Comparative Analysis of the Implementation of the SMED Method on Selected Production Stands

Nowadays, companies are looking for newer and newer methods in order to increase their efficiency and effectiveness. Many of them decide to implement Lean Manufacturing philosophy because the benefits of the introduction of this philosophy apply not only to the industrial but also to the financial and commercial areas. These changes can increase the efficiency of production realized with small investments, improve product quality, reduce inventory as well as material consumption. This philosophy can shorten the delivery time and product quality what leads to the increased customer satisfaction and enhances the competitiveness of enterprises. One of the tools of Lean Manufacturing is the Single Minute Exchange of Die (SMED) method. The implementation of this method reduces machines changeover time, which is a waste. This method makes it possible to implement a continuous flow of the product without long waiting times and, most importantly, without any performance loss. The results of the implementation of the SMED method on several different production work stands are presented in this work. The selected stands differ in type (conventional, semi-automatic, automatic) and their role in a production process (bottlenecks, support process). The work, by means of indicative evaluation, assesses the ability to increase the efficiency of machines for the analysed production work stands. The work indicates the effects a company may expect having decided to implement the SMED method for the production areas that are a part of either the main or support processes

THE IMPACT OF GEOMETRY ERRORS ON THE MOTION TRANSMISSION OF DUAL PATH GEARING

The article presents the numerical analysis of the impact of geometry errors on the motion transmission of dual path gearing. The strength calculations of the elements of the drive were made by means of the Finite Elements Method (FEM). The calculations were made for the two-dimensional models of the dual path gearing. In the first place, the drive of the error-free (theoretical) geometry was tested. Next, the modifications of the selected teeth were introduced to the calculation models. The aim of the modifications of the tooth profile was to simulate pitch errors in compliance with the admissible values defined by PN-ISO 1328-1:2015 norm “Cylindrical gears - ISO system of flank tolerance classification”. Finally, all the results were put together for comparison. The obtained results confirm the high irregularity of work gear as a result of errors tooth geometry

Comparative Tests of the Quality of the Piston Combustion Chamber for a Diesel Engine

Diesel engines are widely used despite their relatively high environmental impact. This fact requires ensuring high quality engine components, including the piston. The article presents a problem related to the occurrence of incompatibility of material structure in the combustion chamber of pistons of one of the Podkarpackie (Poland) piston factories for engines used in passenger cars. The aim of the article is to determine the diagnostic method - optimal from the point of view of quality and economy, convenient for use with large series, 100% control of the combustion chamber of pistons on the production line. Eddy current method was chosen as a solution for automatic inspection of material incompatibilities in the combustion chamber. As a complement to the selected method, a penetration method was proposed for products initially classified as non-compliant. The research was carried out in order to outline the concept of functioning of the proposed system

Appliance to Predict the Quality of Hypothetically Modified Products

Customizing the quality of the product to change customer expectations is a necessary action in good, prospering organizations. In enterprises, the most beneficial solutions consider the future satisfaction of customer with the product. This issue is not easy and is not resolved; therefore, integration of different techniques was proposed as part of a single, coherent appliance. Therefore, the aim is to propose the appliance to predict the quality of hypothetically modified products. The appliance was developed by adequately selected and combined techniques, i.e., survey research with the Likert scale, AHP method (Analytic Hierarchy Process), Pareto rule (20/80), WSM method (Weighted Sum Model) and Naive Classifier Bayes. The concept of the proposed appliance concerns the possibility of determining important product attributes and possible combinations of feature states. Based on this, the quality levels were estimated, and then satisfaction with the hypothetical modifications of the product was predicted. The test was carried out on the vacuum cleaner. As a result, four combinations of product modifications were determined, which have been created based on hypothetical and actual attributes. Each modification was satisfying for the customer. Therefore, the proposed apparatus turned out to be effective in predicting customer satisfaction for the modified quality levels. Originality is to propose a new integration of different techniques to predict levels of quality product modification based on current product quality

Universal Model for the Quality Analysis of Aluminium Alloys Castings

The production of products in foundry technology is fraught with many problems, including the impossibility of controlling all parameters affecting casting quality. It is important to take effective improvement measures related to the implication of non-destructive testing (NDT), but these methods are rarely combined in the diagnostic cycle. As part of quality assurance, it is also important to identify the root causes of problems. In view of this, it is appropriate to develop a model that facilitates diagnosis and the search for the key causes of nonconformity, which would be a combination of NDT and quality management methods. The originality of the model presented in the study is reflected in the combination of NDT and quality management methods. The model presents a universal method that can be implemented in foundries to ensure the stability of production processes. The application of the model brings tangible benefits in the form of an increase in the speed of detection and a reduction in non-conformities in aluminium castings, which significantly increases the quality level of the products offered. Further research directions will address the application of the model within foundry processes characterised by loss of quality stability

Analysis of the Possibility of Used of the Quality Management Techniques with Non- Destructive Testing

The quality of products is, in particular, analyzed in product case from the aerospace industry in order to achieve the desired quality and safety levels. The aim of the study is to propose the use of selected quality management techniques in the quality control process made by non-destructive testing. The subject of the research were two products made of steel 410, in which incompatibilities were detected relatively frequently. It was a four-hole flange bearing housing and a gasodynamic sealant. The products mentioned were subjected (according to the quality procedure) to non-destructive testing with two methods: a fluorescent and a magnetic-powder. In order to identify the source cause of incompatibilities the implementation of selected quality management techniques was proposed. These techniques were: 5W2H method, Ishikawa method and 5Why method. Although these methods are simple, they were not used in the enterprise so far. So it was an order to use them, to check their adequacy. By supplementing the non-destructive research with the proposed sequence of selected quality management techniques, it was shown that it is possible to identify the source cause. In addition, by indicating the source cause it is possible to propose improvement actions adequate to the problem. So it will improve the quality of the next products. The proposed solution using the 5W2H method, Ishikawa diagram and 5Why method is complete and easy in practice technique for qualitative analysis to identify the root cause of incompatibility. After using these not complicated methods, it will be effective to use in the appropriate sequence more advanced methods, such as 8D, Six Sigma and DMAIC

Discrepancies analysis of casts of diesel engine piston

The essential material requirement for pistons concerns its parameters at different piston working temperatures at different ambient temperatures. The study employed penetrating tests in quality control of diesel engines used in passenger cars. The aim of the research was to determine the sources of casts discrepancies detected in penetrating test, using traditional quality management tools. Ultimately, the conducted analysis was aimed to reduce the number of non-compliant products or their total elimination

Comprehensive improvement of the surface quality of the diesel engine piston

An important requirement for the material for pistons concerns its parameters at different temperatures of piston operation at different ambient temperatures. The study uses penetration tests in quality control of diesel engine pistons used in passenger cars. The purpose of the tests was to determine, with the use of traditional quality management tools, the sources of incompatibility of castings detected in eddy current testing. The aim of the analysis was to reduce the number of non-compliant products or to eliminate them altogether

Discrepancies analysis of casts of diesel engine piston

The essential material requirement for pistons concerns its parameters at different piston working temperatures at different ambient temperatures. The study employed penetrating tests in quality control of diesel engines used in passenger cars. The aim of the research was to determine the sources of casts discrepancies detected in penetrating test, using traditional quality management tools. Ultimately, the conducted analysis was aimed to reduce the number of non-compliant products or their total elimination

Analysis of the incompatibility of the product with fluorescent method

The aim is to analyze the surface of the product (posterior bearing housing) with using the fluorescent method and to demonstrate the effectiveness of the sequence application like the fluorescent method and instruments of the quality management to analyze the incompatible of the product. In the production enterprise, during the fluorescent penetration test, the incompatibility was identified on the product (posterior bearing housing), i.e. the porosity cluster. The effective of the used the sequence containing the fluorescent method, the Ishikawa diagram and the 5Why method in order to identify incompatibility, and next the source cause was demonstrated. The analyze, the sequence of the methods and the proposed improvement actions can be used in other companies to analyze quality problems