In the automotive industry, lean project</span></span></span><span style="font-family:Verdana;"><span style="font-family:Verdana;"><span style="font-family:Ver...In the automotive industry, lean project</span></span></span><span style="font-family:Verdana;"><span style="font-family:Verdana;"><span style="font-family:Verdana;"><span style="font-family:Verdana;">s</span></span></span></span><span style="font-family:Verdana;"><span style="font-family:Verdana;"><span style="font-family:Verdana;"><span style="font-family:Verdana;"> and innovation creation come to life by being updated under the control of systematic interdisciplinary process flows. The lean product development process that changes the shell, defined under the light of the variables created by the competitive conditions, is today measured by the value flow efficiency and the global market spread of the final product. Consequently, the lean product development approach, which aims to identify and purify all the wastes that do none value or create value to the system or cause burdens in the new product development process, is shaped by step-by-step approvals in the flow. In the main automotive industry company practices within the scope of the research (3 national, 3 international), the beginning of the concept of lean in design is to define and optimize the steps in the product development process under the value stream map. Therefore, the product function for which the customer has paid for, the function of the new product or the physical structure used to meet the needs in question, the comfort, life, experience, innovations of the scope that constitute the new product concept are planned and verified and implemented in the simplified automotive design stages at the beginning of the lean product development process. In this research, initial automotive design objectives and stages are at the focal point of the innovation and added value creation brought by the concept of </span></span></span></span><span style="font-family:Verdana;"><span style="font-family:Verdana;"><span style="font-family:Verdana;"><span style="font-family:Verdana;">“</span></span></span></span><span style="font-family:Verdana;"><span style="font-family:Verdana;"><span style="font-family:Verdana;"><span style="font-family:Verdana;">lean</span></span></span></span><span style="font-family:Verdana;"><span style="font-family:Verdana;"><span style="font-family:Verdana;"><span style="font-family:Verdana;">”</span></span></span></span><span style="font-family:Verdana;"><span style="font-family:Verdana;"><span style="font-family:Verdana;"><span style="font-family:Verdana;"> approach. The research is modelled on the determination of steps that do not create added value together with the points where the flow circuits’ or stems, the process is devalued, the interdisciplinary holistic studies intensify, the information and delay begin and end in the sequential and simultaneous design validation step transition stages, which are examined under the lean approach. As a visual and virtual tool that enables the elaboration of nominal values such as the total duration of the design verification stages and the influence of interdisciplinary stakeholders or the test level of the product design with the new product added, it reveals the value flow or losses. Hence research;from innovation creation and new product design steps, which constitute the initial stages of the lean product development process, to design verification analysis, the efficiency of the automotive company processes within the scope of the research has been measured by comparing using lean automotive design techniques, methods and concepts.展开更多
The global automotive industry is giving a difficult and common test in order to create advanced life models in the near future plans or scenarios that include current autonomous vehicle technologies. Therefore, the m...The global automotive industry is giving a difficult and common test in order to create advanced life models in the near future plans or scenarios that include current autonomous vehicle technologies. Therefore, the main purpose of the research is to comparatively evaluate the impact of autonomous vehicle technologies, which are newly included in the automotive manufacturing industry under sustainable competition, on lean product development processes, value acquisition and preservation, in different organizational structures in the approach. Although mergers or brand acquisitions in the global automotive industry create joint R & D (Research Development) or joint new P & D (Product Development) process structures for the development of autonomous vehicle technologies, heavy competition continues in the market. These new processes create different needs for the merger and partnership of the renewed traffic infrastructures under national and international regulations, and for the implementation of the new autonomous life model. Firm and brand marriages, mergers or acquisitions in today’s automotive industry have ensured the high diffusion of lean product development processes under the stream of value creation or preservation carried out specific to the company under competition. Brand mergers in automotive industry companies struggling to survive under high competition create new work disciplines, professions, and engineering flow steps in lean product development processes. However, lean product development processes driven by technological innovation under simplification have resulted in the integration of parts and systems within the autonomous vehicle design structure, as well as creating new interdisciplinary value streams or different stakeholders. Therefore, the research revealed the significant effects of lean product development processes on the value stream in the automotive industry, on the mixed and lean product development process structure formed by new or existing vehicle systems (conventional vehicle) under the penetration of each existing and new discipline. This research compares the efficient operation steps of the process stakeholders in the autonomous vehicle design parts or systems containing innovation and new technology together with the value stream in the lean product development process, and the new process stakeholder’s business-oriented global and local automotive industry companies. New autonomous vehicle technologies, together with their unique software, hardware and development analysis, have been involved in the lean product development process with their interdisciplinary studies or expertise. Therefore, the study firstly focused on the technologies in environmental use together with the new basic features of autonomous vehicles, and then examined in depth the new or existing disciplines and interdisciplinary basic structure that these innovations affect under the value stream in the lean product development process. In addition, micro-level results and recommendations were shared, shedding light on how autonomous vehicle levels will create changes in the new product development process.展开更多
For efficient use of value stream mapping(VSM)for multi-varieties and small batch production in a data-rich environment enabled by Industry 4.0 technologies,a systematic framework of VSM to rejuvenate traditional lean...For efficient use of value stream mapping(VSM)for multi-varieties and small batch production in a data-rich environment enabled by Industry 4.0 technologies,a systematic framework of VSM to rejuvenate traditional lean tools is proposed.It addresses the issue that traditional VSM requires intensive on-site investigation and replies on experience,which hinders decisionmaking efficiency in dynamic and complex environments.The proposed framework follows the data-information-knowledge hierarchy model,and demonstrates how data can be collected in a production workshop,processed into information,and then interpreted into knowledge.In this paper,the necessity and limitations of VSM in automated root cause analysis are first discussed,with a literature review on lean production tools,especially VSM and VSM-based decision making in Industry 4.0.An implementation case of a furniture manufacturer in China is presented,where decision tree algorithm was used for automated root cause analysis.The results indicate that automated VSM can make good use of production data to cater for multi-varieties and small batch production with timely on-site waste identification and analysis.The proposed framework is also suggested as a guideline to renew other lean tools for reliable and efficient decision-making.展开更多
Effective temperature level of stream, namely stream pseudo temperature, is determined by its actual temperature and heat transfer temperature difference contribution value. Heat transfer temperature difference con-tr...Effective temperature level of stream, namely stream pseudo temperature, is determined by its actual temperature and heat transfer temperature difference contribution value. Heat transfer temperature difference con-tribution value of a stream depends on its heat transfer film coefficient, cost per unit heat transfer area, actual tem-perature, and so on. In the determination of the suitable heat transfer temperature difference contribution values of the stream, the total annual cost of multistream heat exchanger network (MSHEN) is regarded as an objective func-tion, and genetic/simulated annealing algorithm (GA/SA) is adopted for optimizing the heat transfer temperature difference contribution values of the stream. The stream pseudo temperatures are subsequently obtained. On the ba-sis of stream pseudo temperature, optimized MSHEN can be attained by the temperature-enthalpy (T-H) diagram method. This approach is characterized with fewer decision variables and higher feasibility of solutions. The calcu-lation efficiency of GA/SA can be remarkably enhanced by this approach and more probability is shown in search-ing the global optimum solution. Hence this approach is presented for solving industrial-sized MSHEN which is difficult to deal by traditional algorithm. Moreover, in the optimization of stream heat transfer temperature differ-ence contribution values, the effects of the stream temperature, the heat transfer film coefficient, and the construc-tion material of heat exchangers are considered, therefore this approach can be used to optimize and design heat exchanger network (HEN) with unequal heat transfer film coefficients and different of construction materials. The performance of the proposed approach has been demonstrated with three examples and the obtained solutions are compared with those available in literatures. The results show that the large-scale MSHEN synthesis problems can be solved to obtain good solutions with the modest computational effort.展开更多
The delay in the delivery of laboratory results can be fatal and can even lead to the death of patients. This study was conducted at the clinical laboratory of the University Hospital of Kinshasa (UHK) from October 20...The delay in the delivery of laboratory results can be fatal and can even lead to the death of patients. This study was conducted at the clinical laboratory of the University Hospital of Kinshasa (UHK) from October 2020 to April 2021, aimed to evaluate the laboratory tests’ turnaround time (TAT) and to identify reasons for delay. TAT was quantified using a time and motion analysis approach. The evaluation of TAT consisted of comparing the overall intra-lab TAT with the suggested TAT using student t-test at 95% confidence intervals. Brainstorming was the root cause analysis tool used for identifying reasons for delay. In this study, the laboratory tests’ TATs were significantly higher (p < 0.001) comparing to international guidelines (60 minutes) and customers’ suggested TAT (120 minutes). Only 0.98% of the samples were reported within 60 minutes of patient reception and 1.47% within 120 minutes, i.e. an outlier rate of 98.5%. Root causes of delay related to Machinery, Management, Manpower, Materials, Method and Milieu. Because of many reasons, the laboratory is not meeting the established TAT. Preventive and curative measures must be undertaken to reduce the delay and improve the TAT.展开更多
The increasing customers＇ demands in terms of speed of service and reduced cost at higher quality has generated a new platform on which manufacturing companies compete. This heightened challenge is virtually driving ...The increasing customers＇ demands in terms of speed of service and reduced cost at higher quality has generated a new platform on which manufacturing companies compete. This heightened challenge is virtually driving all manufacturing companies to introducing lean manufacturing principles into their production systems. This paper focuses on the analysis of the current state mapping of a case study and then proposes a future state mapping to the company. The extruder 60 production line of Denki wires and cables limited, Akure, Nigeria was carefully evaluated. Data were collected from actual operators on the shop floor and feedbacks from the customers at the Gemba. Denki＇s extruder 60 production line production lead time was massively reduced from 38.42 days to 5.16 days with a 12.86% waste reduction. At the end, a practical way of implementing this aspect of lean manufacturing was suggested.展开更多
This study aimed to determine the waste that occurs in activities from receiving to delivering of finished products that can result in delays in the delivery of audio to Japan.The waste identified is limited to activi...This study aimed to determine the waste that occurs in activities from receiving to delivering of finished products that can result in delays in the delivery of audio to Japan.The waste identified is limited to activities in the finished goods warehouse.The problem that occurs is the delay in product delivery,because the product is not ready to be delivered so that it causes delays.The lean approach is used to reduce waste in the overall work process activities in the finished goods warehouse.Waste identification was performed through the 7 waste approach.Process Activity Mapping is one of the tools of VALSAT,and is looking for critical waste to find the root cause of waste.Delay can be minimized by making improvements to the layout of the warehouse and routine inspection of goods transporters.Companies should use lean to reduce the waste that occurs so there is no delay in the delivery of audio products.展开更多
This paper presents a new space model developed by general value engineering/value management model. The authors take the function analysis, function optimization and function realization of the development object as ...This paper presents a new space model developed by general value engineering/value management model. The authors take the function analysis, function optimization and function realization of the development object as the basic point, to get the final optimization structure by value evaluation, so as to improve the project quality and reduce the project cost. The final case shows that the application of this model can save about 18% of the time and considerable cost of the usually planned projects under the condition of quality assurance.展开更多
Time compression in supply chains is a crucial aspect involved in the integration of warehousing and transport operations in the manufacturing industries. Sup- ply chain flows could be interrupted due to many sources ...Time compression in supply chains is a crucial aspect involved in the integration of warehousing and transport operations in the manufacturing industries. Sup- ply chain flows could be interrupted due to many sources of delays that lead to additional time in dispatching process and reduction in customer service level. The problem considered in this paper consists of long waiting times of loading vehicles inside the plant. This work presents a simulation-based study to minimize vehicle dispatching time in a steel wire plant. Value stream map is developed to present a system perspective of processes involved in the overall supply chain. Process activity mapping is com- pleted to provide a step by step analysis of activities involved in the vehicle dispatch process. A simulation model is developed for the system and a new model is proposed to improve the delivery performance by mini- mizing vehicles＇ waiting time.展开更多
A five-step method framework is proposed by combing improved value stream mapping with simulation and design of experiment(DOE) to design the lean system for engineer-to-order(ETO) manufacturing,and lean practice impl...A five-step method framework is proposed by combing improved value stream mapping with simulation and design of experiment(DOE) to design the lean system for engineer-to-order(ETO) manufacturing,and lean practice implementation path is decided.Meanwhile,a real company case like HAVC is taken to display the application of the framework.The results indicate that compared to supermarket Kanban,constant work in process(Conwip) has the broader applicability in ETO manufacturing and the critical business process,like purchasing of key parts,and has more significant effects on value stream performance.Therefore,it should have priority in lean practice implementation.展开更多
Numerical simulations are performed for laminar natural convection heat transfer from a centered conducting body enclosed in a square cavity. A high accuracy un steady numerical method is used, combining the unique co...Numerical simulations are performed for laminar natural convection heat transfer from a centered conducting body enclosed in a square cavity. A high accuracy un steady numerical method is used, combining the unique condition of the pressure, the convergent solutions and the streamfunction value of the inside heat conducting body are given simultaneously. Two examples are simulated with this numerical method and compared with the experimental results. The results of the numerical solutions are consistent with the experimental results. It shows that the numerical method is valid and feasible.展开更多
文摘In the automotive industry, lean project</span></span></span><span style="font-family:Verdana;"><span style="font-family:Verdana;"><span style="font-family:Verdana;"><span style="font-family:Verdana;">s</span></span></span></span><span style="font-family:Verdana;"><span style="font-family:Verdana;"><span style="font-family:Verdana;"><span style="font-family:Verdana;"> and innovation creation come to life by being updated under the control of systematic interdisciplinary process flows. The lean product development process that changes the shell, defined under the light of the variables created by the competitive conditions, is today measured by the value flow efficiency and the global market spread of the final product. Consequently, the lean product development approach, which aims to identify and purify all the wastes that do none value or create value to the system or cause burdens in the new product development process, is shaped by step-by-step approvals in the flow. In the main automotive industry company practices within the scope of the research (3 national, 3 international), the beginning of the concept of lean in design is to define and optimize the steps in the product development process under the value stream map. Therefore, the product function for which the customer has paid for, the function of the new product or the physical structure used to meet the needs in question, the comfort, life, experience, innovations of the scope that constitute the new product concept are planned and verified and implemented in the simplified automotive design stages at the beginning of the lean product development process. In this research, initial automotive design objectives and stages are at the focal point of the innovation and added value creation brought by the concept of </span></span></span></span><span style="font-family:Verdana;"><span style="font-family:Verdana;"><span style="font-family:Verdana;"><span style="font-family:Verdana;">“</span></span></span></span><span style="font-family:Verdana;"><span style="font-family:Verdana;"><span style="font-family:Verdana;"><span style="font-family:Verdana;">lean</span></span></span></span><span style="font-family:Verdana;"><span style="font-family:Verdana;"><span style="font-family:Verdana;"><span style="font-family:Verdana;">”</span></span></span></span><span style="font-family:Verdana;"><span style="font-family:Verdana;"><span style="font-family:Verdana;"><span style="font-family:Verdana;"> approach. The research is modelled on the determination of steps that do not create added value together with the points where the flow circuits’ or stems, the process is devalued, the interdisciplinary holistic studies intensify, the information and delay begin and end in the sequential and simultaneous design validation step transition stages, which are examined under the lean approach. As a visual and virtual tool that enables the elaboration of nominal values such as the total duration of the design verification stages and the influence of interdisciplinary stakeholders or the test level of the product design with the new product added, it reveals the value flow or losses. Hence research;from innovation creation and new product design steps, which constitute the initial stages of the lean product development process, to design verification analysis, the efficiency of the automotive company processes within the scope of the research has been measured by comparing using lean automotive design techniques, methods and concepts.
文摘The global automotive industry is giving a difficult and common test in order to create advanced life models in the near future plans or scenarios that include current autonomous vehicle technologies. Therefore, the main purpose of the research is to comparatively evaluate the impact of autonomous vehicle technologies, which are newly included in the automotive manufacturing industry under sustainable competition, on lean product development processes, value acquisition and preservation, in different organizational structures in the approach. Although mergers or brand acquisitions in the global automotive industry create joint R & D (Research Development) or joint new P & D (Product Development) process structures for the development of autonomous vehicle technologies, heavy competition continues in the market. These new processes create different needs for the merger and partnership of the renewed traffic infrastructures under national and international regulations, and for the implementation of the new autonomous life model. Firm and brand marriages, mergers or acquisitions in today’s automotive industry have ensured the high diffusion of lean product development processes under the stream of value creation or preservation carried out specific to the company under competition. Brand mergers in automotive industry companies struggling to survive under high competition create new work disciplines, professions, and engineering flow steps in lean product development processes. However, lean product development processes driven by technological innovation under simplification have resulted in the integration of parts and systems within the autonomous vehicle design structure, as well as creating new interdisciplinary value streams or different stakeholders. Therefore, the research revealed the significant effects of lean product development processes on the value stream in the automotive industry, on the mixed and lean product development process structure formed by new or existing vehicle systems (conventional vehicle) under the penetration of each existing and new discipline. This research compares the efficient operation steps of the process stakeholders in the autonomous vehicle design parts or systems containing innovation and new technology together with the value stream in the lean product development process, and the new process stakeholder’s business-oriented global and local automotive industry companies. New autonomous vehicle technologies, together with their unique software, hardware and development analysis, have been involved in the lean product development process with their interdisciplinary studies or expertise. Therefore, the study firstly focused on the technologies in environmental use together with the new basic features of autonomous vehicles, and then examined in depth the new or existing disciplines and interdisciplinary basic structure that these innovations affect under the value stream in the lean product development process. In addition, micro-level results and recommendations were shared, shedding light on how autonomous vehicle levels will create changes in the new product development process.
基金Project supported by the National Natural Science Foundation of China(Nos.72071179 and 51805479)the Natural Science Foundation of Zhejiang Province(No.LY19E050019)the Ministry of Industry and Information Technology of China(No.Z135060009002)。
文摘For efficient use of value stream mapping(VSM)for multi-varieties and small batch production in a data-rich environment enabled by Industry 4.0 technologies,a systematic framework of VSM to rejuvenate traditional lean tools is proposed.It addresses the issue that traditional VSM requires intensive on-site investigation and replies on experience,which hinders decisionmaking efficiency in dynamic and complex environments.The proposed framework follows the data-information-knowledge hierarchy model,and demonstrates how data can be collected in a production workshop,processed into information,and then interpreted into knowledge.In this paper,the necessity and limitations of VSM in automated root cause analysis are first discussed,with a literature review on lean production tools,especially VSM and VSM-based decision making in Industry 4.0.An implementation case of a furniture manufacturer in China is presented,where decision tree algorithm was used for automated root cause analysis.The results indicate that automated VSM can make good use of production data to cater for multi-varieties and small batch production with timely on-site waste identification and analysis.The proposed framework is also suggested as a guideline to renew other lean tools for reliable and efficient decision-making.
基金Supported by the Deutsche Forschungsgemeinschaft (DFG No.RO 294/9).
文摘Effective temperature level of stream, namely stream pseudo temperature, is determined by its actual temperature and heat transfer temperature difference contribution value. Heat transfer temperature difference con-tribution value of a stream depends on its heat transfer film coefficient, cost per unit heat transfer area, actual tem-perature, and so on. In the determination of the suitable heat transfer temperature difference contribution values of the stream, the total annual cost of multistream heat exchanger network (MSHEN) is regarded as an objective func-tion, and genetic/simulated annealing algorithm (GA/SA) is adopted for optimizing the heat transfer temperature difference contribution values of the stream. The stream pseudo temperatures are subsequently obtained. On the ba-sis of stream pseudo temperature, optimized MSHEN can be attained by the temperature-enthalpy (T-H) diagram method. This approach is characterized with fewer decision variables and higher feasibility of solutions. The calcu-lation efficiency of GA/SA can be remarkably enhanced by this approach and more probability is shown in search-ing the global optimum solution. Hence this approach is presented for solving industrial-sized MSHEN which is difficult to deal by traditional algorithm. Moreover, in the optimization of stream heat transfer temperature differ-ence contribution values, the effects of the stream temperature, the heat transfer film coefficient, and the construc-tion material of heat exchangers are considered, therefore this approach can be used to optimize and design heat exchanger network (HEN) with unequal heat transfer film coefficients and different of construction materials. The performance of the proposed approach has been demonstrated with three examples and the obtained solutions are compared with those available in literatures. The results show that the large-scale MSHEN synthesis problems can be solved to obtain good solutions with the modest computational effort.
文摘The delay in the delivery of laboratory results can be fatal and can even lead to the death of patients. This study was conducted at the clinical laboratory of the University Hospital of Kinshasa (UHK) from October 2020 to April 2021, aimed to evaluate the laboratory tests’ turnaround time (TAT) and to identify reasons for delay. TAT was quantified using a time and motion analysis approach. The evaluation of TAT consisted of comparing the overall intra-lab TAT with the suggested TAT using student t-test at 95% confidence intervals. Brainstorming was the root cause analysis tool used for identifying reasons for delay. In this study, the laboratory tests’ TATs were significantly higher (p < 0.001) comparing to international guidelines (60 minutes) and customers’ suggested TAT (120 minutes). Only 0.98% of the samples were reported within 60 minutes of patient reception and 1.47% within 120 minutes, i.e. an outlier rate of 98.5%. Root causes of delay related to Machinery, Management, Manpower, Materials, Method and Milieu. Because of many reasons, the laboratory is not meeting the established TAT. Preventive and curative measures must be undertaken to reduce the delay and improve the TAT.
文摘The increasing customers＇ demands in terms of speed of service and reduced cost at higher quality has generated a new platform on which manufacturing companies compete. This heightened challenge is virtually driving all manufacturing companies to introducing lean manufacturing principles into their production systems. This paper focuses on the analysis of the current state mapping of a case study and then proposes a future state mapping to the company. The extruder 60 production line of Denki wires and cables limited, Akure, Nigeria was carefully evaluated. Data were collected from actual operators on the shop floor and feedbacks from the customers at the Gemba. Denki＇s extruder 60 production line production lead time was massively reduced from 38.42 days to 5.16 days with a 12.86% waste reduction. At the end, a practical way of implementing this aspect of lean manufacturing was suggested.
文摘This study aimed to determine the waste that occurs in activities from receiving to delivering of finished products that can result in delays in the delivery of audio to Japan.The waste identified is limited to activities in the finished goods warehouse.The problem that occurs is the delay in product delivery,because the product is not ready to be delivered so that it causes delays.The lean approach is used to reduce waste in the overall work process activities in the finished goods warehouse.Waste identification was performed through the 7 waste approach.Process Activity Mapping is one of the tools of VALSAT,and is looking for critical waste to find the root cause of waste.Delay can be minimized by making improvements to the layout of the warehouse and routine inspection of goods transporters.Companies should use lean to reduce the waste that occurs so there is no delay in the delivery of audio products.
文摘This paper presents a new space model developed by general value engineering/value management model. The authors take the function analysis, function optimization and function realization of the development object as the basic point, to get the final optimization structure by value evaluation, so as to improve the project quality and reduce the project cost. The final case shows that the application of this model can save about 18% of the time and considerable cost of the usually planned projects under the condition of quality assurance.
文摘Time compression in supply chains is a crucial aspect involved in the integration of warehousing and transport operations in the manufacturing industries. Sup- ply chain flows could be interrupted due to many sources of delays that lead to additional time in dispatching process and reduction in customer service level. The problem considered in this paper consists of long waiting times of loading vehicles inside the plant. This work presents a simulation-based study to minimize vehicle dispatching time in a steel wire plant. Value stream map is developed to present a system perspective of processes involved in the overall supply chain. Process activity mapping is com- pleted to provide a step by step analysis of activities involved in the vehicle dispatch process. A simulation model is developed for the system and a new model is proposed to improve the delivery performance by mini- mizing vehicles＇ waiting time.
文摘A five-step method framework is proposed by combing improved value stream mapping with simulation and design of experiment(DOE) to design the lean system for engineer-to-order(ETO) manufacturing,and lean practice implementation path is decided.Meanwhile,a real company case like HAVC is taken to display the application of the framework.The results indicate that compared to supermarket Kanban,constant work in process(Conwip) has the broader applicability in ETO manufacturing and the critical business process,like purchasing of key parts,and has more significant effects on value stream performance.Therefore,it should have priority in lean practice implementation.
文摘Numerical simulations are performed for laminar natural convection heat transfer from a centered conducting body enclosed in a square cavity. A high accuracy un steady numerical method is used, combining the unique condition of the pressure, the convergent solutions and the streamfunction value of the inside heat conducting body are given simultaneously. Two examples are simulated with this numerical method and compared with the experimental results. The results of the numerical solutions are consistent with the experimental results. It shows that the numerical method is valid and feasible.
