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Influence of Materials Properties on Process Planning Effectiveness

West Virginia University-Omar Al-Shebeeb, Bhaskaran Gopalakrishnan
Published 2017-03-28 by SAE International in United States
Process planning, whether generative or variant, can be used effectively as through the incorporation of computer aided tools that enhance the evaluator impact of the dialogue between the design and manufacturing functions. Expert systems and algorithms are inherently incorporated into the software tools used herein. This paper examines the materials related implications that influence design for manufacturing issues. Generative process planning software tools are utilized to analyze the sensitivity of the effectiveness of the process plans with respect to changing attributes of material properties. The shift that occurs with respect to cost and production rates of process plans with respect to variations in specific material properties are explored. The research will be analyzing the effect of changes in material properties with respect to the design of a specific product that is prismatic and is produced exclusively by machining processes. The three process plans that have been developed illustrate the importance of consideration of alternate work materials without impacting the product functionality, in attempts to decrease production cost, increase quality, and increase throughput. The results for…
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Using IAC Database for Longitudinal Study of Small to Medium Sized Automotive Industry Suppliers' Energy Intensity Changes

SAE International Journal of Materials and Manufacturing

S. Chaudhari
Southeast Missouri State Univ.-Deepak Gupta
  • Journal Article
  • 2013-01-0833
Published 2013-04-08 by SAE International in United States
Industries related to automotive manufacturing and its supply chain play a key role in leaving a carbon footprint during an automobile's life cycle. Per the report from Lawrence Berkeley National Laboratory (LBNL) in March, 2008 [1], “motor vehicle industry in the U.S. spends about $3.6 billion on energy annually.” The proposed research will focus on energy savings opportunities in automotive manufacturing and its supplier network. The US Department of Energy (DOE) funds 24 Industrial Assessment Centers (IAC) throughout the U.S. that conduct energy assessments at many of these facilities. The results of these assessments are summarized in a database maintained by Rutgers University which acts as the central management body for all the IACs. This research will present key concepts summarized from this database. These concepts include: (1)top 10 energy saving recommendations,(2)top 10 energy savings implemented measures,(3)comparison of energy efficiency investment in small-and mid-sized automotive industry supply chain in pre and post economic slump,(4)impact of major federal incentives on energy efficiency investments and its correlation with the implementation of recommended measures from database, and(5)energy savings…
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Analysis of Compressed Air and Process Heating Systems - A Case Study from Automotive Parts Manufacturer in Mexico

AAM-Afif Bitar
Southeast Missouri State Univ.-Deepak Gupta
Published 2012-04-16 by SAE International in United States
Automotive industries in the US and around the world have enormous impact on the economy of each country. Not just the major vehicle manufacturer, but all the other companies in the supply chain are equally important. This was evident with the earthquake and Tsunami that happened in March 2011. Because of the massive destruction at suppliers' facilities, the automakers in the US and other countries struggled to get the necessary parts and supplies. This created a ripple effect throughout the world and led to the closure of several automakers' facilities for a long time. Thus, the automotive supply chains are as important as the main automotive manufacturing facilities. Since these suppliers produce a lot of parts and supplies, the corresponding energy usage is also significant. The current research is focused on compressed air and process heating system analysis at one of the automotive parts manufacturer in Mexico. The Best Practices software tools (AIRMaster+ and PHAST) developed by the US Department of Energy (DOE) were used to create a baseline of the two systems and estimate…
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Investigation of Relationship between System Efficiency Curve & Measurement and Verification (M&V) of Energy Savings

SAE International Journal of Materials and Manufacturing

Southeast Missouri State University-Deepak Gupta
West Virginia Univ.-Subodh Chaudhari, Bhaskaran Gopalakrishnan
  • Journal Article
  • 2011-01-0324
Published 2011-04-12 by SAE International in United States
This research attempts to investigate the effect of change in system curve on the energy intensity method of measurement and verification of energy savings. With recent push from US government on energy efficiency through EPACT 2007 and upturn in performance contracted energy efficiency project implementations the effective and accurate evaluation of energy savings as compared to the baseline is of paramount importance. The authors have studied different methods of Measurement and Verification (M&V) of energy savings from literature to compare and contrast and clearly bring out merits and de-merits of each. Finally, the role of production level variable plays in establishing the baseline energy usage is discussed. Though modern models proposed in the literature of determining baseline energy usage consider production level, this variable is compounded from two variables viz., time of usage of a system and fraction of total capacity usage. This study aims to find if a model considering these variables yields significantly different baseline energy usage than the traditional model.
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Compressed Air Energy Saving Assessments (ESA) for the Automotive Supply Chain

Southeast Missouri State University-Deepak Gupta
West Virginia University-Bhaskaran Gopalakrishnan
Published 2009-04-20 by SAE International in United States
This research is based on the energy saving opportunities in compressed air systems in seven manufacturing facilities in the automotive supply chain, located in the United States. These plants received compressed air Energy Saving Assessments (ESA) from the US Department of Energy (US DOE)/Industrial Technologies Program (ITP) as a part of the Save Energy Now (SEN) initiative. Data logging equipment were used to monitor the compressed air system. US DOE ITP BestPractices software tools AIRMaster+ and LogTool [Web: Best Practices Software Tools] and other spreadsheet tools were used to develop energy efficiency measures. The most prominent energy efficiency measures were found with respect to installation of automatic sequencers, reducing compressed air leaks, improving end use efficiency, and reducing the compressed air system pressure. Few other interesting energy efficiency measures are also discussed. The paper describes the pre-assessment, assessment, and post assessment activities and the methods that were used to make the assessment effective and beneficial to the plant personnel. The paper discusses the recommended and implemented compressed air energy efficiency measures at the manufacturing facilities.…
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Energy Conservation through Productivity Enhancement in Manufacturing Facilities

SAE International Journal of Materials and Manufacturing

Hydro Aluminum-Hima Bindu Godavarthy
Southeast Missouri State University-Deepak Gupta
  • Journal Article
  • 2008-01-1164
Published 2008-04-14 by SAE International in United States
The goal of this research work is to explore the energy savings that may result from productivity improvement recommendations. The productivity improvement recommendations on setup time reduction and finished goods inventory reduction were taken from Industrial Assessment Center (IAC-WVU) and Industries of the Future (IOF-WVU) databases at West Virginia University (WVU) and analyzed to evaluate the corresponding energy savings. A simulation analysis was performed to compare the peak energy demands (kW) in the present and proposed scenarios for the setup time reduction recommendation. It was found that productivity improvement recommendations can result in significant energy savings (2% to 4%).
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