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"PRODUCTION PROCESS"
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The Stochastic Nature of the Mining Production Process—Modeling of Processes in Deep Hard Coal Mines
The stochastic and undetermined nature of longwall coal mining results from the complex interaction between geological-mining and technical-organizational factors. This interaction causes variability in key parameters of the production process. This article presents three stochastic models developed on the basis of probability density functions, which describe selected process parameters. These mathematical functions serve as the foundation for effective stochastic models, enabling analysis of complex mining operations. The methodology employed in the study involves empirical data collection, statistical analysis, and stochastic simulation, carried out under both laboratory and field conditions. The results include empirical probability functions for output, delays, and crew-dependent productivity, offering insights into process variability and its impact on performance. Each method is characterized by its theoretical foundations, algorithmic structure, and application areas. The models have been validated through statistical tests and operational field data and can be applied as decision-support tools in both scientific research and industrial management. Given the extensive nature of the described methods, the article provides a comprehensive reference list for readers interested in further exploration and practical implementation in mining engineering.
Journal Article
Value-Stream Mapping as a Tool to Improve Production and Energy Consumption: A Case Study of a Manufacturer of Industrial Hand Tools
Manufacturing companies strive to minimize costs, maximize efficiency and improve production quality, which is crucial for market competitiveness. As companies grow and technologies evolve, increasingly complex challenges arise in effectively managing and improving production processes. One of the tools that helps companies improve their processes is value-stream mapping (VSM). The article focuses on the use of VSM in the production process of hand tools used in the construction industry. The paper presents selected aspects of the optimization of the production process using the mapping concept. The research identified and characterized the most important processes occurring in the production of hand tools used in construction. Then, basic data on the value stream was collected and the need for improvements and actions aimed at optimizing the value stream was indicated. Financial results, key performance indicators (KPIs), machine operation and reliability, energy consumption in the production process and overall equipment effectiveness (OEE) before and after improvements were calculated. The analysis carried out allowed for the optimization of the production process in terms of economy and energy consumption. As a result of the improvements, the productivity of injection-molding workers increased by 9.4% and the overall equipment efficiency by 18%. The machine availability rate increased from 70.3% to 85.2%. After implementing the improvements, the company is able to save approximately 295,488 kWh annually, i.e., approximately EUR 53,253, while 1 kWh currently costs producers in Poland EUR 0.18. The conclusions and results described in the paper constitute a solid basis for further development of an improvement project for the selected company.
Journal Article
How to succeed with continuous improvement : a primer for becoming the best in the world
\"The all-you-need-to-know primer on continuous improvement--offering best practices presented in a comprehensive, detailed case study illustrating what works and what doesn'tHow to Succeed with Continuous Improvement takes the reader through a real-life case study of one organization's journey towards a world-class continuous improvement process. It provides practical advice on methods, tools, and leadership to help operations professionals set up, execute, and continuously build upon their organization's improvement work.The book offers specific advice and practical application on how to get all employees to give maximum contributions by using their ideas to improve the organization. Each chapter details part of the transformation story and then reflects on and analyzes each concept of continuous improvement illustrated. Joakim Ahlstrom is Head of Consulting for C2, a firm that helps companies establish continuous improvements that provide measurable results. \"-- Provided by publisher.
Book
Design and Simulation of the Biodiesel Process Plant for Sustainable Fuel Production
The biodiesel production process is extensively studied in the literature, focusing on mechanisms, modeling, and economic aspects, yet plant design and fluid flow losses remain underexplored areas. The study addressed this gap by designing a biodiesel production plant, analyzing flow losses, and developing a pipe network and suitable pump models. In this study, an integration of biodiesel production plant design and simulation of continuous production of Calophyllum inophyllum biodiesel was investigated. Biodiesel production encompasses complex stages that involve systematic planning and system design. The goal of the plant design is to reduce the losses that occur during the conversion process, which can reduce the capital cost of the plant. A few assumptions were made when selecting biodiesel plant materials, such as pipes, pumps, fittings, and bends. These assumptions were based on considerations of the biodiesel fluid properties and pressure requirements. On the other hand, Aspen Plus was used to simulate the biodiesel production process. Calophyllum inophyllum was considered oil as the biodiesel feedstock and was inputted to the Aspen Plus as triglyceride composition. The simulation was carried out with rigorous kinetic reactions using the Non-Random Two-Liquid (NRTL) method to predict the liquid equilibrium in the reactor. Results revealed that the designed steel pipe meets safety requirements with a bursting pressure of 49.68MPa, capable of withstanding the maximum pressure of 4 bar and turbulent flow conditions. Additionally, the selected pump satisfies the required head and flow rate, ensuring efficient fluid movement. Moreover, simulation results closely matched experimental data, and 88% of biodiesel yield was recorded.
Journal Article
Computer simulations in planning production processes as a tool of decision making
Production planning in terms of defining the number of resources necessary to execute the production plan in a precisely defined time is a complex task. The complexity of the planning process results from the large number of variables affecting the production process. Planning the production process in such a way as to shorten its duration, reduce costs and at the same time ensure the appropriate quality of the product determines the competitiveness of a given company on the market, which is a key factor today. The aim of the article was to present the justification for using simulation software as a tool supporting decision-making in the field of selecting the appropriate number of production resources necessary to implement the assumed production plan. The subject of the research was the actual production process (case study). For the purposes of the research, a five-stage methodology was developed, the effect of which was to conduct a computer simulation of the production process. The obtained results allowed to indicate the best of the analyzed solutions, ensuring reduction, among others, of the duration of the production process and the costs generated by it. The analysis confirmed the justification for using computer simulation in planning production processes as a tool supporting decision-making.
Journal Article
Virtual Sensing of Key Variables in the Hydrogen Production Process: A Comparative Study of Data-Driven Models
Hydrogen is an ideal energy carrier manufactured mainly by the natural gas steam reforming hydrogen production process. The concentrations of CH4, CO, CO2, and H2 in this process are key variables related to product quality, which thus need to be controlled accurately in real-time. However, conventional measurement methods for these concentrations suffer from significant delays or huge acquisition and upkeep costs. Virtual sensors effectively compensate for these shortcomings. Unfortunately, previously developed virtual sensors have not fully considered the complex characteristics of the hydrogen production process. Therefore, a virtual sensor model, called “moving window-based dynamic variational Bayesian principal component analysis (MW-DVBPCA)” is developed for key gas concentration estimation. The MW-DVBPCA considers complicated characteristics of the hydrogen production process, involving dynamics, time variations, and transportation delays. Specifically, the dynamics are modeled by the finite impulse response paradigm, the transportation delays are automatically determined using the differential evolution algorithm, and the time variations are captured by the moving window method. Moreover, a comparative study of data-driven virtual sensors is carried out, which is sporadically discussed in the literature. Meanwhile, the performance of the developed MW-DVBPCA is verified by the real-life natural gas steam reforming hydrogen production process.
Journal Article
Perfect Copies
Analyzing the way that recent works of graphic narrative use the
comics form to engage with the \"problem\" of reproduction, Shiamin
Kwa's Perfect Copies reminds us that the mode of
production and the manner in which we perceive comics are often
quite similar to the stories they tell. Perfect Copies
considers the dual notions of reproduction, mechanical as well as
biological, and explores how comics are works of reproduction that
embed questions about the nature of reproduction itself. Through
close readings of the comics My Favorite Thing Is Monsters
by Emil Ferris, The Black Project by Gareth Brookes,
The Generous Bosom series by Conor Stechschulte,
Sabrina by Nick Drnaso, and Panther by Brecht
Evens, Perfect Copies shows how these comics makers push
the limits of different ideas of \"reproduction\" in strikingly
different ways. Kwa suggests that reading and thinking about books
like these, that push us to engage with these complicated
questions, teaches us how to become better readers.
eBook
The Evaluation and Improvement of the Production Processes of an Automotive Industry Company via Simulation and Optimization
Production delays are significant problems for the loss of goodwill of the customers and the loss of profits associated with them. The delays may accrue as a result of insufficient resource planning and poorly designed unsatisfactory procedures. In this study, a new mathematical model is proposed to optimize the production processes by minimizing production delays, and a simulation model is developed to test the alternative facility designs. The purpose is to increase customer satisfaction by ensuring that the products are delivered timely and preventing lost sales in an automotive company that manufactures garbage collectors by using real data. The mixed-integer programming problem related to the minimization of production delays is solved by the GAMS CPLEX 24.1.3 software. In this way, the total delay in the production area is minimized by the mathematical model to prevent labor and time loss. Accordingly, the alternative designs are investigated for the improvement of the production processes by using discrete system simulation. A system analysis is performed to determine the bottlenecks in the production processes by developing a simulation model via the ARENA simulation software. With the proposed facility layout alternatives, the delays are eliminated, the total production time is reduced, and an increase in production efficiency is observed.
Journal Article