Process Industry with Focus on Steel Essay Sample
1. Introduction
This research addresses application of thin fabrication constructs to the uninterrupted production/process sector with a focal point on the steel industry. After World War II Nipponese industries. peculiarly in the automotive industry. were faced with the quandary of deficits of stuff. fiscal and human resources. Eiji Toyoda and Taiichi Ohno at the Toyota Motor Company on Japan pioneered the construct of Toyota Production System. or what is known as “Lean Manufacturing. “The basic thought behind the system is extinguishing waste. Waste is defined as anything that does non add value to the terminal merchandise from the customer’s position. The primary aim of thin fabrication is to help makers who have a desire to better their company’s operations and go more competitory through the execution of different thin fabrication tools and techniques.
Quickly following the success of thin fabrication in Japan other companies and industries. The term “lean” as Womack and Joness defined it denotes a system that utilizes less in footings of all inputs to make the same end products as those created by a traditional mass production system. while lending increased assortments for the terminal client. Lean is to fabricate merely what is needed by the client. when it is needed and in the measures ordered. The industry of Goods is done in a manner that minimizes the clip taken to present the finished goods. the sum of labor required and the floor infinite required. and it’s done with the highest quality and unusual. at the low cost.
2. History of Lean
Although there are cases of strict procedure thought in fabricating all the manner back to the Arsenal in Venice in the 1450s. the first individual to truly incorporate an full production procedure was Henry Ford. At Highland Park. MI. in 1913 he married systematically interchangeable parts with standard work and traveling conveyance to make what he called flow production. The populace grasped this in the dramatic signifier of the traveling assembly line. but from the point of view of the fabrication engineer the discoveries really went much further. Ford lined up fiction stairss in procedure sequence wherever possible utilizing special-purpose machines and go/no-go gages to manufacture and piece the constituents traveling into the vehicle within a few proceedingss. and present absolutely suiting constituents straight to line-side. This was a genuinely radical interruption from the store patterns of the American System that consisted of all-purpose machines grouped by procedure. which made parts that finally found their manner into finished merchandises after a good spot of puttering ( suiting ) in subassembly and concluding assembly. The job with Ford’s system was non the flow: He was able to turn the stock lists of the full company every few yearss. Rather it was his inability to supply assortment.
The Model T was non merely limited to one coloring material. It was besides limited to one specification so that all Model T human body were basically indistinguishable up through the terminal of production in 1926. ( The client did hold a pick of four or five organic structure manners. a drop-on characteristic from outside providers added at the very terminal of the production line. ) Indeed. it appears that practically every machine in the Ford Motor Company worked on a individual portion figure. and there were basically no conversions. When the universe wanted assortment. including theoretical account rhythms shorter than the 19 old ages for the Model T. Ford seemed to lose his manner. Other car manufacturers responded to the demand for many theoretical accounts. each with many options. but with production systems whose design and fiction stairss regressed toward procedure countries with much longer throughput times. Over clip they populated their fiction stores with larger and larger machines that ran faster and faster. seemingly take downing costs per process measure. but continually increasing throughput times and stock lists except in the rare case—like engine machining lines—where all of the procedure stairss could be linked and automated.
Even worse. the clip lags between procedure stairss and the complex portion routings required of all time more sophisticated information direction systems climaxing in computerized Materials Requirements Planning ( MRP ) systems. As Kiichiro Toyoda. Taiichi Ohno. and others at Toyota looked at this state of affairs in the 1930s. and more intensely merely after World War II. it occurred to them that a series of simple inventions might do it more possible to supply both continuity in procedure flow and a broad assortment in merchandise offerings. They hence revisited Ford’s original thought. and invented the Toyota Production System. This system in kernel shifted the focal point of the fabricating applied scientist from single machines and their use. to the flow of the merchandise through the entire procedure.
Toyota concluded that by right-sizing machines for the existent volume needed. presenting self-monitoring machines to guarantee quality. run alonging the machines up in procedure sequence. open uping speedy apparatuss so each machine could do little volumes of many portion Numberss. and holding each procedure measure notify the old measure of its current demands for stuffs. it would be possible to obtain low cost. high assortment. high quality. and really rapid throughput times to react to altering client desires. Besides. information direction could be made much simpler and more accurate. The thought procedure of tilt was exhaustively described in the book The Machine That Changed the World ( 1990 ) by James P. Womack. Daniel Roos. and Daniel T. Jones. In a subsequent volume. Thin Thinking ( 1996 ) . James P. Womack and Daniel T. Jones distilled these thin rules even further to five: * Specify the value desired by the client
Identify the value watercourse for each merchandise supplying that value and dispute all of the otiose stairss. Presently necessary to supply it * Make the merchandise flow continuously through the staying value-added stairss * Introduce pull between all stairss where uninterrupted flow is possible * Manage toward flawlessness so that the figure of stairss and the sum of clip and information needed to function the client continually falls.
The term “lean” is used because Nipponese concern methods used less human attempt. capital investing. floor infinite. stuffs. and clip in all facets of operations. The resulting competition among U. S. and Nipponese car manufacturers over the last 25 old ages has led to the acceptance of these rules within all U. S. fabrication concerns Lean Today
As these words are written. Toyota. the taking thin example in the universe. bases poised to go the largest car manufacturer in the universe in footings of overall gross revenues. Its dominant success in everything from lifting gross revenues and market portions in every planetary market. non to advert a clear lead in intercrossed engineering. stands as the strongest cogent evidence of the power of thin endeavor. This continued success has over the past two decennaries created an tremendous demand for greater cognition about thin thought. There are literally 100s of books and documents. non to advert 1000s of media articles researching the topic. and legion other resources available to this turning audience.
3. PROBLEM STATEMENT
Major concerns in the United States have been seeking to follow new concern enterprise in order to remain alive in the new competitory market topographic point. Thin fabrication is one of these enterprises that focuses on cost decrease by extinguishing non – value added activities. These tools and techniques of thin fabrication have been widely used in the distinct industry get downing with the debut of the original Toyota production system. Tools include merely in clip. cellular fabrication. entire productive care. individual – minute exchanges of dies and production smoothing have been widely used in distinct parts fabricating sectors such as automotive. electronics and contraption fabrication. Applications of thin fabrication to the uninterrupted procedure industry have been far fewer. In portion. it has been argued that this is because such industries are inherently are more efficient and present comparatively less need for such betterment activities.
Directors have besides been hesitating to follow thin fabrication tools and techniques to the uninterrupted procedure industry because of grounds such as high volume and low assortment merchandises. big inflexible machines and the long set up times that characterize the procedure industry. As an illustration. it is hard to utilize the cellular fabrication construct in a procedure installation due to the fact that equipment is big and non easy to travel. While it seems that some thin fabrication tools are hard to accommodate in the procedure industry. others are non. For illustration Cook and Rogowski ( 1996 ) and Billesbach ( 1994 ) used merely – in – clip constructs at a procedure installation and both reported good consequences. This research is driven by the fact that while researches and practicians have widely used thin fabrication tools in the distinct industry. cipher has consistently investigated how to use thin tools and techniques to a uninterrupted procedure installation due the differences exhibited between the two fabrication environments. In order to vie in today’s planetary competitory market the uninterrupted procedure industry besides needs to look for more ways to derive a competitory border.
The aim is to consistently show how thin fabrication tools when used suitably can assist the procedure industry to:
1. better merchandise quality.
2. better overall fiscal and operational processs.
3. eliminate waste
4. have better stock list control.
The end of this research is to look into how the tools of thin fabrication can be adapted from the discrete to the uninterrupted fabrication environment and to measure their benefits at a specific industrial concern. The research hypothesizes that there are large chances for betterment in the procedure industries if thin tools are utilised. Although the procedure and discrete industry portion several common features. there are besides countries where they are really different. Both fabricating scenes have overlap. but at the extreme. each has its alone features. The aim is to look at commonalties between distinct and uninterrupted fabrication where thin techniques from the distinct side are straight applicable. and to besides analyze ways to make so in other countries where this may non be rather so straightforward.
In this research the steel industry will be used to stand for the uninterrupted procedure industry. and much of the work will be carried out at an existent steel fabricating installation 4. Research Objective
5. RESEARCH APPROACH
The initial measure in this research is to consistently analyze and specify the history of the thin fabrication construct and its different tools and techniques. It will so analyze where most of the thin tools and techniques have been used. This will be followed by a literature reappraisal of the procedure industry and a survey of the findings sing applications of thin constructs to uninterrupted fabrication and the steel industry in peculiar. The following measure is to develop taxonomy of the uninterrupted procedure industry with regard to its merchandise /process features and the comparative balance of distinct and uninterrupted operations. This taxonomy is used to contrast the procedure industry and to characterize the procedure industry distinguishable groups. Following. this taxonomy is used to analyze and place specific thin fabrication tools and techniques that could be applicable. To analyze the consequence of thin tools at a procedure sector the steel industry is used to exemplify the processs of implementing thin tools at a procedure installation. First value watercourse function is used to map the current province for ABS. this is used to place beginnings of waste and so place thin tools to seek to cut down this waste. The future province map is so developed for a system with thin tools applied to it.
