62 research outputs found
A new Lean tool for efficiency evaluation in SMED projects
No full textThe ability of companies to rapidly conduct a changeover from one product to another as part of a production process is a fundamental step towards a more flexible production system that can deal with an increasingly dynamic and competitive market. Single-Minute Exchange of Die (SMED) is the best-known lean tool that aims to reduce time consumption in the changeover process. This paper presents a new Lean tool called Set-up Saving Deployment (SSD), which improves set-up efficiency by classifying, analyzing, and removing set-up losses within a changeover process, and which supports decision-making for SMED implementation. SSD uses three matrices, constructed sequentially from the first (L-Matrix) to the last (ECE-Matrix), in order to assess the possible time savings that can be achieved by eliminating losses and, in addition, to forecast possible improvements resulting from implementing a SMED project. SSD also provides a new basket of tailored set-up efficiency indicators that allow the analysis team to correctly assess set-up efficiency, and compare the 'as is' condition with the subsequent 'to be' condition from an operational perspective. The effectiveness of SSD in addressing set-up losses and predicting time savings is illustrated using an industrial case study of a resin doming machine. Thanks to its structured step-by-step procedure, SSD significantly improves the efficiency of the changeover process
A new lean tool for design management: design cost deployment
No full textThe design process wields substantial influence across various dimensions in product's life cycle, encompassing functionality, manufacturability, assembly, safety and numerous other facets. Consequently, it represents a significant contributor to the product's overall cost. Enhancing the design process translates into accessing diverse opportunities within an ever-competitive market landscape. This paper introduces a novel lean framework explicitly that pinpoints and eradicates losses occurring during the design phases using an Overall Design Effectiveness (ODE) metric that assesses the performance of a company's technical department. Our Design Cost Deployment (DCD) lean toolkit then identifies, analyses and eliminates design-related losses. The DCD implementation involves five core steps, each necessitating a purpose-built matrix for loss detection, cause-effect relationship investigation, cost quantification related to losses and guidance for decision-making in the context of improvements. This framework was tested in a real-world industrial scenario, involving a mechanical manufacturing company and was both to use straightforward and effective in its results
A new set of Lean indicators to assess Greenhouse Gas emissions related to industrial losses
No full textPurpose – This paper presents a new and well-structured framework that aims to assess the current environmental impact from a Greenhouse Gas (GHG) emissions perspective. This tool includes a new set of Lean Key Performance Indicators (KPIs), which translates the well-known logic of Overall Equipment Effectiveness in the field of GHG emissions, that can progressively detect industrial losses that cause GHG emissions and support decision-making for implementing improvements.
Design/methodology/approach – The new metrics are presented with reference to two different perspectives: (1) to highlight the deviation of the current value of emissions from the target; (2) to adopt a diagnostic orientation not only to provide an assessment of current performance but also to search for the main
causes of inefficiencies and to direct improvement implementations.
Findings – The proposed framework was applied to a major company operating in the plywood production sector. It identified emission-related losses at each stage of the production process, providing an overall performance evaluation of 53.1%. The industrial application shows how the indicators work in practice, and the framework as a whole, to assess GHG emissions related to industrial losses and to proper address improvement actions.
Originality/value – This paper scrutinizes a new set of Lean KPIs to assess the industrial losses causing GHG emissions and identifies some significant drawbacks. Then it proposes a new structure of losses and KPIs that not only quantify efficiency but also allow to identify viable countermeasures
Quick Changeover Design: a new Lean methodology to support the design of machines in terms of rapid changeover capability
No full textPurpose - This paper presents Quick Changeover Design (QCD), which is a structured methodological approach for Original Equipment Manufacturers, to drive and support the design of machines in terms of rapid changeover capability.
Design/methodology/approach - To improve the performance in terms of set up time, QCD addresses machine design from a Single-minute digit exchange of die. Although conceived to aid the design of completely new machines, it can be adapted to support for simple design upgrades on pre-existing machines. The QCD is structured in three consecutive steps, each supported by specific tools and analysis forms to facilitate and better structure the designers’ activities.
Findings - QCD helps equipment manufacturers to understand the current and future needs of their customers to: (i) anticipate the requirements for new and different set-up process; (ii) prioritize the possible technical solutions; (iii) build machines and equipment that are easy and fast to set-up under variable contexts. When applied to a production system consisting of machines subject to frequent or time-consuming set-up processes, QCD enhances both responsiveness to external market demands and internal control of factory operations.
Originality - The QCD approach is a support system for the development of completely new machines and is also particularly effective in upgrading existing ones. Its practical application is demonstrated using a case study concerning a vertical spindle machine
A new lean tool to enhance internal logistics in Engineer and Design-to-Order industrial environment - plan for every order
No full textThe paper presents a new Lean Logistics tool specifically designed for Engineer and Design-To-Order (ETO and DTO) industrial environments. The new tool, namely Plan For Every Order (PFEO), conceptually derives from the well-known Plan For Every Part used in the automotive serial production context. PFEO is proposed as a tool for industrialization, focusing on the design and logistics optimization of internal material flows at ETO and DTO plants. In the paper, the principles, and concepts behind PFEO are presented and developed. The tool collects information on both suppliers and materials, improving both the management of materials and spaces and communication between the company and suppliers. The operability of the tool is proven in a real business case involving an shipyard. The PFEO has provided a solid database for the development of auxiliary monitoring and visualization tools, the application of which increases order in the warehouse and assembly areas and reduces costs and errors
Conciliare sicurezza alimentare e impatti ambientali: Water Footprint di scenari di produzione agricola nella Striscia di Gaza
No full textIl presente studio analizza gli impatti ambientali e, in particolare, l’impronta idrica della produzione agricola
su piccola scala nella Striscia di Gaza, area in cui le risorse naturali sono scarse, la densità demografica è
molto elevata e buona parte della popolazione soffre di insicurezza alimentare. L’analisi confronta in una
prospettiva di ciclo di vita una serie di scenari di rotazione colturale in termini di Water Footprint e di impatto
ambientale, valutato mediante il metodo ReCiPe. I risultati mostrano discordanze tra gli ordinamenti dei diversi
scenari ottenuti mediante le due metodologie. Viene, inoltre, valutata l’opportunità di affiancare alla
produzione agricola l’acquacoltura basata sull’utilizzo dei bacini di accumulo dell’acqua piovana allo scopo di
migliorare l’approvvigionamento proteico della popolazione. Risultati preliminari suggeriscono che tale attività
non sia una soluzione efficiente in termini di consumi idrici, a causa degli elevati tassi di evaporazione
Applicazione principi di lean manufacturing in un'azienda specializzata nella produzione di carta Tissue: il caso Sofidel.
No full textPartendo dall’analisi dei fermi macchina della linea di produzione di Converting presso lo stabilimento Soffass di via Fossanuova, si svilupperanno le correlazioni causa/effetto tra fermo e intervento. L’obiettivo consta nello sviluppo di un upgrade dell’attuale sistema di Supervisione per il miglioramento dell’analisi relativa all’individuazione della causa radice dei fermi macchina, da un lato, e la formazione dell’operatore alla risoluzione dei problemi dall’altro
Exploring the relationship between Project Cost Deployment and Industry 4.0 through an industrial application in an Engineer-to-Order environment
No full textThe literature on Lean Manufacturing has predominantly emphasized mass production and batch systems, leaving a considerable knowledge gap regarding the challenges and considerations specific to implementing Lean principles in Engineer-to-Order (ETO) manufacturing contexts. This paper addresses this gap by exploring the interaction between Project Cost Deployment (PCD), a tailored method for ETO environments, and the digital technologies of Industry 4.0. The research aims to identify the synergies between Lean Manufacturing and Industry 4.0, investigating how their integration can enhance productivity, quality, and competitiveness in the manufacturing industry. While Lean Manufacturing is adept at addressing loss reduction and elimination across various industrial contexts, Industry 4.0 leverages digital technologies to revolutionize manufacturing operations and enable more efficient and intelligent production systems. The paper demonstrates the effectiveness of the PCD method through an industrial application involving an international company specializing in customized paper converting machinery and lines. By utilizing PCD in conjunction with Industry 4.0 technologies, analysts were able to uncover hidden losses and quantify them from an economic perspective, while also evaluating the potential impacts of improvement activities. The results highlight the significance of synergizing Lean Manufacturing and Industry 4.0 for ETO environments, offering valuable insights into how digital technologies can be effectively integrated into Lean principle
A preliminary framework to address the industrial environmental challenge
No full textGrowing awareness of the need to enhance environmental performance resonates across various industrial sectors. However, efforts toward sustainability remain inadequate, especially given the pressing issue of Climate Change. To address this, this paper introduces a novel preliminary approach grounded in Lean Thinking principles, featuring a structured three-step process enhanced with visual tools. Step one involves pinpointing the green sustainability measures and their deployment locations, facilitating the identification of urgent actions. Step two delves into identifying potential barriers that could hinder measure adoption, resulting in a refined set of implementable actions for greater improvements. Finally, in the third step, we select and prioritize the most viable measures, accounting for case-specific factors like costs and their impact on environmental performance. This study culminates in a real-world application within a luxury plywood production company, illustrating the framework's ability to align environmental objectives with economic success by avoiding unprofitable choices
{EPR studies of new mesostructured silica synthesis and hemoglobin encapsulation}
No full textEnzyme encapsulation in ordered porous silica has been modified by introducing a natural surfactant such as lecithin during the sol-gel process. beta-lactose has been used as the enzyme protecting agent and tetraethoxysilane as the source of Silica in all hydroalcoholic media. In the present study, the EPR spectroscopy of paramagnetic probes has allowed to monitor the formation of mesophases and the condensation of silica in all isotropic three-dimensional structure, named Sponge Mesoporous Silica, with a pore size of 6 nm and a specific Surface area of 600 m(2)/g. Different techniques of characterization (nitrogen sorption, XRD, TEM, SEM) have been used to study the influence of the different reactants oil the. structure of the materials. Hemoglobin has been encapsulated in the different materials and its catalytic pseudo peroxydase activity has been evaluated
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