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A Review of Assembly Line Changes for Lean Manufacturing
IOSR Journal of Mechanical and Civil Engineering (IOSR-JMCE) ISSN: 2278-1684, PP: 01-05 www.iosrjournals.org A Review of Assembly Line Changes for Lean Manufacturing Awasare Anant Dattatray 1, M.V.Kavade 2 1 (Mechanical Engineering Department, Rajarambapu institute of Technology India) 2(Head Mechanical Engineering Department, Rajarambapu institute of Technology, India) ABSTRACT: The orientation towards an efficient mass customization confronts most companies with two opposing requirements: While the applied mass production system should be able to produce a huge product variety, the cost must be kept low. Therefore assembly lines have to be planned in a much more flexible way. The more complex the product, the more extensive the product mix—the more difficult the task. Shorter product life cycles also complicate the situation. Due to the volatile nature of market, companies cannot afford to manufacture same type of product for long period of time and neither can maintain high inventory level; to tackle this problem we propose a Continuous improvement tools and techniques are introduced to address these issues, allowing the manufacturing of superior quality products with efficient processes. The Lean tools and techniques is one of them. Keywords - production planning, Mixed-model assembly line balancing, Just-in-time scheduling, Lean tools, Product life cycle I. INTRODUCTION Assembly is an important manufacturing process for cost effective product variety. Significant research has been done in the Design and operations of assembly systems in support of high product variety, but many opportunities exist for future research. Assembly is the capstone process for product realization where component parts and subassemblies are integrated together to form the final products. -
Urban Concentration: the Role of Increasing Returns and Transport Costs
i'445o Urban Concentration: The Role of Increasing Retums and Transport Costs Public Disclosure Authorized Paul Krugman Very largeurban centersare a conspicuousfeature of many developingeconomies, yet the subject of the size distribution of cities (as opposed to such issuesas rural-urban migration) has been neglected by development economists. This article argues that some important insights into urban concentration, especially the tendency of some developing countris to have very large primate cdties, can be derived from recent approachesto economic geography.Three approachesare comparedrthe well-estab- Public Disclosure Authorized lished neoclassica urban systems theory, which emphasizes the tradeoff between agglomerationeconomies and diseconomies of city size; the new economic geogra- phy, which attempts to derive agglomeration effects from the interactions among market size, transportation costs, and increasingreturns at the firm level; and a nihilistic view that cities emerge owt of a randon processin which there are roughly constant returns to city size. The arttcle suggeststhat Washingtonconsensus policies of reducedgovernment intervention and trade opening may tend to reducethe size of primate cties or at least slow their relativegrowth. Over the past severalyears there has been a broad revivalof interestin issues Public Disclosure Authorized of regional and urban development. This revivalhas taken two main direc- dions. T'he first has focused on theoretical models of urbanization and uneven regional growth, many of them grounded in the approaches to imperfect competition and increasing returns originally developed in the "new trade" and anew growth" theories. The second, a new wave of empirical work, explores urban and regional growth patterns for clues to the nature of external economies, macro- economic adjustment, and other aspects of the aggregate economy. -
Panel Assembly Line (PAL) for High Production Rates
2015-01-2492 Panel Assembly Line (PAL) for High Production Rates Michael Assadi, Sean Hollowell, Joseph Elsholz Electroimpact Inc. Samuel Dobbs, Brian Stewart Boeing Co. Copyright © 2015 SAE International Abstract Developing the most advanced wing panel assembly line for very The final solution was a coherent, streamlined and efficient assembly high production rates required an innovative and integrated solution, line capable of very high aircraft production rates (Figure 1). relying on the latest technologies in the industry. Looking back at over five decades of commercial aircraft assembly, a clear and singular vision of a fully integrated solution was defined for the new panel production line. The execution was to be focused on co-developing the automation, tooling, material handling and facilities while limiting the number of parties involved. Using the latest technologies in all these areas also required a development plan, which included pre-qualification at all stages of the system development. Planning this large scale project included goals not only for the final solution but for the development and implementation stages as well. The results: Design/build philosophy reduced project time and the number of teams involved. This allowed for easier communication and extended development time well into the project. All design teams (machine, tooling, automation, controls) Figure 1 PAL, automation cell, Line 4, Position 1 (L4P1) collocated and worked together on integration during all stages of development and implementation for the highest Introduction level of integration. Innovative integration of the tooling and the automated equipment evolved throughout project with the teams At the conception of the Panel Assembly Line (PAL), goals targeted working as one group. -
HANDLING and ASSEMBLY Technologysubject to Change Without Notice
INDUSTRY GUIDE HANDLING AND ASSEMBLY TECHNOLOGY EFFICIENT APPLICATIONS SOLUTIONS HANDLING AND ASSEMBLY TECHNOLOGYSubject to change without notice TABLE OF CONTENTS 2 HANDLING AND ASSEMBLY TECHNOLOGY | SICK 8019952/2016-05-13 Subject to change without notice TABLE OF CONTENTS Challenges Challenges in handling and assembly technology 4 Applications in focus The application graphics shown are not binding, they are no substitute for the need to seek expert technical advice. Small part assembly: Example of pre-assembly involving an optics module 6 Small part assembly: Example of pre-assembly involving a housing assembly 14 Small part assembly: Example of final assembly involving a sensor 28 Products Product overview 42 Special pages We simply detect any object 118 IO-Link 120 Software Tool Sopas 122 Smart Sensor Solutions 124 4Dpro 126 Expertise in machines safety 128 Safe control solutions 130 Safety controller Flexi Soft 132 Safe networking: Flexi Line 134 Safe sensor cascade: Flexi Loop 135 Safe motion monitoring 136 Encoder and Motor feedback systems 138 General information Company 140 Industries 142 SICK LifeTime Services 144 Versatile product range for industrial automation 146 Industrial communication and device integration 150 Services 155 8019952/2016-05-13 HANDLING AND ASSEMBLY TECHNOLOGY | SICK 3 Subject to change without notice HANDLING AND ASSEMBLY TECHNOLOGYSubject to change without notice CHALLENGES Challenges in handling and assembly technology Many industries such as automotive, electronics, metal, machine tools, and medical engineering can be identified as the driving force behind handling and assembly technology. They rely heavily on automated han- dling and assembly processes that in turn contribute to streamlining high quality and accuracy and improving productivity and PSDI times. -
High Volume Automated Spar Assembly Line (SAL) 2017-01-2073 Published 09/19/2017
High Volume Automated Spar Assembly Line (SAL) 2017-01-2073 Published 09/19/2017 Rick Calawa Electroimpact Inc. Gavin Smith Boeing Co CITATION: Calawa, R. and Smith, G., "High Volume Automated Spar Assembly Line (SAL)," SAE Technical Paper 2017-01-2073, 2017, doi:10.4271/2017-01-2073. Copyright © 2017 SAE International Abstract build process and an exercise of the lean principles. As is typical, relatively good data was available from the automated equipment, but The decision to replace a successful automated production system at analyzing it showed that machine run time was only a fraction of the the heart of a high volume aircraft factory does not come easily. A point overall build time. Numerous manual interactions required frequent is reached when upgrades and retrofits are insufficient to meet machine stops. All maintenance required production stops or late increasing capacity demands and additional floor space is simply night and weekend work. Build times varied widely. unavailable. The goals of this project were to increase production volume, reduce floor space usage, improve the build process, and The wish list for a new spar production system was ambitious: smooth factory flow without disrupting today’s manufacturing. Two decades of lessons learned were leveraged along with advancements in • No large production disruptions. the aircraft assembly industry, modern machine control technologies, and maturing safety standards to justify the risk and expense of a • Increase production capacity. ground-up redesign. This paper will describe how an automated wing ◦ Create a single flow line and reduce buffer requirements by spar fastening system that has performed well for 20 years is analyzed matching the takt time of the wing lines. -
Iot Integrated Assembly Line - a Conceptual Model Development for Car Toys Assembly Line
Advances in Intelligent Systems Research, volume 173 1st International Conference on Engineering and Management in Industrial System (ICOEMIS 2019) IoT Integrated Assembly Line - a conceptual model development for car toys assembly line I Kurniawan,1, S Awibowo,1 and A T Pratama1 1 Department of Industrial Engineering, Swiss German University, Alam Sutera, Tangerang, Banten, Indonesia Keywords: Lean Manufacturing, Cloud Manufacturing (CMfg), Internet of Things (IoT) Abstract. Lean manufacturing is a common methodology widely used by manufacturers around the world. The keys in order to apply lean manufacturing are efficiency and continuous improvement. Efficiency can be achieved towards the utilization of technology between shopfloor and supporting business layers occurs in a system. One of the technologies that can be used is IoT (Internet of Things) and Cloud Manufacturing (CMfg) in specific. This paper contains the concept design of IoT technologies that will be applied in a car toys assembly line. Technology such as RFID, Sensors, and Android-based cloud services will be included in the assembly line system design. RFID and sensors are used to capture a number of components & subassembly parts that occur in the assembly line and the data captured will be forwarded to the ERP Systems. Android-based cloud services are used to monitor and control the systems especially for the shop floor area. Introduction Nowadays, all manufacturers around the world are trying to achieve efficiency as high as possible that being driven by global competition and the fast changing of market demand and needs. Efficiency becomes one of the most critical factors in order to reduce resources usage such as labours, materials, and machines which all leading to cost reduction and productivity increases. -
Sustainable Agricultural Mechanization Framework for Africa
African Union SUSTAINABLE AGRICULTURAL MECHANIZATION A FRAMEWORK FOR AFRICA FAO_SAMA Report_Cover.indd 1 17/9/18 11:30 AM FAO_SAMA Report_Cover.indd 4 19/9/18 10:06 AM SUSTAINABLE AGRICULTURAL MECHANIZATION A Framework for Africa Edited by: Patrick Kormawa Geoffrey Mrema Nomathemba Mhlanga Mark Kofi Fynn Josef Kienzle Joseph Mpagalile Food and Agriculture Organization of the United Nations and the African Union Commission Addis Ababa, 2018 FAO_SAMA Report_Contents and Intro.indd 1 17/9/18 11:27 AM Required citation Under the terms of this licence, this work may be copied, redistributed FAO & AUC. 2018. Sustainable Agricultural Mechanization: A Framework and adapted for non-commercial purposes, provided that the work is for Africa. Addis Ababa. 127pp. Licence: CC BY-NC-SA 3.0 IGO appropriately cited. In any use of this work, there should be no suggestion that FAO endorses any specific organization, products or services. The The designations employed and the presentation of material in use of the FAO logo is not permitted. If the work is adapted, then it must this information product do not imply the expression of any opinion be licensed under the same or equivalent Creative Commons license. If a whatsoever on the part of the Food and Agriculture Organization of translation of this work is created, it must include the following disclaimer the United Nations (FAO) or Africa Union Commission concerning along with the required citation: “This translation was not created by the legal or development status of any country, territory, city or area the Food and Agriculture Organization of the United Nations (FAO). -
Automated High Speed Assembly Machine Design
AUTOMATED HIGH SPEED ASSEMBLY MACHINE DESIGN Murat Demirci Zheng Jeremy Li, PhD Graduate Student Associate Professor School of Engineering School of Engineering University of Bridgeport University of Bridgeport Abstract Recent years, automation is still important for industrial world and in the global economy. Because of the global competition, industries started to look for new technologies and designs in automation field. There is no more enough time, energy and material to catch people needs for industries in nowadays. Thus, automated systems are becoming more interesting and important. The potential benefits of automated systems are reducing the cost of product, labor and waste; increasing the production quality, repeatability, work safety. In this paper, I describe the design steps of an automated high speed machine which is assembling the parts of a pen, according to manufacturing and production specifications. In the design project, automated system perform different kinds of process in assembly line, such as cartridge loading, point fitting, ink filling, plug fitting, gas charging and cap installing and final sealing. Furthermore, as our goals in project, automated machine must be cheaper, easier to maintain and working at “high speed” repeatedly. Working on the design project, it was really good experience to solve major design problems and to understand of engineering technology limitations in today’s world. I concluded my paper with a description designing of an automated high speed system and its distinguished advantages. Introduction In current world, the population of humanity is increasing day by day. Simultaneously, people needs are increasing, as well. In order to catch this trend and to meet the people needs; design engineers created automated machines to produce more products in short times. -
Agricultural Mechanization and Agricultural Transformation
www.acetforafrica.org Agricultural Mechanization and Agricultural Transformation Paper written by Xinshen Diao, Jed Silver and Hiroyuki Takeshima INTERNATIONAL FOOD POLICY RESEARCH INSTITUTE BACKGROUND PAPER FOR African Transformation Report 2016: Transforming Africa’s Agriculture FEBRUARY 2016 Joint research between: African Center for Economic Transformation (ACET) and Japan International Cooperation Agency Research institute (JICA-RI) Background Paper for African Transformation Report 2016: Transforming Africa’s Agriculture Agricultural Mechanization and Agricultural Transformation Xinshen Diao, Jed Silver and Hiroyuki Takeshima (International Food Policy Research Institute) February 2016 Joint research between African Center for Economic Transformation (ACET) and Japan International Cooperation Agency Research institute (JICA-RI) Contents Executive Summary ............................................................................................................................................. 3 1. Introduction ............................................................................................................................................... 5 2. Definitions and Concepts ....................................................................................................................... 6 Definitions of Mechanization ............................................................................................................... 6 Mechanization and Agricultural Intensification .............................................................................. -
The Impact of Farm Mechanization on Small-Scale Rice Production
THE IMPACT OF FARM MECHANIZATION ON SMALL-SCALE RICE PRODUCTION Y OLANDA L . TAN MASTER OF SCIENCE (Agricultural Economics) March , 1981 THE IFPACT OF FARM MECHANIZATION ON SMALL-SCALE RICE PRODUCTION YOLANDA L. TAN SUBMITTED TO THE FACULTY OF THE GRADUATE SCHOOL UNIVERSITY OF THE PHILIPPINES AT LOS BmOS IN PARTIAL FULFILLMENT OF THE REQUIREMENTS FOR THE DEGREE OF MASTER OF SCIENCE (Agricultural Economics) March, 1981 The thesis attached hereto entitled: THE IMPACT OF FARM MECHANIZATION ON SMALLeSCALE RICE PRODUCTIONp prepared and submitted by YOLANDA L. TAN, in partial fullfillment of the requirements for the degree of Master of Science (Agricultural Economics), is hereby accepted: BART DUFF' Member. Guidance Committee Member, Guidance Committe fl. /- TIRSO B. PARIS, Adviser and Chairman Guidance Committee 3-&rP/ (Date) Accepted as partial fullfillment of the requirements for the degree of Master of Science (Agricultural Economics). DOLORES A. RAMIREZ Dean, Graduate School University of the Philippines at Los Ba5os BIOGRAPHICAL SKETCH Yolanda L. Tan was born in San Pablo City, Laguna on October 17, 1956. She finished her high school education in 1974 at the Laguna College in San Pablo City. In the same year, she was awarded the local State Scholarship grant to pursue undergraduate studies at the University of the Philip- pines at 1.0s Baiios. She finished her college education in 1978 with the degree of Bachelor of Science in Statistics. After graduation, she joined the Commerce Department's teaching staff of the Laguna College. In 1979, she was granted J' an IAPMP (Integrated Agricultutal Productivity and Marketing Program) Fellowship to pursue a Master's degree in Agricul- tural Economics at the University of the Philippines at Los Bafios. -
Mental Strain As Field of Action in the 4Th Industrial Revolution
View metadata, citation and similar papers at core.ac.uk brought to you by CORE provided by Elsevier - Publisher Connector Available online at www.sciencedirect.com ScienceDirect Procedia CIRP 17 ( 2014 ) 100 – 105 Variety Management in Manufacturing. Proceedings of the 47th CIRP Conference on Manufacturing Systems Mental strain as field of action in the 4th industrial revolution Uwe DOMBROWSKI, Tobias WAGNER* Institute for Advanced Industrial Management (IFU), Technische Universität Braunschweig, Langer Kamp 19, 38106 Braunschweig * Corresponding author. Tel.: "+49 531 391-2725" ; Fax: +49 531 391-8237. E-mail address: [email protected] Abstract Industrial revolutions have changed the society by a development of key-technologies. The vision of the 4th industrial revolution is triggered by technological concepts and solutions to realize a combination of the economy of scale with the economy of scope. This aim is also known as mass customization and is characterized by handling a high level of complexity with a total network integration of products and production processes. These technology-driven changes also lead to new fields of activity in the industrial science and the occupational psychology. The 4th industrial revolution intends to implement the collaboration between humans and machines. At the same time, processes are locally controlled and planned. For humans, this results to new work items. Resulting psychological effects should be investigated. This paper classifies the 4th industrial revolution systematically and describes future changes for employees. It derives the necessity of labor- psychological analysis of new key technologies like cyber physical systems. A theoretical foundation of a psychological work requirement analysis by using the VERA method is given. -
TRANSACTION COST LIMITS to ECONOMIES of SCALE Cotton M
DO RATE AND VOLUME MATTER? TRANSACTION COST LIMITS TO ECONOMIES OF SCALE Cotton M. Lindsay & Michael T. Maloney Department of Economics Clemson University In the traditional treatment, economies of scale are attributed to a hodgepodge of sources. A typical list might include Adam Smith's famous "division of labour," economies of large machines, the integration of processes, massed reserves, and standardization. The list can be partly systematized because, when considered in detail, these various economies are themselves the result of various other more basic and occasionally overlapping principles. For example, both economies of massed reserves and economies of standardi- zation are to a certain extent the product of the statistical “law of large numbers.” However, even this analysis fails to strike to the heart of the matter because the technological factors however described that reduce costs with scale do not in themselves imply that large firms can produce at lower cost than small firms. The possible presence of such technological scale economies does not give us adequate knowledge to predict the structure of industry. These forces of nature may combine to make it cheaper to get things done in big chunks. However, this potential will be economically important only in the presence of transactions costs. Firms can specialize their production processes and hire out the jobs that require large scale. Realistically all firms hire out some portion of the production process regard- less of their size. General Motors ships many of its automobiles by rail, but does not own a railroad for this purpose. Anaconda uses a great deal of fuel oil in its production of copper, but it does not own oil wells or refineries.