Title: Assignment 4

Author: Ye Chen
Class: IE655 Fall2015
Due Date: November 22nd
eLearning Package ID: IE655-Fall 2015-32-19
Collaboration Companies:
1. MD+DI (Medical Device and Diagnostic Industry)
2. Converting hotline
3. OPEX Corporation
4. Muratec Machinery
Statement: This following assignment is solely done by Ye Chen
Contents
1.

Introduction and Objectives

2.

Methodologies Applied

3.

Main Body of Project

3.1 Sustainable green design, assembly and manufacturing
3.2 Other green design and manufacturing methods
3.3 Questions and answers from chapter 3

3.4 Alternative green sustainable green product design and

PLM Methods
3.5 Collaboration
4.

Summary

5.

Further Work Needed

6.

References

1. Introduction and Objectives

The center of the ICAutomechanic is to furnish clients with high caliber,
renewable, practical energy source. These compartments will be produced
using a renewable asset that is an absolutely biodegradable material and
which won't just be renewable at the same time, is manageable too. The
biodegradable part of the material will guarantee that once the tablets are of
no more use to the designers taking a shot at it, there will be naturally
agreeable choices to discard the material. This can be expert by permitting
the PCs to be fertilizer. It will likewise be able to be brought into landfill
where, regardless of the fact that it is covered, will debase into innocuous
eco-accommodating material. We likewise begin our central goal
remembering to add to a green and supportable environment. Consequently
we have executed the sun oriented force innovation to energize these
gadgets. What's more, with the part of drawing out a top notch result we set
forth polyurethane bundling froth which is exceedingly rough and gives great
insurance to achieve the customer as a qualifying and energizing finished
item. We have likewise utilized Lean innovation for assembling our items,
subsequently lessening the expenses and expanding the income. These will
likewise permit the laborers and this thus will manufacture their eagerness
while working and build their efficiency. This assembling procedure will occur
inside a best in class producing office that is itself a green building. The
carbon foot shaped impression of the building and in addition the assembling
procedure it contains will be minimized. All vitality necessities will be
diminished to a base and there will be a zero landfill approach as a result to
guarantee the plant creates no waste itself.

2. Methodologies Applied
The approachs that ICAutomechanic utilized as a part of the task incorporate
Deming's 14 principles of administration and quality ideas, POKA YOKE,
Kaizen, KANRI, MUDA, MURA, and MURI. Deming's 14 rules ideas serve as the
premise of numerous green CE/PLM techniques, for example, Design for
quality, plan for manufacturability, outline for get together, and plan for
environment. POKA YOKE is an approach in view of Deming's standards which
construct plans, frameworks, and procedures that expect to lessen the
mistakes which people are innately inclined to submit. Kaizen depends on
Deming's standards too which concentrated on progressive change of item
and procedures without losing existing upgrades. Our company would take
after the rule of those routines and execute it orderly began from the
configuration stage to the end of procedure.

3. Main Body of Project

3.1 Sustainable green design, assembly and manufacturing

The objective of ICAutomechanic is creating manageable green items and

meeting the prerequisite of traditions. The strategies of simultaneous building
offer us some assistance with meeting the prerequisites of clients and
upgrade the nature of items, dissecting the information which gathered from
the techniques, enhancing the outline at any stage and assembling
procedures in the workshop. We execute the systems for Concurrent
Engineering and participate with the working together organizations to fulfill
the clients' necessity and continue minimizing the expense as low as could be
expected under the circumstances with green and feasible core interest.

At the first stage, outline stage, ICAutomechanic will meet the necessity of
client to plan the items, with the configuration guidelines and tenets of
industry world, ISO. At the point when ICAutomechanic get the request from
the clients, we will begin to set up a group to plan the items and meet the
prerequisite of clients. The group would begin to employee CAD/CAM
programming to practically plan and reenact the production process,
inquiring about and examining the procedures are outline well or not. At that
point, it can be enhanced and balanced by using the CORA spreadsheet and
PFRA spreadsheet. With the routines for CORA and PFRA spreadsheet, the
group could lessen the procedure disappointment chance and accomplish the
deformity free. The assembling hardware we use in the production line will be
kept up and checked extremely well by the shrewd accuracy gadget. Amid
the assembling and get together stage, the procedure would be composed
and enhanced to deliver items effectively with imperfection free. The
discharge, which would be created from the procedure, will be de
disintegrated to not hurtful gas and synthetic. The waste would be decreased
by the well-plan and proficient procedures. All the procedure and discharge
will take after and keep up the most noteworthy estimations of national and
worldwide standard. Likewise, in those stage, the association will employee
KAISEN strategy, which is a Japanese method alluding to continuous item
outline and process change, to diminish MUDA, MURA and MURI, the three
sort of issues for expanding the nature of items.
3.2 Other green design and manufacturing methods
We will utilize special design to mimic the assembling procedures and the
work process ways. This will lessen the material taking care of expense and in
the meantime decrease achieving so as to work cost and machine run times
there a control over force use. This will indicate the Green center of the
organization. For our assembling firm, most manageability activities
concentrate on operational exercises fabricating items utilizing less materials
and vitality, yet better administration of surplus and unmoving gear can
likewise have a noteworthy effect. Our item offers us some assistance with
improving maintainability, by giving a stage that incentivizes everybody in
the association to get included in the administration of surplus and unmoving
resource.

3.3 Questions and answers from chapter 3

1) Explain the Deming's 14 Rules of Management and Quality Concepts and
how Deming's 14 Rules affect our concurrent engineering mission?
Answer - The Deming's 14 rules:1. Managers should create consistency and continuity of purpose for the
improvement of products and services.
2. Leaders have to refuse to allow commonly accepted levels of mistakes,
defects.
3. Building quality into the first phase to eliminate the need for and
dependence upon inspection.
4. Team should reduce the number of suppliers and do the business base on
statistical evidence, not on price.
5. Team must continually search problems in the system and seek ways to
improve it in order to decrease cost.
6. Organization has to set up modern methods of training and education on
the job for creating good products.
7. Organization needs to focus on leadership and supervision to help workers
do a better job.
8. Organization encourages open, honest, constructive communication and
eliminates fear in the company.
9. Organization has to break down barriers between departments.
10. Team should eliminate the use of numerical goals, slogans and posters for
the workers
11. Team use statistical methods to improve quality and eliminate standards
prescribing numerical quotas.
12. Let workers talk freely and discuss issues as they occur.
13. Organization institutes a program of regular education to keep workers
following new developments.
14. Leaders clearly define managements permanent commitment to quality
and productivity and assure the transformation is everybodys job.

2) What are the advantages of design for quality, manufacturing and

assembly?
Answer Due to increasing competition in market quality assurance has
become more than a necessity. In order to achieve so, a perfect design in
advance should be formed by engineers. This design also contains the details
for manufacturing and assembly of the product. It helps in eliminating defects
in advance.

3) What are the advantages of using minimum parts in a design?

Answer Advantages of having minimum parts in a design are:-

Minimum number of parts in an assembly makes it simple.

It is easy to carry out maintenance on assemblies with fewer parts.
The cost of assembly decreases.
Cost of testing and processes required to carry out quality assurance
reduces.
Manufacturing processes become easy.

4) What is Poka-Yoke?
Answer - POKA-YOKE is a Japanese term which means mistake-proofing. It
mainly involves the elimination of human error and aiming for zero defects at
all levels of work. Its purpose is to eliminate product defects by preventing,
correcting, or drawing attention to human errors as they occur .In other words
designs and work practices should be such that error is eliminated. This
concept assumes people inherently make mistakes but by creating designs,
technology, systems, and procedures that focus on the elimination of these
errors, an error free organization can be achievable.

5) How does Kaizen help an organization?

Answer - KAIZEN is a Japanese term which means gradual product design and
process improvement over time. It is gradual improvement by breaking
through the current ways but still maintaining current improvements as
gradual improvements are applied. The aspects include the acceptance that
problems exist, acting as a team, and identification of problems.

6) What is the importance of Design for Demanufacturing, disassembly and

virtual product disassembly?
Answer - Demanufacturing involves the disassembly and recycling of obsolete
consumer products. When a product reaches the end of its life it can be
broken down and reused or disposed of. The idea of design for
demanufacturing is that you take into account during the design phase the
product may need to be broken down into reusable components or to be
disposed of. There are also products that may require demanufacturing
because it cannot be disposed of without separating toxic components.
Products like cars may need to be disassembled frequently for maintenance.
Tools such as virtual product disassembly can be in the form of software tools
which can assist with the breakdown of parts for visualization without going
through the physical process. The disassembly can be modeled using this
tool for various purposes.

7) What is Quality circle?

Answer - A quality circle is a group of workers who do the same or similar
work, who meet regularly to identify, analyze and solve work-related
problems. Typical topics for the attention of quality circles are

improving occupational safety and health, improving product design, and

improvement in the workplace and manufacturing processes.

8) What is MUDA, MURA and Muri?

Answer - Muda means waste. It includes all those factors which do not
contribute in the process and decrease the quality of project or increase the
cost and time of the project.
Mura means unevenness; irregularity; lack of uniformity; non-uniformity;
inequality. It occurs due to lack of inventory or man power at any point during
the process. It increases the process time and reduces profits.
Muri means unreasonableness; impossible; beyond one's power; too difficult;
by force; perforce; forcibly; compulsorily; excessiveness; immoderation. It can
be eliminated by planning the way in a standard way. Standardization is
nothing but making things easy for everyone to carry out.

9) What are the steps of Kanri?

KANRI is a Japanese term which means quality control is the responsibility of

the entire company from top level management to the factory floor to
develop, design, manufacture, inspect, market and service products to the
satisfaction of customers at the time of purchase and beyond. Furthermore it
means the continual check on processes to ensure they are meeting
standards and well tested procedures. The four steps include:
Plan Setting the criteria for controls and objectives
Do Perform operations per procedures and standards.
Check verify and study the results of the operation
Action Take actions based on the result.

10) What are CNC machines?

Answer Computer numerical control machine is the automation of machine
tools that are operated by precisely programmed commands encoded on
storage medium, as opposed to controlled manually via hand wheels or
levers, or mechanically automated via cams alone, operated through a

computer. These machines are highly accurate. They are really useful for
mass production. The initial cost of this machine is high. Due to high
production rate the initial cost can be recovered really fast and makes it
worth every penny.

3.4 Alternative green sustainable green product design and

PLM Methods
As people in general turns out to be more mindful of natural issues and a
dangerous atmospheric devotion, shoppers will be getting some information
about the items they are buying. Organizations will need to expect questions
about how green their assembling procedures and store network are, their
carbon foot shaped impression and how they reuse. The standard of Green
Supply Chain is that organizations enhance ecological execution.
Organizations have looked to their inventory network and seen zones where
enhancements in the way they work can do the commitment to nature. We
will apply the green inventory network system to accomplish the Green core
interest. We will concentrate on the carbon foot shaped impression,
diminishing the seasons of conveyance and acquiring material. Thusly, the
expense of conveyance will be lessened and ICAutomechanic accomplishes
the commitment for the earth.
Amid the configuration and improvement of new items, fashioners and
designers depend on the base up and top-down systems. The rule of the
routines is beneath: The base up strategy is using existing segments which
are chosen and incorporating into the item. The top-down strategy, a custom
procedure, would be planned such that it would fit legitimately in the getting
parts. In industry world, it's more critical to minimize cost and expand
segment accessibility, for example, with assembling gear, a more base up
methodology would be taken, and whatever number off-the-rack segments
would be chosen as could be allowed. Hence, we would apply the base up
strategy to amass our items to minimize the expense of operation and build
the accessibility of part to enhance the nature of items.

3.5 Collaboration
ICAutomechanic works together with four organizations, which named New
York International Automobile Show, TRUMPF, Mayfran International and APC
by Schneider Electric. Those organizations are agreeable and accommodating
for supporting us what we require in our procedures and configuration. The
strategies we use on the venture will be actualized and consolidate with our
companions. We utilize KANRI strategy to arrange and outline forms. At that

point, as per the outcome which we got from the exploration, we buy the
supplies, which can fit in our procedures appropriately, from TRUMPF,
Mayfran International and APC. Further, we connected POKA-YOKE system to
buy the materials and devices from them to keep the human blunder which
may deliver amid the assembling and amassing procedures. In this way, by
participating with our buddies, we can meet the prerequisite of clients and
enhance our nature of items.

4. Summary
The systems we utilized on the undertaking are valuable for ICAutomechanic
to deliver top notch and green maintainable items, and it assist us with
meeting so as to satisfy our clients their necessity without stream on our
items. Along these lines, the objective of ICAutomechanic could be
accomplished by actualize and apply it. Those techniques ought to be
regarded as fundamental criteria and standard of procedure for us to serve
clients in the aggressive business sector.

5. Further Work Needed

ICAutomechanic will keep continuous screen our procedures to guarantee the
nature of items is enhanced and keep up on the same level. All the strategies
and apparatuses which appear on the web and digital book are valuable and
accommodating for us to serve our clients. In this manner, we have to keep
redesign our information and exploration for enhancing our items and serving
in the competitive market on the planet.

6. Reference
http://www.cimwareukandusa.com/All_IE655/IE655Fall2015.html
IE655 Fall 2015 ELearning Package
http://www2.cleantechopen.org/
http://www.cleantech-syndicate.com/