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Article
Publication date: 1 October 2018

Jagdeep Singh, Harwinder Singh and Inderdeep Singh

The purpose of this paper is to uncover the significance of SMED in manufacturing environments.

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Abstract

Purpose

The purpose of this paper is to uncover the significance of SMED in manufacturing environments.

Design/methodology/approach

The paper gives setup instructions and guidelines to prepare the standardized setup procedure without ignoring actual constraints in production environment. It uses a case study in a small-scale manufacturing unit of northern India to generate an integrated setup reduction approach, utilizing Single Minute Exchange of Die (SMED)-based industrial engineering tools to achieve faster setups. It describes the feasibility of quick changeovers in small enterprises based on an “SMED” approach. Finally, the paper carries out empirical analysis of the financial/non-financial benefits incurred from setup reductions.

Findings

Setup activities are a vital part of the production lead time of any product and so affect overall product cost. Industrial engineering techniques have been used to analyze the existing procedure of setups. A SMED approach can help eliminate unwanted activities, externalize the internal activities, if possible, and reduce them by simplification or standardization.

Originality/value

The paper demonstrates the practical application of SMED showing how it can bring real breakthroughs in reducing setup time in small-scale manufacturing.

Details

Benchmarking: An International Journal, vol. 25 no. 7
Type: Research Article
ISSN: 1463-5771

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Article
Publication date: 7 October 2014

Amrinder Pal Singh, Manu Sharma and Inderdeep Singh

Damage induced during drilling of polymer matrix composites depends upon torque during drilling. Modeling of torque with feed rate and its control becomes imminent for damage free…

167

Abstract

Purpose

Damage induced during drilling of polymer matrix composites depends upon torque during drilling. Modeling of torque with feed rate and its control becomes imminent for damage free drilling of composite laminates. Therefore, the purpose of this paper is to construct a transfer function between drilling torque and feed rate based upon experiments. Thereafter, the torque is controlled by using PID controller.

Design/methodology/approach

This paper presents step-by-step procedure to capture complex drilling dynamics of polymer matrix composites in a mathematical model. A glass fiber reinforced plastic (GFRP) composite laminate is drilled at constant feed rate during experimentation. The corresponding time response of torque is recorded. First order, second order and third order transfer functions between torque and feed rate are identified using system identification toolbox of Matlab®. These transfer functions are then converted into state-space models. Experimental verification is performed on GFRP composite laminate. PID controller is designed using Simulink® to track a given reference torque during drilling of polymer matrix composite. The controller is then validated using different reference torque trajectories.

Findings

Good match is observed between torque response from state-space models and experiments. Error analysis based on integral absolute error and integral squared error on experimental and simulated response show that third-order system represents the complex drilling dynamics in a better way than first and second-order systems. PID controller effectively tracks given reference trajectories.

Originality/value

Third-order model between torque and feed rate for drilling of composites not available in literature has been presented. PID controller has previously been applied successfully for drilling of conventional materials, this paper extends implementation of PID torque control for drilling of composites.

Details

Multidiscipline Modeling in Materials and Structures, vol. 10 no. 3
Type: Research Article
ISSN: 1573-6105

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Article
Publication date: 4 November 2014

Amrinder Pal Singh, Manu Sharma and Inderdeep Singh

Damage due to delamination is an important issue during drilling in polymer-matrix composites (PMCs). It depends on thrust force and torque which are functions of feed rate…

136

Abstract

Purpose

Damage due to delamination is an important issue during drilling in polymer-matrix composites (PMCs). It depends on thrust force and torque which are functions of feed rate. Transfer function of thrust force with feed rate and torque with feed rate is constructed through experiments. These transfer functions are then combined in state-space to formulate a sixth-order model. Then thrust force and torque are controlled by using optimal controller. The paper aims to discuss these issues.

Design/methodology/approach

A glass fiber reinforced plastic composite is drilled at constant feed rate during experimentation. The corresponding time response of thrust force and torque is recorded. Third-order transfer functions of thrust force with feed rate and torque with feed rate are identified using system identification toolbox of Matlab®. These transfer functions are then converted into sixth-order combined state-space model. Optimal controller is then designed to track given reference trajectories of thrust force/torque during drilling in composite laminate.

Findings

Optimal control is used to simultaneously control thrust force as well as torque during drilling. There is a critical thrust force during drilling below which no delamination occurs. Therefore, critical thrust force profile is used as reference for delamination free drilling. Present controller precisely tracks the critical thrust force profile. Using critical thrust force as reference, high-speed drilling can be done. The controller is capable of precisely tracking arbitrary thrust force and torque profile simultaneously. Findings suggest that the control mechanism is efficient and can be effective in minimizing drilling induced damage in composite laminates.

Originality/value

Simultaneous optimal control of thrust force and torque during drilling in composites is not available in literature. Feed rate corresponding to critical thrust force trajectory which can prevent delamination at fast speed also not available has been presented.

Details

Multidiscipline Modeling in Materials and Structures, vol. 10 no. 4
Type: Research Article
ISSN: 1573-6105

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