Manufacturing Principles Research Articles

ТЕХНОЛОГИЯ ПОЛУЧЕНИЯ СТАНДАРТНОГО ОБРАЗЦА РЕТИНОЛА ПАЛЬМИТАТА, ВЫДЕЛЕННОГО ИЗ ПРИРОДНОГО СЫРЬЯ, ОПРЕДЕЛЕНИЕ ОСНОВНЫХ ПОКАЗАТЕЛЕЙ, ХАРАКТЕРИЗУЮЩИХ ЕГО КАЧЕСТВО

This article discusses the issues of creating a standard sample (CO) with the use of a substance obtained from natural raw materials as a starting component, using the principles of lean manufacturing and affecting the problem of the production of domestic raw materials. The paper also discusses issues related to the standardization of the finished product, starting from the stage of choosing the material of the CO and ending with control at the stage of forming the material stock of products in a warehouse. As the main model of the study, a material with retinol palmitate isolated from natural raw materials is used. We have used technological techniques for the production of the product under development with the use of step-by-step, starting from the stage of CO preparation, stability control according to the indicator "Uniformity", which in turn is one of the main quality characteristics. Classical manufacturing techniques of pharmaceutical products were used, quantitative and qualitative determination methods, high-performance liquid chromatography (HPLC) at a wavelength of 326 nm and IR spectroscopy in the radiation range of the spectrum from 4000 to 400 cm-1 were used to control the quality of the initial component. A variant of the technological scheme for the production of vitamin A CO has been considered, this technology has been tested, and the received applicant has been standardized according to the main compliance indicators. The developed SO allows, when conducting chemical research, to ensure metrological comparability and convergence of the analysis results between tests conducted not only by different chemical experts, but also between different laboratories and at different times, it is possible only with the use of measuring instruments of a standard sample (SO) with the appropriate certified characteristic for calibration. The use of CO in conformity assessment is one of the first conditions in the work of the laboratory for the recognition of its test results as reliable.

Improving Productivity Employ Simulation Model: A Case Study of a Steel Pipe Manufacturing Company

Productivity improvement in the manufacturing industry of piping is a key challenge facing manufacturers in today's competitive markets. Improving productivity in the pipe manufacturing companies by implementing manufacturing principles that utilize simulation modeling was the purpose of this study. To improve productivity, an approach that focuses on the workstations and workforces process was suggested. The suggested approach’s goal was to increase productivity by providing customer prerequisites and leaving some products for other customers in the store. Based on the data has been gathered from the company of steel pipes, Bansal Ispat Tubes Private Limited in India, a simulation model was utilized to enhance its performance of operational. The investigation methodology consists of a simulation model, acceptable distribution, and data investigation. By simulating individual workstations and evaluating all relevant processes according to the data collected, the simulation model was built. Actual employment data were gathered from the line of manufacturing and supervisory workers, with observations carried out throughout the process of manufacturing. The used method involves videotaping of the process and interviewing workers using a video-camera. The superior continuous distributions were picked to fulfill a convenient statistical model. The results could be helps to ameliorate the manufacturing industry productivity. Furthermore, the outcomes could assist to solve the problems of scheduling in pipe manufacturing "simulating and modeling" which reveals active ways in enhancing pipe manufacturing productivity. Consequently, the findings might support well competition among companies.

Влияние расширенных принципов бережливого производства на экономическую эффективность промышленных предприятий

The main purpose of this study is an analytical proof of the effect of the extended principles of lean manufacturing of economic products on the economic efficiency of industrial companies. To achieve this goal, the following tasks were performed: the tendency to increase the share of value-added operations was investigated, the analysis of existing cost accounting methods was carried out, it was proposed to consider the cost structure depending on the type of operation.
 The object of research is modern industrial enterprises using the concept of lean manufacturing and its analogues. The subject of the study is the effect of the extended principles of lean manufacturing in the creation of economic products.
 Methods of abstraction and comparative analysis were used to study the impact of the extended principles of lean manufacturing. In addition, methods of analysis and synthesis were used to study the existing methods of cost accounting. The historical method was also used in the work to analyze stable trends in the development of industry.
 Based on empirical data, there is a tendency to increase the share of operations that add value to the final product. It was found that non-value-added operations account for 84% of the cost of an economic product, which confirms the need to apply the expanded concept of lean manufacturing in modern realities, as it will significantly reduce this share by eliminating material and especially information losses. As a result of the study of existing methods of cost accounting, it is proposed to consider the cost of any economic product structurally consisting of material and information components for operations that add and do not add value to the final product.
 As a result of the conducted research, the influence of the expanded principles lean manufacturing of economic products on the economic efficiency of modern industrial enterprises was analytically proved and the expediency of applying the proposed concept of lean manufacturing was confirmed.

End-to-end dataflow engineering framework of honey manufacturing from intermediates to process by TAS1R2@AuNPs/SPCE biosensor coupled with quality transfer principle

This study reported an original end-to-end dataflow engineering framework for the quality transfer principle to overcome the quality challenges in real-world honey manufacturing. Firstly, 650 pivotal data points of physical and chemical quality attributes from 65 batches of honey intermediates were characterized through multiple sensors, which included rheological properties, acidity, moisture, and sugars. Furthermore, a hypersensitized TAS1R2@AuNPs/SPCE biosensor was developed to identify biological quality attributes of honey, the powerful affinities between honey intermediates and the TAS1R2 receptor were discovered (KD < 1 × 10−8 M), and the abnormal batches of B2, B23 and C23 were diagnosed by TAS1R2@AuNPs/SPCE biosensor and multivariable algorithm. Finally, the end-to-end dataflow containing physical, chemical and biological critical quality attributes was successfully established to interpret the quality transfer principle of honey manufacturing, which revealed that the front-end refining process was relatively unstable and the back-end refining process was a negligible influence on the quality of honey manufacturing. This framework embraces quality management, quality transfer, and biosensor information, which will contribute to discovering the quality transfer principle in industrial innovation for intelligent manufacturing.

Adaptive reversible composite-based shape memory alloy soft actuators

This research demonstrates how a combination of two-way shape memory alloy (SMA), low-temperature liquid epoxy cure composites, and fibre reinforced plastic (FRP) may be utilised to create a novel reversible actuator with built driven functionality. The novelty of this work is that the actuator can reverse its original shape and be mounted on different customized structures. The strategy is based on a knowledge of SMA wires and the manufacturing principle underlying composite structure, as well as experiments to see how soft SMA-FRP can be programmed to bend. The folding mechanism is studied in terms of fabrication factors such as SMA training and strong interfacial bonding between SMA and epoxy resin, which influence the programming process and shape change. The two-way SMA wires are trained using the pre-straining method to programme the SMAs. The technique has been used to assemble the SMA wires with bond reliability to enhance the actuator interface's thermal behaviour. The SMA elements are directly inserted into FRP strips and epoxy resin is used as an adhesive, resulting in dynamic hybrid composites. The module is actuated using an electrical board with a current value between 3 and 6 A. The robustness, controllability, mechanical properties, and 500 life cycles of the actuator are tested. Results indicate a bending angle of 58° with 30 mm of deflection in 7 s after actuating the module. Also, 3D printing is used to print a gripper inspired by human fingers and a structure to lift various weights. The actuator’s performance as a soft gripper is reliable in terms of grasping objects of different shapes. • Fabricating a novel fast responsive composite-based shape memory alloy actuator. • Developing reversible SMA-FRP soft actuators which can be mounted on various designs. • Adjusting current intensity and FRP/epoxy resin thickness, soft actuators demonstrated electrically reversible bending. • Programming of two-way shape memory alloy wires. • Grasping/release is achieved in an electrically-actuated gripper by 3D-printed structures.

Design-for-Manufacturing-and-Assembly (DfMA) for the construction industry: A review

Applying Design for manufacture and assembly (DfMA) principles in building has gained attention in recent years. Studies reported that the application of DfMA in building projects can significantly enhance overall productivity. However, the literature on DfMA in the construction industry is still limited. This paper aims to provide an updated and comprehensive review of DfMA approach and its applicability in the construction industry. Web of science, and Google Scholar databases were used to obtain relevant articles from the literature. The study is based on a systematic review of 52 selected articles through search keywords for DfMA. The bibliometric results mapped the research publications by year, journal, and country in which the DfMA study is conducted. The thematic analysis results revealed the research themes and trends. In conclusion, the DfMA literature has increasingly focused on integration and sharing of information during project life-cycle to optimize design, manufacturing, and assembly, and to address issues relating to the integration of off-site manufacturing with on-site assembly. Finally, the review is concluded by providing recommendations for researchers and practitioners, and by identifying future works and opportunities for the application of DfMA in the construction industry. The results of this paper can help future theoretical and empirical research and developments.

Implementation of the principles of lean production at the enterprise of JSC "Tannery"

The purpose of the work. The purpose of the work is to develop a plan for the implementation of lean manufacturing principles at the enterprise of JSC "Tannery" in order to improve in-shop logistics and ensure the competitive advantages of the enterprise. The relevance of the work. The relevance of the chosen research topic is due to the fact that in modern conditions of a rapidly changing external environment, an enterprise needs to have competitive advantages in order to sell its products. For most enterprises, the main competitive advantage is to reduce the cost of production, which can be provided, for example, by optimizing in-store logistics. And here lean manufacturing comes to the rescue, which allows you to optimize existing resources. In this regard, the author identified the need to develop a plan for the implementation of lean manufacturing principles on the example of a leather goods manufacturing enterprise. The method or methodology of the work. The research is based on a general scientific methodology, which provides for the application of a systematic approach to solving the problems of in-store logistics by developing a specific plan for the implementation of lean manufacturing principles on the example of the enterprise JSC "Tannery". Results. In this work, a plan was developed to implement the principles of lean manufacturing in order to improve in-house logistics and ensure competitive advantages on the example of the enterprise JSC "Tannery" for the production of leather products. The paper considers the methods of traditional planning designed for analysis and decision-making in uncertain situations when implementing the principles of lean production on the example of the enterprise JSC "Tannery". The author assessed the effectiveness of the logistics system of JSC "Tannery" and identified its weaknesses; spaghetti diagrams for bottlenecks were constructed, a tree of problems and a tree of goals were formulated and constructed. Based on the results of the analytical study, the author proposed to redevelop the racks, which is reflected in detail in the developed plan for the introduction of lean manufacturing principles in order to improve in-store logistics and ensure the competitive advantages of the enterprise of JSC Tannery. Thus, the effectiveness of the plan developed by the author to implement the principles of lean manufacturing in order to improve in-store shelving logistics is beyond doubt and is confirmed by the calculations performed by the author. The scope of the results. The results of the conducted research can be used in the implementation of the principles of lean manufacturing at enterprises producing leather products in any region of the Russian Federation in order to improve warehouse logistics and ensure competitive advantages. Conclusions. In general, all of the above will lead to an improvement in the organization of financial and economic activities of enterprises producing leather products in the Russian Federation. This is especially relevant at present in the context of sanctions imposed by foreign countries against the Russian Federation.

A Recent Trend on Additive Manufacturing Sustainability with Supply Chain Management Concept, Multicriteria Decision Making Techniques

In the past 3 decades, the emerging technology in manufacturing sector other than conventional manufacturing is additive manufacturing (AM). The additive manufacturing principle was completely born from the research gaps of conventional manufacturing concepts such that the elimination of wastage and produce the component layer upon layer. Every new technology obtains the sustainability that may consider in the supply chain management principle of the raw material to finished products and decision-making techniques are to reach the consumer or customer as properly and periodically but these things are addressed challenges in additive manufacturing. This review paper aims to narrate the common research gaps on additive manufacturing, the structure of the supply chain management on AM, MCDM tools/techniques, AM application in different fields, challenges of selection of additive manufacturing, AM processes, and its application. The traditional method of literature review has been used for this review. The outcome of this review has helped the new researcher’s decision making on the AM various problems as easily and the new researchers may give the experimental solution for explored research gaps.

SCRUTINIZING THE IMPACT OF ESSENTIAL LEAN METHODS ON SUSTAINABLE PERFORMANCE IN MALAYSIAN MANUFACTURING FIRMS

Despite the fact that Malaysian manufacturing firms have implemented lean manufacturing principles to reduce resource waste and focus on customer demand, they still lack statistically validated lean manufacturing models to guide them in enhancing the sustainability of their businesses. This paper conducts empirical research of the multi-dimensionality of essential Lean Manufacturing (LM) methods (i.e., Total Productive Maintenance (TPM), Continuous Improvement (CI), and Just-In-Time (JIT)) and their association with sustainable performance (SP). 69 of 121 respondents’ usable surveys were collected from manufacturing sectors that are recognised by the Negeri Sembilan Investment Centre (NSIC). They are made up of small, medium, and large businesses. The structural relationship of constructs was validated using the Structural Equation Modelling (SEM). For direct linkages between LM Methods with Sustainable Performance, the JIT is the most significant determinant, and for the inter-relationship between LM Methods, the Continuous Improvement and TPM, both were significantly inter-connected, depend on one another. In terms of LM implementation, the developed model contributes to the well-being and comprehension of practitioners engaged in top management. Sustainable indicators for manufacturing organization decision makers to ensure that the LM implementation is compatible with the sustainability impact.

An approach to improve the microstructure and mechanical properties: A hybrid manufacturing of laser directed energy deposition and shot peening

As one of the most popular additive manufacturing technologies, laser directed energy deposition (LDED) has been extensively and deeply studied to improve the microstructure and properties of formed materials. Hybrid additive manufacturing(HAM) of LDED and shot peening is an innovative technology that combines the principle of surface strengthening and additive manufacturing. It can improve the mechanical properties and optimize the microstructure of the formed materials by strengthening the surface layer-by-layer. In this paper, the phase, oxygen content, microstructure, tensile properties, hardness and fracture morphology of the samples formed by LDED and HAM are compared. It is found that the mechanical properties of the forming samples are significantly improved by HAM, and the yield strength, ultimate tensile strength and average hardness are increased by 53%, 12% and 7%, respectively. Meanwhile, the microstructure of the sample is improved, some of the coarse columnar grains are refined, the heterogeneity of grain size is reduced, and the fibrous microstructure between layers is reduced. The hybrid additive manufacturing of LDED and shot peening can achieve high efficiency and high quality integrated manufacturing of forming parts, which is expected to promote its efficiency and applicability in practical cases in the future.

Efficient design of a prefabricated steel structure integrating design for manufacture and assembly concepts

ABSTRACT Volumetric steel structures are commonly used in the construction of modular buildings to overcome environmental hazards, control wastage, minimise construction safety issues, improve productivity and cost-effectiveness, reduce labour, and execute quick project completion. An adequate structural design and effective manufacturing are both integral processes to produce efficient and durable volumetric steel structures. Design for Manufacture and Assembly (DfMA) principles known for efficient design in the automobile industry can significantly improve the design of volumetric steel structures in terms of overall cost, safety, sustainability, productivity and time. The current research presents a case study of a volumetric steel structure in which structural design and DfMA approaches were integrated, and 3D visualisation was achieved by Building Information Model (BIM) and Solidworks that has limited previous research. The findings of this research reveal sustainable, material and cost optimised design for the prefabricated 3D steel structures. Furthermore, the novelty of the current research is enhanced by proposing a model for the automated efficient design and production of volumetric steel structures.

QUALITY AS AN ELEMENT OF THE SHIP REPAIR ENTERPRISE MANAGEMENT SYSTEM

The situation in the ship repair industry taking into account the organization of production, quality management and quality control during the ships repair is analyzed. The necessity of improving the technological processes of ship repair production is proved. It is proposed to continuously improve the production process by reducing losses arising from irrational production management. The introduction of lean manufacturing principles will significantly reduce losses. It is pointed out that it is necessary to solve the problems of providing ship repair production with modern means of non-destructive testing and complexes of new devices in order to improve the processes of quality control of ship repair work, since the improvement of means and methods of control contributes to improving the efficiency and quality of ship repair work. Conclusions that the high quality of repair work is ensured by the exact compliance with the established technology and careful consistent control, starting from the original materials and ending with the testing of finished products are drawn. The lack of preventive control functions, and therefore an active impact on quality, is the main drawback of the existing control system. It is indicated that there are such negative indicators as insufficient depth of theoretical justifications and the sequence of taking control actions, non-compliance with the basic principles of building control systems (centralization and independence of control, quantitative quality measurement, factor-causal analysis), lack of a comprehensive nature of measures and a systematic approach. In the future, it is proposed to create a quality management system that could prevent defects, and preventive control functions would allow systematically improving the quality of ship repair work.

3D bioprinting technology and its latest application in ophthalmology

<p indent="0mm">3D bio-printing technology is an emerging technology in recent years, which is driven by digital three-dimensional model and based on a certain additive manufacturing principle, positioning and assembling biological materials and cell units to form medical devices, engineered tissues, artificial organs and other products. Its emergence may solve the shortage of organs for transplant and thus prolong the life of patients or improve their quality of life. In the field of ophthalmology, it is expected to construct eyeball refractive system components through “bio-printing”, which has great development prospects in the field of ophthalmology. This paper briefly introduces 3D bioprinting technology and its latest application in ophthalmology. We will report the current research progress and future development trend, aiming to improve the understanding of ophthalmology doctors and related fields on 3D bioprinting in the application of ophthalmology, so as to accelerate the development and application of 3D bioprinting.

In-line Fluorescence Spectroscopy for Quantification of Low Amount of Active Pharmaceutical Ingredient

The pharmaceutical industry is currently implementing new manufacturing principles and modernizing the related processing solutions. A key element in this development is implementation of process analytical technologies (PAT) for measuring product quality in a real-time mode, ideally for a continuously operating processing line. Near-infrared (NIR) spectroscopy is widely used for this purpose, but has limited use for low concentration formulations, due to its inherent detection limit. Light-induced fluorescence (LIF) spectroscopy is a PAT tool that can be used to quantify low concentrations of active pharmaceutical ingredient, and recent development of instrumentation has made it available for in-line applications. In this study, the content of tryptophan in a dynamic powder flow could be measured as low as 0.10 w/w % with LIF spectroscopy with good accuracy of RMSEP = 0.008 w/w %. Both partial least squares regression and support vector machines (SVM) were investigated, but we found SVM to be the better option due to non-linearities between the calibration test and the in-line measurements. With the use of SVM, LIF spectroscopy is a promising candidate for low concentration applications where NIR is not suitable.

The design of the Customs Clearance Process Improvements Using Value Stream Mapping, Critical Path Method and Benchmarking

This research aims to develop a methodology for applying the principles of lean manufacturing in the service industry Courier Express. Customs is the main process in the industry express courier and the objective here is to apply lean principles to eliminate processes that have no added value and common parameters between the processes and optimization of resources humans or the allocation of workers. Value Stream Mapping (VSM) is used to identify a variety of waste on the current conditions and the Critical Path Method (CPM) identify the critical path in the process that takes place at this time. Model simulation of the Current Value Stream Mapping and Future State Mapping developed by using lean principles in the model simulation. The design of the repair process scheduling is done by analyzing the critical path process of Customs Clearance, with a critical path analysis we can determine the most process priority and most influential against the thorough repairs. A fusion method of Value stream mapping and Cricital Path Method supported by the method of benchmarking to finding best practice that has been done in the industry and doing the improvement so that the simulation generate a future state map with with the new critical path with faster acceleration time of customs clearance process from a total of 936 minutes before improvement and only required 389.6 minutes after improvements.

Nanochitin: Chemistry, Structure, Assembly, and Applications.

Chitin, a fascinating biopolymer found in living organisms, fulfills current demands of availability, sustainability, biocompatibility, biodegradability, functionality, and renewability. A feature of chitin is its ability to structure into hierarchical assemblies, spanning the nano- and macroscales, imparting toughness and resistance (chemical, biological, among others) to multicomponent materials as well as adding adaptability, tunability, and versatility. Retaining the inherent structural characteristics of chitin and its colloidal features in dispersed media has been central to its use, considering it as a building block for the construction of emerging materials. Top-down chitin designs have been reported and differentiate from the traditional molecular-level, bottom-up synthesis and assembly for material development. Such topics are the focus of this Review, which also covers the origins and biological characteristics of chitin and their influence on the morphological and physical-chemical properties. We discuss recent achievements in the isolation, deconstruction, and fractionation of chitin nanostructures of varying axial aspects (nanofibrils and nanorods) along with methods for their modification and assembly into functional materials. We highlight the role of nanochitin in its native architecture and as a component of materials subjected to multiscale interactions, leading to highly dynamic and functional structures. We introduce the most recent advances in the applications of nanochitin-derived materials and industrialization efforts, following green manufacturing principles. Finally, we offer a critical perspective about the adoption of nanochitin in the context of advanced, sustainable materials.

IMPACT OF BIG DATA ANALYTICS ON DISTRIBUTED MANUFACTURING: DOES BIG DATA HELP?

Big data (BD) analytics has brought progressive improvement in the business environment. It provides businesses with optimized production, personalization and improvement in the way production is dispersed. Nevertheless, conflicts arise in the use of these methods in certain industries, like retail items, which usually basis on large-scale production and prolonged supply chain. The study develops a theoretical structure to investigate if big data coupled with different production solutions can provide for a dispersed production system. Through investigation of twenty-one buyer products business instances applying secondary and main data, the study investigated changing production processes, the inherent catalyst, the function of analytics, and its effect on distributed production. The study discovers several uses of distributed manufacturing principles to evaluate the current production processes worked for larger customer product solutions by using analytics and industry analysis. The evaluation’s suggested structure mentioned in this research has a deeper impact on planning, comprehension relationships, among factors of data analytics and distributed production.

Improving Replenishment Flows Using Simulation Results: A Case Study

Background: Replenishment process is one of the success factors for a more efficient management of operations and a regained profitability. The application of the principles of lean manufacturing in the field of industrial logistics, where substantial improvements in the replenishment process are necessary, is relevant with the objective of optimising the replenishment flow of raw materials from assembly lines in order to propose and implement robust solutions capable of mitigating or even eliminating all types of waste and maximising the productivity of value-added activities. Methods: To achieve this goal, the paper follows the spirit of the DMAIC (Define, Measure, Analyse, Improve and Control) and 5-Why methods that allow the mapping of internal processes of factory logistics in the particular case of a Wire Harness Automotive Plant. Results: Based on the data collected, as well as on specific analysis methods, simulations are launched to challenge and validate the improvements made to the replenishment process. Conclusions: Several generalisable lessons are learnt regarding replenishment flow management, covering topics such as inventory traceability, in addition to logistics costs and process flow optimisation.

First principles of smart manufacturing

AbstractThe democratizing of innovation and technology happens when tools and expertise are made affordable and accessible at scale to most manufacturers. To realize the democratization of smart manufacturing innovation, it is not only necessary to democratize the technology, but also necessary to provide wide access to the knowledge required to implement the strategies and leverage the solutions and insights in a more digitally enabled manufacturing ecosystem. We are at a point in the journey where it is time to converge on a concrete set of guiding principles and a framework that organizes expectations and requirements for the implementation of smart manufacturing. This paper summarizes the practices that define smart manufacturing as developed by the industry leaders, early adopters, and expert practitioners working in the ecosystem at CESMII, the smart manufacturing institute. In smart manufacturing, organizations, people, and technology work in synergy via processes and technology‐based solutions that follow these seven First Principles: Flat &amp; real‐time, open &amp; interoperable, proactive &amp; semi‐autonomous, sustainable &amp; energy efficient, secure, scalable, orchestrated &amp; resilient. All the design principles must be considered to fully realize the vision for smart manufacturing. This paper will further explain how the seven principles work collectively to achieve new levels of connectivity, intelligence, and automation in the manufacturing ecosystem.

The Challenges of Lean Transformation and Implementation in the Manufacturing Sector

In this study we explored the challenges involved in Lean Transformation and implementation in the manufacturing sector. Using survey data from 50 North American manufacturing organizations, we examined the challenges involved in implementing and sustaining Lean Manufacturing (LM) principles and practices in production processes. The fuzzy analytic hierarchy process (FAHP) and the fuzzy analytic network process (FANP) were used to rank the considerable challenges observed in these organizations. We concluded that the need for a change in organizational culture was the major barrier to Lean implementation. It is challenging to sustain Lean without a culture shift and a clear direction set by the organization’s leadership team. The originality of the paper relates to prioritizing the cultural aspects of organizations as a major barrier to LM implementation. Other challenges encountered during Lean implementation in the manufacturing industries were related to management support, technical knowledge, and employee resistance to change. Early identification of these challenges enables companies to question their capabilities before implementing the Lean philosophy. In this study we used results obtained from 50 manufacturing companies in North America, representing a subset of manufacturing organizations. As a result, it must be interpreted based on the data acquisition method and the study’s sample size.