Enhancing Productivity and Alleviating Fatigue in General Purpose Machining by SMART Approach

Abstract

In the realm of general lathe machining, the objective of improving output while decreasing worker fatigue is critical. An emphasis is placed on factors contributing to fatigue such as prolonged standing, repetitive motions particularly in the measuring concern, interruptions in operation, continuous targeted stress in linking of manufacturing-measurement and achievement of target dimensions, and lack of on-machine back guidance. This increases cycle time, raises rejection rates and impacts on product quality. The SMART with a simplified developed algorithm technique promotes fatigue relief and increased productivity by allowing for automated inline measuring of workpieces to get live status and offering continuous advice for process completion. It consists of an online communication display that allows the operator to refer to the live work dimensions. A sensor data of work piece dimensions is processed through communication system and displayed for operator perusal and action. The wholistic approach of the method reveals strengths such as, notable 26% improvement in manufacturing time, a substantial 75% reduction in defects per batch, 100% comprehensive guidance, 80% reduction in engagement per batch, 40% increased production, reduction in repetitive motions by 25%, 100% reduced rejection rates. Likewise so many factors resulting in a positive impact on operational productivity and output excellence. Keywords: Continual feedback system, inspection elimination, fatigue-free, quality improvement, cycle time, rejection rates