This paper presents an example of how a differential pressure sensor can be used to improve grasping of in-mold-labelling (IML) robots. In order to minimize mold-open time on injection molding machines, shorter operation time is desirable. To achieve this goal, an analysis of grasping labels using the in-mold-labelling robots was done with different approaches to improving the grasping process by measuring pressure in the chambers of the cylinder which carries the tool for grasping labels. The approach that uses the differential pressure sensor has proved best.

Statistical process control is an excellent quality assurance tool to improve the quality of manufacture and ultimately scores on end-customer satisfaction. SPC uses process monitoring charts to record the key quality characteristics (KQCs) of the component in manufacture. This paper elaborates on one such KQC of the manufacturing of a connecting rod of an internal combustion engine. Here the journey to attain the process potential capability index (Cp) and the process performance capability index (Cpk) values greater than 1.33 is elaborated by identifying the root cause through quality control tools like the cause-and-effect diagram and examining each cause one after another. In this paper, the define-measure-analyze-improve-control (DMAIC) approach is employed. The definition phase starts with process mapping and identifying the KQC. The next phase is the measurement phase comprising the cause-and-effect diagram and data collection of KQC measurements. Then follows the analysis phase where the process potential and performance capability indices are calculated, followed by the analysis of variance (ANOVA) of the mean values. Finally, the process monitoring charts are used to control the process and prevent any deviations. By using this DMAIC approach, standard deviation is reduced from 0.48 to 0.048, the Cp values from 0.12 to 1.72, and the Cpk values from 0.12 to 1.37, respectively.

The define–measure–analyze–improve–control (DMAIC) approach is a five-strata approach, namely DMAIC. This approach is the scientific approach for reducing the deviations and improving the capability levels of the manufacturing processes. The present work elaborates on DMAIC approach applied in reducing the process variations of the stub-end-hole boring operation of the manufacture of crankshaft. This statistical process control study starts with selection of the critical-to-quality (CTQ) characteristic in the define stratum. The next stratum constitutes the collection of dimensional measurement data of the CTQ characteristic identified. This is followed by the analysis and improvement strata where the various quality control tools like Ishikawa diagram, physical mechanism analysis, failure modes effects analysis and analysis of variance are applied. Finally, the process monitoring charts are deployed at the workplace for regular monitoring and control of the concerned CTQ characteristic. By adopting DMAIC approach, standard deviation is reduced from 0.003 to 0.002. The process potential capability index (CP) values improved from 1.29 to 2.02 and the process performance capability index (CPK) values improved from 0.32 to 1.45, respectively.

A heat exchanger network (HEN) for the process of methanol synthesis has been studied by combination of pinch design method and the application of “Twisted Tube” heat exchanger units as a new technology. The HEN is reconstructed based on the full utilization of maximum allowable pressure drops for the process hot and cold streams. An algorithm is developed to generate design procedure for twisted tube application. The algorithm needs to extend and develop correlation among the pressure drops, heat transfer coefficients, and required surface area through a simple relationship for twisted tube exchangers. It is revealed that a great economic, energy savings and process improvement are realized by using pinch analysis and applying twisted tube units in comparison to existing plants. The paper reveals highly potential benefits of this technology in design and replacement of twisted tube heat exchangers with the conventional shell and tubes type. The HEN is reconstructed by adding 4 new twisted tube units with their detail design in methanol process as a case study. The results show that the application of twisted tube exchangers may achieve significant energy saving for the methanol process with a one year payback. Moreover, these units may result in a great reduction of carbon emission, operational problems such as heat exchanger fouling, and tube bundle vibration of heat exchangers.

This paper first enlists the generic problems ofalloy wheel machining and subsequently details on theprocess improvement of the identified critical-to-qualitymachining characteristic of A356 aluminum alloy wheelmachining process. The causal factors are traced using theIshikawa diagram and prioritization of corrective actions isdone through process failure modes and effects analysis. Process monitoring charts are employed for improving theprocess capability index of the process, at the industrialbenchmark of four sigma level, which is equal to the valueof 1. 33. The procedure adopted for improving the processcapability levels is the define-measure-analyze-improvecontrol(DMAIC) approach. By following the DMAICapproach, the Cp, Cpk and Cpm showed signs of improvementfrom an initial value of 0. 66,-0. 24 and 0. 27, to afinal value of 4. 19, 3. 24 and 1. 41, respectively.