Benefits of Implementing Automated Costing in a Small Machine Shop: A Case Study

Knowledge based cost estimating systems are available, but is there a lower limit to their applicability in an industrial environment?  This paper answers this question by examining a knowledge based cost estimating expert system application in a small machine shop.  Differences between the traditional experienced-based system currently employed and the automated system are studied.  Data is gathered to analyze time effectiveness, accuracy, and payback of the software.  Data from seventy part models is recorded to study the time experiment and data from fifty part models is used to study accuracy and consistency.The results indicate that the software is faster than traditional quoting systems; however, the payback point is high. Also, results show that the software has a smaller average time to manufacture percent difference between the automated system and the actual time to manufacture (TTM) compared to the percentage difference between the traditional TTM and actual TTM. Standard deviation for the automation is also less, implying better consistency.  As a result, the attractiveness of the automated system in the limiting case of a small machine shop rests with significantly improved accuracy and consistency rather than payback.

A Survey-Based Vision for Restructuring Concrete Business in the New Residential Communities in Egypt

Due to its evolving technology and dynamic nature, a sizeable segment of the world’s construction market that used to partly rely on traditional site-mixed concrete (SMC) had almost completely shifted to ready-mixed concrete (RMC) several decades ago in the developed countries. Likewise, this targeted trend has been observed in developing countries. The Egyptian residential sector has also adopted some corrective changes in this direction in the last decade. Nevertheless, the vast majority of builders in the Egyptian market have continued to oppose to this global paradigm shift. The observed “cultural” resistance to change seems to be chiefly driven by the difference in the unit price of SMC and RMC, overlooking the latter’s superior characteristics and its added values that fundamentally overweigh this apparent difference in cost.This study aims at promoting the use of RMC over SMC for construction of new residential communities in Egypt. Proper business measures need to be implemented for the desired change in the culture of concrete market. A mixed (qualitative and quantitative) approach was used in this survey. A customized survey, comprised of a series of interviews with consultants/contractors in the field and a detailed questionnaire targeting practitioners (developers, contractors and end users), was conducted to gage market responsiveness to the desired change. The desired market shift towards RMC (targeted variable) hinges on generic variables: price, concrete quality and customer satisfaction, and market-specific variables: local concrete culture, perception of average customers, and permitting process.The survey revealed that professional participants, a small fraction of the local concrete market, are aware of the added values of utilizing RMC. The participation rate is clearly indicative of the absence of awareness of the numerous competitive advantages of using RMC in the Egyptian market.  The resistance to change, unarguably, still hinges on the mistakenly believed difference in SMC and RMC unit prices, not the cost/benefit ratio

Instructional Software for Reliability Estimation and Fault Tree Analysis

This paper describes a software tool to introduce fundamental concepts of reliability and fault tree analysis to engineering students.  Students can fit common failure distributions to failure data.  The data can be complete, singly censored, or multiply censored.  The software computes distribution and goodness-of-fit parameters.  The students can use the tool to validate hand calculations.  Failure distributions and reliability values for various components can be identified and stored in a database.  Various components and sub-systems can be used to build series- parallel or complex systems.  The components data can also be used to build fault trees.  The software tool can compute reliability of complex state independent and state dependent systems.  The tool can also be used to compute failure probability of the top node of a fault tree.  The software was implemented in Visual Basic with SQL as the database.  It operates on the Windows 7 platform

Opposites Attract: An Approach to Collaborative Supply Chain Management between Semiconductor and Automotive Companies

This article illustrates the differences between the semiconductor and the automotive industry and the subsequent challenges to their common supply chain. The weak points at the interfaces between the two supply chains will systematically be identified and assessed. Based on this analysis, a toolkit for collaborative supply chain planning and execution between the automotive and the semiconductor industry is presented. A fit/gap analysis assesses the measures and their potential to solve the supply chain challenges in a systematic manner. The model is built upon existing supply chain management frameworks and defines a set of specific optimization measures for the problem at hand. These are designed to ensure a better alignment of planning and control processes between the automotive and the semiconductor industry