Manufacturing and enterprise: an integrated systems approach PDF
Preview Manufacturing and enterprise: an integrated systems approach
Manufacturing and Enterprise An Integrated Systems Approach Systems Innovation Series Series Editor Adedeji B. Badiru Air Force Institute of Technology (AFIT) – Dayton, Ohio Systems Innovation refers to all aspects of developing and deploying new technology, methodology, techniques, and best practices in advancing industrial production and economic development. This entails such topics as product design and development, entrepreneurship, global trade, environmental consciousness, operations and logis- tics, introduction and management of technology, collaborative system design, and product commercialization. Industrial innovation suggests breaking away from the traditional approaches to industrial production. It encourages the marriage of systems science, management principles, and technology implementation. Particular focus will be the impact of modern technology on industrial development and industrializa- tion approaches, particularly for developing economics. The series will also cover how emerging technologies and entrepreneurship are essential for economic development and society advancement. Defense Innovation Handbook Guidelines, Strategies, and Techniques Edited by Adedeji B. Badiru and Cassie Barlow Productivity Theory for Industrial Engineering Ryspek Usubamatov Quality Management in Construction Projects Abdul Razzak Rumane Company Success in Manufacturing Organizations A Holistic Systems Approach Ana M. Ferreras and Lesia L. Crumpton-Young Introduction to Industrial Engineering Avraham Shtub and Yuval Cohen Design for Profitability Guidelines to Cost Effectively Manage the Development Process of Complex Products Salah Ahmed Mohamed Elmoselhy Handbook of Measurements Benchmarks for Systems Accuracy and Precision Edited by Adedeji B. Badiru, LeeAnn Racz Global Engineering Design, Decision Making, and Communication Carlos Acosta, V. Jorge Leon, Charles R. Conrad and Cesar O. Malave For more information about this series, please visit: https://www.crcpress.com/ Systems-Innovation-Book-Series/book-series/CRCSYSINNOV Manufacturing and Enterprise An Integrated Systems Approach by Adedeji B. Badiru, Oye Ibidapo-Obe, and Babatunde J. Ayeni CRC Press Taylor & Francis Group 6000 Broken Sound Parkway NW, Suite 300 Boca Raton, FL 33487-2742 © 2019 by Taylor & Francis Group, LLC CRC Press is an imprint of Taylor & Francis Group, an Informa business No claim to original U.S. Government works Printed on acid-free paper International Standard Book Number-13: 978-1-4987-4488-1 (Hardback) This book contains information obtained from authentic and highly regarded sources. Reasonable efforts have been made to publish reliable data and information, but the author and publisher cannot assume responsibility for the validity of all materials or the consequences of their use. The authors and publishers have attempted to trace the copyright holders of all material repro- duced in this publication and apologize to copyright holders if permission to publish in this form has not been obtained. If any copyright material has not been acknowledged, please write and let us know so we may rectify in any future reprint. Except as permitted under U.S. Copyright Law, no part of this book may be reprinted, repro- duced, transmitted, or utilized in any form by any electronic, mechanical, or other means, now known or hereafter invented, including photocopying, microfilming, and recording, or in any information storage or retrieval system, without written permission from the publishers. For permission to photocopy or use material electronically from this work, please access www. copyright.com (http://www.copyright.com/) or contact the Copyright Clearance Center, Inc. (CCC), 222 Rosewood Drive, Danvers, MA 01923, 978-750-8400. CCC is a not-for-profit organiza- tion that provides licenses and registration for a variety of users. For organizations that have been granted a photocopy license by the CCC, a separate system of payment has been arranged. Trademark Notice: Product or corporate names may be trademarks or registered trademarks, and are used only for identification and explanation without intent to infringe. Library of Congress Cataloging ‑ in ‑ Publication Data Names: Badiru, Adedeji Bodunde, 1952- author. | Ibidapo-Obe, Oye, author. | Ayeni, Babatunde J., author. Title: Manufacturing and enterprise: an integrated systems approach / by Adedeji B. Badiru, Oye Ibidapo-Obe, and Babatunde J. Ayeni. Description: Boca Raton : CRC Press/Taylor & Francis, [2019] | Series: Systems innovation series Identifiers: LCCN 2018039375| ISBN 9781498744881 (hardback : acid-free paper) | ISBN 9781498744898 (ebook) Subjects: LCSH: Manufacturing processes. Classification: LCC TS183 .B33 2019 | DDC 670--dc23 LC record available at https://lccn.loc.gov/2018039375 Visit the Taylor & Francis Web site at http://www.taylorandfrancis.com and the CRC Press Web site at http://www.crcpress.com Contents Preface ................................................................................................................xv Acknowledgment ..........................................................................................xvii Authors .............................................................................................................xix Chapter 1 Modern and traditional manufacturing processes ..............1 Introduction ........................................................................................................1 What is 3D printing? ..........................................................................................2 Definition of manufacturing and its impact on nations ..........................3 Manufacturing processes and process planning ..........................................4 Manufacturing processes .............................................................................4 Process planning and design.......................................................................4 Traditional manufacturing processes .............................................................7 Casting and molding processes ..................................................................7 Bulk forming processes ..............................................................................10 Sheet forming processes .............................................................................13 Polymer processes .......................................................................................14 Machining processes ..................................................................................17 Assembly and joining processes ...............................................................18 Finishing processes .....................................................................................19 Non-traditional manufacturing processes ...................................................19 Manufacturing systems ..................................................................................21 Interchangeability and assembly operations ..........................................22 Systems metrics and manufacturing competitiveness ..........................22 Automation of systems ...............................................................................23 Conclusions .......................................................................................................24 References .........................................................................................................24 Chapter 2 Manufacturing enterprise and technology transfer ............27 Introduction ......................................................................................................27 Characteristics of technology transfer ..........................................................27 Emergence of new technology .......................................................................31 Technology transfer modes ............................................................................34 Technology change-over strategies ..........................................................36 v vi Contents Post-implementation evaluation ....................................................................37 Technology systems integration ....................................................................37 Role of government in technology transfer .................................................38 US templates for technology transfer ............................................................39 Pathway to national strategy ..........................................................................41 Using PICK chart for technology selection ..................................................44 PICK chart quantification methodology ..................................................46 DEJI model for technology integration .........................................................47 Design for technology implementation ........................................................48 Evaluation of technology ................................................................................50 Justification of technology ..............................................................................51 Integration of technology ................................................................................51 Conclusion .........................................................................................................53 References .........................................................................................................53 Chapter 3 Manufacturing cost analysis ..................................................55 Cost concepts and definitions ........................................................................55 Cost and cash flow analysis ............................................................................57 Time value of money calculations ............................................................58 Compound amount factor .....................................................................58 Present worth factor ...............................................................................58 Uniform series present worth factor ....................................................59 Uniform series capital recovery factor ................................................59 Uniform series compound amount factor ..........................................60 Uniform series sinking fund factor .....................................................61 Capitalized cost formula .......................................................................61 Arithmetic gradient series ....................................................................62 Increasing geometric series cash flow .................................................63 Decreasing geometric series cash flow ................................................64 Internal rate of return ............................................................................65 Benefit-cost ratio .....................................................................................66 Simple payback period ..........................................................................66 Discounted payback period ..................................................................67 Investment life for multiple returns ....................................................68 Effects of inflation .......................................................................................69 Mild inflation ...............................................................................................72 Moderate inflation ..................................................................................73 Severe inflation .......................................................................................73 Hyperinflation ........................................................................................73 Break-even analysis .........................................................................................73 Example ........................................................................................................74 Profit ratio analysis ..........................................................................................75 Amortization analysis .....................................................................................78 Example ........................................................................................................80 Contents vii Manufacturing cost estimation ......................................................................82 Budgeting and capital allocation ...................................................................83 Top-down budgeting ..................................................................................84 Bottom-up budgeting .................................................................................84 Mathematical formulation of capital allocation ......................................84 Example....................................................................................................85 Cost monitoring................................................................................................88 Project balance technique ...............................................................................89 Cost control system ..........................................................................................89 Sources of capital ..............................................................................................91 Activity-based costing .....................................................................................93 Conclusion .........................................................................................................94 References .........................................................................................................94 Chapter 4 Learning curves in manufacturing operations ...................95 Introduction ......................................................................................................95 Half-life theory of learning curves ................................................................95 Human-technology performance degradation ............................................97 Half-life derivations .........................................................................................98 Half-life of the log-linear model ................................................................99 Half-life computational examples ...............................................................101 The S-curve model ....................................................................................101 The Stanford-B model ...............................................................................102 Badiru’s multi-factor model .....................................................................103 DeJong’s learning formula .......................................................................104 Levy’s technology adaptation function. ................................................106 Glover’s learning model ...........................................................................106 Pegels’ exponential function....................................................................107 Knecht’s upturn model .............................................................................108 Yelle’s combined technology learning curve ........................................109 Aggregated learning curves ....................................................................109 Half-life of decline curves ..............................................................................110 Conclusion .......................................................................................................112 References ........................................................................................................113 Bibliography .....................................................................................................115 Chapter 5 Computational tools for manufacturing ............................117 Learning curve computations .......................................................................117 The average cost model .............................................................................117 Computational example .......................................................................118 Computational example .......................................................................119 The unit cost model ...................................................................................120 Productivity calculations using learning curves ......................................121 The improvement ratio .............................................................................122 viii Contents Computational example ...........................................................................122 Solution .......................................................................................................122 Computation for improvement goal in unit time .................................123 Computation of machine output capacities ...........................................123 Machine utilization ratio: Determining how often a machine is idle ........................................................................................124 Calculation for number of machines needed to meet output .............124 Example..................................................................................................124 Solution ..................................................................................................124 Alternate forms for machine formula ....................................................124 Example..................................................................................................125 Calculating buffer production to allow for defects ..............................126 Example..................................................................................................126 Adjusting machine requirements to allow for rejects .........................126 Example..................................................................................................126 Solution ..................................................................................................127 Output computations for sequence of machines ..................................127 Example..................................................................................................127 Calculating forces on cutting tools .........................................................128 Calculating pressure .................................................................................129 Example..................................................................................................129 Finding required horsepower .................................................................129 Example..................................................................................................129 Machine accuracy ......................................................................................130 Example..................................................................................................130 Calculating the goal dimension ..............................................................130 Example..................................................................................................131 Drill thrust .................................................................................................131 Example..................................................................................................132 Drill torque .................................................................................................132 Example..................................................................................................132 Drill horsepower .......................................................................................132 Example..................................................................................................132 Calculating speed and rotation of machines ........................................132 Shaft speed .................................................................................................133 Example..................................................................................................133 Example..................................................................................................133 Example..................................................................................................133 Surface speed .............................................................................................134 Example..................................................................................................134 Tool feed per revolution ...........................................................................134 Example..................................................................................................134 Tool feed per minute .................................................................................135 Example..................................................................................................135 Contents ix Tool feed per tooth ....................................................................................135 Example..................................................................................................135 Computation to find the volume of material removed ........................135 Time rate for material removal in a rectangular cut ............................136 Example..................................................................................................136 Calculation of linear feed for rectangular material removal ..............136 Example..................................................................................................136 Takt time for production planning ..............................................................137 Production crew work-rate analysis ............................................................138 Production Work Rate Example ..............................................................139 Case of multiple resources working together ............................................139 Computational examples .........................................................................140 Calculation of personnel requirements ......................................................142 Calculation of machine requirements .........................................................142 References .......................................................................................................143 Chapter 6 Introduction to project management ..................................145 Introduction ....................................................................................................145 What is a project? ...........................................................................................146 Project stakeholders .......................................................................................146 General overview of project management .................................................147 History of project management ...................................................................148 Motivation for undertaking IT projects ......................................................150 Examples of IT projects .................................................................................150 Advantages of using formal project management ....................................151 The triple constraint ......................................................................................151 Project management framework ..................................................................152 Scope management ...................................................................................152 Time management .....................................................................................153 Cost management ......................................................................................153 Quality management ................................................................................153 Human resources management ..............................................................153 Communications management ...............................................................154 Risk management ......................................................................................154 Procurement management .......................................................................154 Improvements in project’s success...............................................................154 Project management knowledge areas .......................................................154 Project management tools and techniques.................................................155 Gantt charts and WBS ...................................................................................155 Network diagrams .........................................................................................156 An EPM tool ....................................................................................................157 Relationship of project management to other disciplines ........................157 The business analyst .................................................................................158 The software designer ..............................................................................158
The list of books you might like
