Thai Industrial Engineering Network Journal

Defect Reduction in Nylon Fibers Manufacturing Process

Suphattra Sriyanalugsana, Pannaphat Punnaphasasiphas — Sun, 30 Jun 2024 00:00:00 +0700

This research aims to reduce the number of defects in the manufacturing process of nylon synthetic fibers. The approach involves using a fishbone diagram to analyze the root causes of the problem, Pareto charts to prioritize the issues, ECRS principles, and factorial experimental design for process improvement. Through data collection and analysis, it was found that the most significant defects were attributed to ‘yarn breaks’ and ‘pack changes’. After using the Fishbone Diagram and brainstorming, it was discovered that the main causes of yarn breaks were related to blockages in the Exhaust Monomer tube, Godet Roller, and Yarn Path. This issue was addressed by refining work instructions, creating inspection sheets, and scheduling regular checks on the Godet Roller. The main reasons for pack changes were found to be the lack of work instructions and the incorrect assembly of the polymer filter following standards. This issue was addressed by reducing the duration of work processes, implementing work instructions, and using Factorial experimental design setups to determine the optimal interval for pack changes. As a result of these improvements, the defect percentage decreased from 6.51% to 5.84%, resulting in an annual cost reduction of 199,800 baht and the potential extension of the improvement methods to other departments.

Effect of Face Milling Parameters on Surface Roughness of ADC 12 Aluminum Alloy Using 3 Levels Full-Factorial Design

Sun, 30 Jun 2024 00:00:00 +0700

The purpose of this study aims to determine the influence of machining parameters which were consisted of three parameters; feed per tooth, cutting speed and depth of cut on surface roughness in CNC face milling process of ADC 12 aluminum alloy. The settings of machining parameters were conducted through 3 levels full-factorial design with 2 replicates. In addition, CNC machining center and carbide insert were fitted together with milling cutter which 63 millimeters of diameter, under wet cutting condition. The surface roughness of end-milled face was measured by the surface roughness tester. It was found that the most influence main factor was feed per tooth, followed by cutting speed. It was also found that interaction between cutting speed and feed per tooth, cutting speed and depth of cut as well as feed per tooth and depth of cut also impact the surface roughness. In contrast, Depth of cut was not affected on surface roughness at significant level of 0.05. Moreover, the minimum of surface roughness value was obtained with 800 m/min of cutting speed, 0.05 mm/tooth of feed rate and 0.6 mm of depth of cut which result 0.142 of Ra.

Improving the Production Process of Line Gen for Furniture Production

Suphattra Sriyanalugsana, Kitikul Punsri — Sun, 30 Jun 2024 00:00:00 +0700

Furniture is an important part of home and condo decoration. The case study factory is a furniture factory where the Line Gen production process is responsible for producing sample furniture as well as managing various repairs and work that is returned for repairs. The production process focuses on the speed of production. Currently, there are problems with returns and rejected work in the production process of Line Gen. There were errors in determining delivery dates and preparing raw materials for production, including the lack of clear coordination among each relevant department, resulting in production work exceeding the delivery deadline. There were thus delays in the production of furniture. Therefore, in order to solve these problems, this research has prepared a standard work manual (Work Instructions: WI) and a production sequence plan checklist, including capacity analysis. The results show that before the improvement, 80 returned jobs were generated, of which 38 exceeded the transfer date of 47.5%, and the number of days beyond the average transfer period was 2.42 days. After the improvement, 68 jobs were returned, 17 of which exceeded the transfer deadline (25%), and the days beyond the transfer deadline decreased on average to 1.47 days. In the case of rejecting jobs before improvement, there was a total of 96 jobs, 77 of which were beyond the transfer date of 80.2%, and the number of days beyond the average transfer period was 4.56 days. After improvements, there were 98 rejected jobs, with 49 jobs exceeding 50% of the transfer date, and we were able to reduce the average transfer overdue days to 2.24 days.

Schedule an Ambulance to Transport Plague Patients to the Quarantine Hospital Using Multiple 0–1 Knapsack Problem

Sun, 30 Jun 2024 00:00:00 +0700

The outbreak of the novel coronavirus disease Corona 2019 (COVID-19) has been in Wuhan, China since November 2019 and has spread to more than 160 countries around the world. As a result, the need to call for ambulances has increased from the incident. Found that there are many patients who do not have an ambulance to pick them up after finding themselves with symptoms similar to the new coronavirus disease Corona 2019 (COVID-19). It should find ways to improve the ambulance system to be able to respond to future epidemic incidents. Therefore, this study proposes the scheduling of epidemic patient transfers to quarantine hospitals for handling potential future epidemics using multiple 0–1 knapsack problem in scheduling simulations. An ambulance to transport the patient to the hospital for quarantine. By scheduling an ambulance, the goal is to maximize the effectiveness of prioritizing patients in relation to their health status.

Process Improvement for Combining Production Lines with Work Study and Line Balancing Techniques: A Case Study of Stereo Manufacturer

Poom Luangjamekorn, Siravit Swangnop, Todsaporn Kulngamnet — Sun, 30 Jun 2024 00:00:00 +0700

An objective of this research is to study and improve the production process to reduce the usage of production area by combining production lines. A case study factory was a stereo manufacturer which needed the area for a new production line. A methodology started from studying and analyzing each production process, then choosing the production line to be removed and finally improving the production line to receive products from the removed production line. Main concepts for analysis and improvement consisted of work study, capability analysis and line balancing. The selected production lines to be combined considered from capacity utilization rate and limitations of the equipment and machine. An improvement of the production line to receive products from the removed production line was to sequence tasks to stations by considering line balancing, cycle time and production conditions. After reducing the line and improving the process, the factory had an additional area as expected and could move the product to produce in another line without any problems. In addition, reducing the production line and moving products to be produced in another line also increased capacity utilization rate from 32 % to 55%.

The Improving Productivity in Seasonal Product Manufacturing by Motion and Time Study and Jig Design

Sun, 30 Jun 2024 00:00:00 +0700

Increasing productivity is key to fulfilling customer requirements and remaining competitive in today's fast-paced business world. The purpose of this research was to increase the productivity of sprinkler parts. Through the analysis of motion and time, it was discovered that the leaf stamping process and the leaf and stalk arc stages exceeded the Takt time. To address this issue, left-right hand charts and jig design were used to minimize work waste. The research yielded a reduction in the processing time of the leaf stamping process from 7.07 seconds to 3.02 seconds, a reduction of 57.25 percent, and the stem and leaf arc process time was reduced from 7.77 seconds to 2.97 seconds, a reduction of 61.78 percent, respectively. These improvements helped the company in the case study to produce according to customer demand and reduce its inventory levels.

Appropriate Factors for Forming Packaging with 3D Printing Technology

Chalida Chanwichit, Potiwat Ngamkajornwiwat — Sun, 30 Jun 2024 00:00:00 +0700

This research aims to determine the optimal parameter settings for a 3D printer used in manufacturing packaging boxes through experimental design. The current manufacturing process has encountered issues with incomplete part formation, leading to delays in delivery to customers due to the robot's inability to pick and deliver parts. The root causes were identified using a Cause & Effect diagram analysis, which revealed that the incomplete part formation was mainly impacted by nozzle temperature and bed temperature. A full factorial experimental design investigated these factors at three levels each, showing significant effects of nozzle temperature on part formation. The optimal settings for both factors were found to be a nozzle temperature of 235°C and bed temperature of 70°C resulting in a substantial reduction of defects from 90% to 16.68%, representing a remarkable decrease of 73.32% in defects.

Efficiency Improvement of Cooking Stove Process Using Waste Reduction by ECRS Principle

Sun, 30 Jun 2024 00:00:00 +0700

This research studies and improves the efficiency of the cooking stove production process to reduce waste. A study of the production workflow reveals that the honeycomb-making step involves non-value-added activities, resulting in delays due to waiting, transportation, and over motion, respectively. For these issues, The ECRS principle select to eliminate non-necessary; design and manufacture for the steps. The honeycomb punching mold is the assistance device by design and construction engineering. In this step combines a compress plate molding and punching steps. After the improvements, the honeycomb-making activities reduces from 14 to 11 and the work time decreases from 6,100.75 minutes per piece to 4,657.35 minutes per piece (23.66% of work efficiency). Additionally, the cycle time of the cooking stove production process reduces from 6,102.45 minutes per unit to 4,662.45 minutes per unit.

Factors of Success in Developing New Car Window Visors

Munyaporn Pooripanyakun — Sun, 30 Jun 2024 00:00:00 +0700

The successful design and development process of the product is a challenge for organizations. In the case study company, a small industrial business that designs and manufactures interior and exterior plastic parts for automobiles, initiated a project to develop a new pattern of car window visor in order to transform from an OEM (Original Equipment Manufacturer) to an OBM (Original Brand Manufacturer) or to produce under its own style and brand. The case study company successfully implemented the project and was able to quickly introduce innovative new products to the market before new competitors emerged. This research aims to study the various factors used in developing a new pattern of car window visor (car awning trim) and analyze the factors affecting the success of the project. The researcher studied the development process of the new pattern of car window visor (car awning trim) of this case study company. The resource data and related details were collected using secondary data obtained from two previous research articles under the project of developing a new car window visor product of the case study company. The researcher also analyzed the data on various factors that are used in this project. To summarize the factors affecting the success of the project, it was found that the key success factors have 5 elements called ‘SEPIC’, which come from Speed of each process, Equipment support, Person involved, Innovation, and Capital strength.