G. Belingardi, P.M. Calderale, G. Cozzari and F. Zingariello
The automotive industry is very interested in sheet metal forming simulation using numerical techniques such as the finite element method. A cooperative research program between…
Abstract
The automotive industry is very interested in sheet metal forming simulation using numerical techniques such as the finite element method. A cooperative research program between the Stamping Division of FIAT Auto and the Mechanics Department of the Politecnico di Torino was established with the aim of exploring the present possibilities of these techniques. This paper deals with the simulation of the deep forming of an axisymmetrical component, the axisymmetry being characterized by a double curvature profile, and is considered to be the first feasibility study. A sheet was modelled by fournode axisymmetric elements; the punch, the die and the blankholder were modelled by gap elements. The metal sheet was free to move along the punch and the die edges, with a continuous variation of the boundary conditions. The highly non‐linear problem requires an adequate description through the carefully considered use of the appropriate options of the MARC package (release K2). Moreover, some subroutines were written ad hoc to complete the discretization. Results are presented as strain and stress histories during the stamping process and as total forming force exerted by the punch to deform the sheet. In addition the spring‐back phase was considered in order to calculate the back deformation and the residual stress. Lastly, a comparison of the behaviour obtained with two different kinds of steel are reported.
The purpose of this paper is to highlight the lessons learned from two kaizen events for productivity improvement in a printing company. The paper suggests how to organize lean…
Abstract
Purpose
The purpose of this paper is to highlight the lessons learned from two kaizen events for productivity improvement in a printing company. The paper suggests how to organize lean tools to improve productivity through the use of organized kaizen events in the printing industry to meet defined targets.
Design/methodology/approach
This paper is based on a field study involving participant observations. The relationships among the three specific tools, line balancing, standardized work and standardized layout that are used in a kaizen event of a printing factory, are examined.
Findings
Application of a mix of lean tools resulted in significant productivity improvements of 10-30 percent in the assembly area of the printing company. Based on the outcomes of the lean tools that are applied in various work areas, the best combinations of lean tools are identified and several key considerations are discussed.
Practical implications
This paper shows that a combined set of lean tools such as line balancing, standardized work and standardized layout can be applied to improve productivity in the printing operations, which is identifiable with a mix of processes that are both labor intensive and equipment flexible.
Originality/value
The paper fills the literature gap on the use of specific lean tools: line balancing, standardized work and standardized layout in the printing industry. The findings from this research can be applied to other assembly systems that are similar to the printing industry.