items (sneakers, business shirts, belts, and underwear).The results of ANOVA showed that fashion categories in which customers have the needs for responsive market orientation have much potential for developing customized products, whereas fashion categories in which customers have the needs for responsive market orientation have less potential for providing customized products. The results also showed that fashion categories in which customers have the needs for proactive market orientation have much potential for providing new, innovative (mass-produced) products, whereas fashion categories in which consumers have proactive market orientation have less potential for providing new, innovative (mass-produced) products.Firms should emphasize on the responsive market orientation if their customers perceive much potential for developing a customization system in the category; firms should emphasize on the proactive market orientation if customers perceive much potential for offering new, innovative products under the previous mass-production system. If there are potentials for developing both innovative mass-produced products and customized products, firms need ambidextrous market orientation.

A Novel Delivery System for the Root Symbiotic Fungus, Sebacina vermifera, and Consequent Biomass Enhancement of Low Lignin COMT Switchgrass Lines

Sebacina vermifera (MAFF-305830) is a mycorrhizal fungus originally isolated from the roots of orchids that we have previously shown to be tremendously beneficial in enhancing biomass yield and drought tolerance in switchgrass, an important bioenergy crop for cellulosic ethanol production in the United States. Towards this end, we have developed a bentonite clay particle-based delivery system for mass production and dissemination of S. vermifera for large-scale field trials. A greenhouse-based experiment was conducted to evaluate this novel delivery method for biomass enhancement of wild type and transgenic, low lignin (COMT down-regulated) switchgrass lines compared to an efficient in vitro colonization method. S. vermifera colonization enhanced plant biomass regardless of delivery method, although the percentage of fungal biomass in planta increased with the clay-based delivery system. Further, we found that release of some clay minerals in solution was enhanced in the presence of S. vermifera, while others were seemingly reduced. Intriguingly, the presence of S. vermifera has little or no impact on cell wall composition, including lignification. This research is the first report documenting the development of a bentonite clay particle-based delivery system for mass production of any symbiotic microbe and suggests that S. vermifera can be packaged with a mineral composite and effectively delivered to a target host plant.

A Novel Silicon/Graphite/Carbon Composite Anode for High Performance Lithium Ion Batteris

To response the multiply increased demand in portable electronics, hybrid electric vehicles and large scale energy storage over the last decade, Li-ion batteries (LIBs) with higher energy density and power capability have been desired. With respect to the anode of LIB, Silicon have received a great deal of interest as the fully lithiated (ca. Li22Si5) alloy has the highest theoretical capacity of any known material at 4140 mAh/g (3579 mAh/g for Li15Si4at room temperature). Although it is about 10 times higher than that of a conventional graphite anode, a Si-based electrode has yet to find use in commercial application because of its low coulombic efficiency (C.E.) and poor capacity retention. Si is typically known to undergo over 300% of volume expansion on Li insertion, which leads to cracking and crumbling of active particles and the resultant loss of electrical contact between electro-active materials causes rapid capacity fading. Although extensive researches have been reported to alleviate the problems, most of approaches are commercially unviable as they usually involve complicated and prohibitively high cost processes. Hence, a Si anode with sufficient performances and low cost production is highly desired. This study presents a novel cost-saving Si-based anode material with high coulombic efficiency and prolonged cyclability of excellent electrochemical performances using a low-cost synthesis though the attractive route. As a part of our strategy, we attempted to employ a by-product derived from a granular poly-Si mass production system for the feedstock of solar cell application. In such a way, a certain amount of amorphous silicon particles (ASP), the by-product, is derived homogeneously from the nucleation of gas dust in a silane-based gas phase reactor. (Fig. 1 shows HRTEM image and SAD pattern for ASP.) Our pioneering attempt is advantageously characterized by follows: 1) obtained sub-micron sized Si particles are superior to nano-sized Si particles in the battery performance and business value and 2) the production cost is expected to be many times lower than nano-sized Si by utilizing the by-product from an already matured mass production. Further improvement in consideration of commercial feasibility and processing cost is achieved by employing ASP into spherical Si/graphite/carbon composite systems. In Fig. 2, it is seen that spherical ASP/graphite/carbon composite is obtained with the particle size around 7-11 μm. Representative cross-section view demonstrates carbon coated ASP are enclosed by graphite layers; though vacant areas exist sparsely. In the optimized system, the mechanical stress on Si particles induced by huge volume expansion on Li insertion is alleviated and the direct contact between Si and electrolyte is prevented, by which irreversible reaction leading to deterioration of coulombic efficiency is reduced. In this context, we have performed a systematic study on the influence of choice and application method of carbon material which is a critical element in the composites. In such a way, ASP are carbon coated before or during the fabrication process of spherical composites and the achieved advantageous characteristics are summarized as follows: 1) separation of each silicon particles, preventing agglomeration and 2) a strong bonding between Si and graphite for maintaining the electrical contact on charge-discharge, 3) a ductile matrix to buffer the huge stress caused by volume expansion and 4) vacant space inside the composite to accommodate the huge volume changes. It is worth noting that such extraordinary ASP/graphite/carbon composites are manufactured in an inexpensive way as the process consists of only a few steps. The electrochemical characterization demonstrates remarkable performances as the coulombic efficiency at the first cycle reaches up to 90% and the capacity retention after 100cycle is over 92% at 620 mAh/g. Material characterization is performed through several different analytical methods including HRTEM, in-situ solid state lithiation, in-situ dilatometer to support and discuss the unique properties of ASP and the superior performances of our spherical Si/graphite/carbon composite systems.

Lean Production “with Chinese Characteristics”: A Case Study of China’s Automobile Industry

The concept of “lean production” has attracted much attention and sparked considerable debate among social scientists on work and workplace restructuring. This study seeks to engage with the lean production debate through a case study of China’s automobile industry. Drawing on ethnographic research conducted in seven large auto-assembly plants in China, the article explores how lean production is implemented in the Chinese context, how it has affected workplace and workers, and what successes and problems have arisen. It finds that intensified competition and China’s specific conditions have driven automakers to adopt mixed strategies by combining certain lean techniques with the existing Fordist–Taylorist mass production system, while utilizing some effective socialist organizational practices. Despite the general move toward a lean-flexible workplace, there are notable variations in employment practices at the factory level that influence outcomes of lean production. The Chinese case provides new evidence that supports the “diversity” perspective and an integrated approach, which underline substantial national and subnational variations in the implementation and outcomes of lean production. The evidence shows that in the absence of independent trade unions, lean production leads to an intensification of work and greater managerial control. The findings suggest the need to bring analysis of capitalist labor process and shop-floor control, resistance, and accommodation back in to understand lean production.

Implementation of Improved Jigs and Fixtures in the Production of Non-Active Rotary Paddy Weeder

Paddy weeder is a manual weeding tool and is used to control weeds in the concerned area. Presently, the manufacturing of paddy weeder employs traditional methods, i.e. production process was being executed without the implementation of jigs. Jigs are special work holding and tool guiding device. The use of jigs and fixtures is an economical way to produce a component in mass, and hence they serve as an important component for mass production system. The primary objective of this research was to increase the production by reducing operation time thus reducing the cost associated with it. The jigs and fixtures were firstly designed with the software solidworks. The implementation of improved jigs proved remarkably efficient and helped in saving 35% of the time elapsed in the production cycle, with increased worker safety and hence, proved helpful in facilitating mass production.

Scaffold-free three-dimensional culture systems for mass production of periosteum-derived progenitor cells

Mesenchymal stem cells (MSCs) are capable of self-renewal and can differentiate into various types of cells for therapeutic purposes. MSCs are frequently cultured in a two-dimensional (2D) system. However, MSCs can lose their differentiation capacity over time in this culture system. In addition, the available surface area for the propagation of cells is limited. Therefore, various three-dimensional (3D) culture systems have been developed. In this study, we developed the scaffold-free 3D culture systems for the expansion of periosteum-derived progenitor cells (PDPCs) as spheres. The spheroid formation of PDPCs was induced using a rotation platform. The spheres maintained their viability and proliferation ability. Moreover, expression levels of the stemness marker genes and proteins were higher in cells grown on 3D culture system than in 2D culture system. In conclusion, a simple and economical 3D culture system has been developed that can increase the potential of PDPCs for clinical use.

30pm1-E-6 マイクロチューブ大量生産システムの開発

This paper describes mass production system of micro-tube for microbes culture. Microbes are used in many fields, especially oil production microbe, Aurantiochytrium, gathering attention as a new fuel. We suggested a microbe culture system in an open environment using hydrogel micro-tubes. The micro-tube can protect a purpose microbe from competitive microbes, and absorb only oxygen and nutrient into micro-tube. So we can culture many microbes at low cost by using micro-tube. The tube is generated by microfluidic technique, with excellent manipulation on microflows show great potential for manufacturing micro-tubes. In this paper, we propose mass production system of micro-tube with microfluidic technique, and permit mass culture of microbes more effectively.

Steelmaking Technology for the Last 100 Years: Toward Highly Efficient Mass Production Systems for High Quality Steels

Steelmaking Technology for the Last 100 Years: Toward Highly Efficient Mass Production Systems for High Quality Steels

F161001 ロール・ツー・ロールPE

This paper describes a new mass production system of high functional plastic films, and an application to guide new technology named "Roll-to-Roll Printed Electronics". The primary advantages of this approach are that (1) the use of a web means that the material is extremely thin and large area, (2) formation of three-dimensional wiring with high precision is possible, (3) ultra-high speed mass production is possible, (4) the liquid process eliminates the need for vacuum processing and allows for production at low-temperatures, (5) the freedom to select the web materials is high, and (6) scaling from the nano to the meter size is possible. Although there are many such advantages to this type of roll-to-roll printed electronics, there are still problems that need to be overcome before this technology can be generally applied. In particular, the materials are becoming ever thinner, and the processing precision is higher than in the past, so it is necessary to completely prevent defects such as slip and wrinkles. In addition, it is necessary to reduce stretching as much as possible, making low tension transport essential. As such, significantly progressing the web handling technology accumulated thus far has become an issue for the future.