Algorithm for Process Innovation by Increasing Ideality
Abstract
:1. Introduction
2. Methods
2.1. Ideality
2.2. Innovation by Increasing Ideality
- Problem;
- Purpose;
- Principle;
- Ideal state;
- Ideality questions;
- Inspiration in effects and trends;
- Contradiction;
- Other TRIZ tools;
- List of solutions;
- Final solution.
2.3. Development of the Algorithm for Process Innovation by Increasing Ideality
2.4. Case Study—Packing Process
- Gravitation conveyors transport parts to the packing station (in plastic boxes, which are returned by a secondary gravitation conveyor back);
- Parts are packed into the frames with soft and flexible membranes. Frames are then put into foldable boxes from wood or plastic (all frames and boxes have a universal dimension and are stored close to the packing station);
- Filled frames are put into the foldable box. The box is on the weighing machine during the filling;
- After the packing is complete, the weight of the package is read (because only universal parts are used, the known weight of used frames and the box can be easily calculated to find the net weight of the packed parts);
- Weight and other information are written in small form and put into the small pocket on the box (this step can be further automatized by a printer connected to the weighing machine);
- Gravitation conveyors transport the complete box to the preparation station for the final export;
- The box has holes so that wheels can be attached to the box. Several boxes can also be easily connected.
2.5. Case Study—Process of Heat Exchanger Units Assembly
- Parts are transported to the gravitation trays by the individual single worker units (D-shops);
- A worker takes parts and assembles them by following the assembly manual. During the testing, they use the time for other activities such as preparation or pre-assembly of the next part;
- In the second part of the workplace, the assembled unit is packed and transported via a gravitation conveyor to the place for finished parts;
- Regular transport takes finished parts and supplies workplaces with parts for assembly.
3. Results
3.1. Packing Process (Chandeliers)
3.2. Assembly Line (Heat Exchanger Units)
3.3. General Results
4. Discussion
5. Conclusions
Author Contributions
Funding
Institutional Review Board Statement
Informed Consent Statement
Conflicts of Interest
References
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Parameter | Original State | Improved State | |
---|---|---|---|
Length of parts’ throughput | (m) | 82.6 | 47.7 |
Sum of workers’ walking distance | (m) | 78.3 | 59.5 |
3I Step | Content |
---|---|
Problem/Process | Packing process of glass and metal parts |
Purpose | To pack parts into transport packaging. The package should protect parts during transportation to the final destination. |
Principle | Parts are put together with soft materials into boxes (paper, wooden), boxes are transported to the customer. |
Ideal state |
|
Ideality questions |
|
Trends and effects | Segmentation, Dynamization, Protect-solid; move-solid; |
Technical contradiction(s) | TC1: 39. Productivity should be improved, /36. Device complexity should not worsen. 12. Equipotentiality; 17. Another dimension; 28. Mechanics substitution; 24. Intermediary TC2: 27. Reliability/39. Productivity 1. Segmentation; 35. Parameter changes; 29. Pneumatic and hydraulics; 38. Strong oxidants TC3: 9. Speed/27. Reliability 11. Beforehand cushioning; 35. Parameter changes; 27. cheap and short-living objects; 28. Mechanics substitution |
Physical contradiction(s) | None |
Other tools | None |
List of ideas | Automation, aerogel, auxetics materials, bubbles, foam, origami, lamination, use of universal air-bags Equipotentiality, Another dimension, Mechanics substitution, Intermediary, Segmentation, Parameter changes, Pneumatic and hydraulics, Strong oxidants, Beforehand cushioning, Parameter changes, Cheap and short-living objects, Mechanics substitution |
Solution | Not satisfying |
Idea/Possible Solution | Resolved Problem/Improved Step |
---|---|
Use of light-sensitive areas on boxes | Printing by light |
Packing on weighing-machine | Weighing—during processing |
Weighing—machine in a transport unit | Weighing—during processing |
Electronic documentation | Elimination of printing of documentation; Elimination of putting documentation into the box |
Sticky materials | Gluing of boxes together/into the shape |
Magnets | Closing of boxes |
Gravitation and cylinders (conveyors) | Automatic folding (building) of boxes during the transport |
Gravitation | Putting parts into boxes |
Static electricity | Packing material around the parts |
Package out of packing material | Elimination of boxes |
Transport by gravitation conveyors | Optimization of material transport |
New material or structure (aerogel, auxetic material, bubbles, lamination, foam, origami, ⋯) | Innovation of packing material |
Transport in air-bags | Instead of boxes and packing material, use bags filled by air (repetitive use) |
Paper palettes | Stability during transportation of packages |
Membranes inside a firm frame | Instead of packing material. Use of membranes in frames (universal) |
Mushrooms as packing material | Ecology |
Addable wheels to the boxes | Easier transport |
“Paper wrap” | Paper instead of bubble foil |
Use of tools and materials needed for final assembly as packaging or packing materials. | Reduction of packing material |
Idea/Possible Solution | Resolved Problem/Improved Step |
---|---|
Re-design of parts to eliminate riveting | Parts are re-designed such that there is no need for riveting. Joints enable parts to be attached just by pushing them together. This leads to a reduction in the assembly time. There is a need to use DFA (Design for Assembly). |
Assembly at the place of the final installation | By simplifying assembly steps, part of assembly activities can be made at the place of the final installation. This leads to a reduction in process activities at the assembly line, a reduction in the transported volume, and fewer costs. There is a need to use DFA (Design for Assembly). |
Reorganization of the production—instead of one assembly line, several individual workplaces, i.e., D-Shops (one worker does all activities) | Whole process. This leads to an elimination of transport, an improvement in ergonomy, and better use of workers. |
Ergonomic improvement in workplaces | Small parts and tools are available in each D-Shop, reducing the time for preparation and assembly. |
Use of fixtures, jigs, and Poka-Yoke | Faster positioning of parts, easier manipulation, and a reduction in quality checks. |
During the testing, perform other activities (preparation, etc.) | Time reduction, elimination of waiting time. |
Computer assistance | Computer, sensors, and signals to assist with mistake-proof assembly. |
Parameter | Original State—Real Values | Original State—Equation Coefficients | Improved State—Real Values | Improved State—Equation Coefficients |
---|---|---|---|---|
POd | 1 | 1 | 1 | 1 |
POe | 0 | 0 | 0 | 0 |
T | 21 | 1 | 17.5 | 0.83 |
F | 85.5 | 1 | 73.36 | 0.86 |
P | 8 | 1 | 8 | 1 |
Eq | 21 | 1 | 21 | 1 |
E | 8.6 | 1 | 8.6 | 1 |
M | 299 | 1 | 299 | 1 |
W | 120 | 1 | 120 | 1 |
NOK | 0.04 | 1 | 0.04 | 0.96 |
Sp | 2.06 | 1 | 1.36 | 0.66 |
Se | 0.8 | 1 | 0.64 | 0.8 |
O | 0 | 0 | 0 | 0 |
Parameter | Original State—Real Values | Original Stat—Equation Coefficients | Improved State—Real Values | Improved State—Equation Coefficients |
---|---|---|---|---|
POd | 1 | 1 | 1 | 1 |
POe | 0 | 0 | 0 | 0 |
T | 17.5 | 1 | 8.5 | 0.49 |
F | 73.36 | 1 | 28.33 | 0.39 |
P | 8 | 1 | 8 | 1 |
Eq | 21 | 1 | 2 | 0.1 |
E | 8.6 | 1 | 6.2 | 0.72 |
M | 299 | 1 | 12 | 0.04 |
W | 120 | 1 | 0 | 0 |
NOK | 0.04 | 1 | 0.02 | 0.51 |
Sp | 1.36 | 1 | 0.06 | 0.04 |
Se | 0.64 | 1 | 0.16 | 0.25 |
O | 0 | 0 | 0 | 0 |
Process State | Process Ideality | Ideality Change | Ideality Change |
---|---|---|---|
(-) | (-) | (%) | |
Original (REF.) | 0.1 | - | - |
Improved (Lean) | 0.101 | 0.001 | 1 |
Improved (REF.) | 0.1 | - | - |
Innovated (AP3I) | 0.283 | 0.183 | 183 |
Process State | Average Production Time | VA Index | Number of Steps | Throughput Distance | Walking Distance |
---|---|---|---|---|---|
(min) | (-) | (-) | (m) | (m) | |
Original | 21.0 | 0.262 | 20 | 82.6 | 78.3 |
Improved (Lean) | 17.5 | 0.314 | 16 | 47.7 | 59.5 |
Innovated (AP3I) | 8.5 | 0.412 | 8 | 36.3 | 12.1 |
Process State | Process Ideality | Ideality Change | Ideality Change |
---|---|---|---|
(-) | (-) | (%) | |
Original (REF.) | 0.1 | - | - |
Improved (Lean) | 0.102 | 0.002 | 2 |
Improved (REF.) | 0.1 | - | - |
Innovated (AP3I) | 0.11 | 0.01 | 10 |
Process State | Average Production Time | VA Index | Number of Steps | Number of Parts | Walking Distance |
---|---|---|---|---|---|
(min) | (-) | (-) | (pcs./10 days) | (m) | |
Original | 40.24 | 0.418 | 40 | 237 | 8.6 |
Improved (Lean) | 37.89 | 0.444 | 40 | 331 | 8 |
Innovated (AP3I) | 28.10 | 0.556 | 32 | 401 | 2.9 |
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Sojka, V.; Lepsik, P. Algorithm for Process Innovation by Increasing Ideality. Processes 2022, 10, 1283. https://doi.org/10.3390/pr10071283
Sojka V, Lepsik P. Algorithm for Process Innovation by Increasing Ideality. Processes. 2022; 10(7):1283. https://doi.org/10.3390/pr10071283
Chicago/Turabian StyleSojka, Vladimir, and Petr Lepsik. 2022. "Algorithm for Process Innovation by Increasing Ideality" Processes 10, no. 7: 1283. https://doi.org/10.3390/pr10071283
APA StyleSojka, V., & Lepsik, P. (2022). Algorithm for Process Innovation by Increasing Ideality. Processes, 10(7), 1283. https://doi.org/10.3390/pr10071283