Department of Industrial Engineering

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Reduction of waiting time and down time by using SMED
(University of Management and Technology, 2014) Muhammad Omer Baing; Muhammad Talah Baig; Rana Mohsin Rashid
Nagina Group Pvt, ltd wanted to reduce their setup time and waiting time to increase their production and meet their customer's demand, in order to maintain their quality of fabric, they also want to reduce their down time during changing setup time in three sections warping, sizing, weaving. Nagina Group has different customers some in a country and other are from different countries. The average production is 1.5 lacs meter in a month. They face problem in waiting time, loading and unloading time in different section at the result the found low quality of their fabric. By using SMED technique we reduce their down time, waiting time in warping, loading and unloading time in sizing by brain storming, and down time in weaving section applying this method their down time is minimum. We use Mini tab for graphs.
Implementation of kanban in mitchells industry
(University of Management and Technology, 2014) Sabeeh ur Rahman; Hassan Tanveer; Talha Tahir
The aim of the project is to design and implement a system in which is foolproof and provide the smooth production as well as decrease costs and eliminating of bottlenecks and a functional prototype for visualizing and operating a multi-platform virtual "Kanban Taskboard”. Kanban (see References) is an agile methodology for visualizing, managing and optimizing the flow of production a given application and for distributing the associated work among the development team. Kanban methodology should be used by the team itself for the Kanban Taskboard development. The project should focus on interfaces and algorithms (not on technologies).
Improvement in yarn quality with the help of root cause analysis
(University of Management and Technology Lahore, 2014) Waseem Khalid; Syed M. Najam ul Hassan; M. Hussain Haider
Spinning is the process of changing of fiber into yarn. The spinning mills includes many processes like cotton mixing, carding, combing, drawing, winding. Winding is the final process in spinning mill where the yarn of small quantity is wound into a big package known as cones. The important aspect in all departments is to remove basic defects to improve yarn quality. In blow room there is improper mixing, in spindles there is speed variation issue, in moisture room there is insufficient supply, and in mixing there is no defined method. Root cause analysis is lean manufacturing tool by using this we remove all these errors. By doing this the proper mixing improves, moisture standard maintained and by proper opening yarn quality can be improved. The drawback of basic errors that we find can reduce the fiber length and it reduces the operating efficiency of the whole process. This leads to reduction in quality of yarn. The aim of the proposed work is to implement the root cause analysis and thus the quality of yarn improved.
To produce high mix products with same machine by eliminating non value added activitiers to reduce change over time by implementing SMED in knitting department of Interloop Faisalabad
(University of Management and Technology, 2014) Moazam Hassan; Hasnain Nisar; Faizan Saleem; Suhaib Ahmed Khawaja
Changeover time was the big issue for INTERLOOP'S knitting department and because of it they cannot achieve high mix products. We help to reduce changeover time by implementing “Single Minute Exchange of Dies”. They are using hit and trial method to change their setup to one product to other also they don't have any standardize method to change setups efficiently. So that's why their changeover time was very high and because of time constraint they also have troubles to achieve their daily knit socks requirement. When the time was to change the setup machine stops and downtime was very huge and that's why production stops and which effects their lead time directly. We gave them solution which is implementation of SMED in their Knitting department. When we start's working on SMED we analyze that the worker who involve in changeover did many extra activities and rework. The thing we do is to eliminate the maximum possible extra activities which are also known as Mudas.We standardize the whole changeover procedure gave responsibilities to those who involves directly and in directly in changeover. Due to these implementations we achieved our target which reducing changeover time and achieving high mix products.
Reduction in rejection rate of garment at master textile through implementation of six sigma
(University of Management and Technology, 2014) Umar Farooq; Adeel Ahmad; Saad Ahmed; Iqbal Nisar
Due to global competition it becomes impossible for an organization to earn profits without reducing the rejection rate of the manufactured products. Rejection rate of any product plays a very important role for customer satisfaction and financial conditions of any company. Rejection rate causes a direct effect on profit margin of a product and decreases the quality of a product. Therefore the companies are struggling to reduce their rejection rate during the process of manufacturing through different quality tools, checking and inspection during different operations and implementing changes and strict quality checks where more defects are produced. High rejection rate of garments due to different number of defects during sewing is the major problem faced by Master textile mills. This project is very important from industry point of view because high rejection rate is creating customer dissatisfaction and financial loss to organization. Reduction in rejection rate is the project in which it is successfully attempted to prompt-out root causes along with a number of factors by adopting Six Sigma methodology. It was decided to implement DMAIC methodology in sewing department where high rejection rate stitched garment was recorded. This research presents a comprehensive study which focuses on the implementation of Six Sigma. The main aim of this study is to introduce DMAIC process of Six Sigma. The problem was identified practically in garments manufacturing industry in research. It was then measured to identify the extent of the problem so that it can be eliminated or reduced. Potential causes of problem was identified in the analyze phase. Finally, a pilot production run was made in order to make sure that the improvements being made does actually work and in control phase the work being doni previous phases properly implemented and sustained for providing the desired results. The statistical work for the project was done using Microsoft Excel 2010 and Smart Draw .After that an optimum solution was suggested along with the areas of improvement which reduced rejection rate and provided a significant financial benefit.
HVAC system design of a commercial building
(University of Management and Technology, 2014) Mohsin Raza; Azeem Tariq; Aftab Ahmed
In any building environment play important role in its comfort level. Heat gain by different sources which increase its temperature and humidity level which may cause uncomfortable circumstances. To maintain comfort conditions heat gain must be removed.The main theme of this project is to design the HVAC cooling load calculation. The calculation of cooling and heating loads on a building or zone is the most important step in determining the design of HVAC system. The main theme of this project is to design the HVAC cooling load calculation The calculation of cooling and heating loads on a building or zone is the most important step in determining the design of HVAC system.
Reduction of waste by using value stream mapping in Maqsood Faisal paper and borad mill
(University of Management and Technology Lahore, 2014) Ramisha Fatima; Mubeen Arif; Hamza Tariq
Purpose of this report is to inform about the lean tool value steam mapping. It itself is not a strategy but imply different strategies in this tool for the improvement. It is used to differentiate non-value added activities from the value added activities. It creates an image about the material flow and information flow in products and services. Many other organizations are using this method because by using this method they come to know about their problems and improves the processes by several techniques. It includes information flow from top management to workers and from the suppliers to the customers. As lean has been developed it is being implied in different industries for the improvement of the material and service flow. In this report value stream mapping is implemented in a paper industry located near kasoor named as maqsoodfaisal paper and board mill. For this purpose firstly the six key performance factors are identified and their performance is identified and secondly differentprocess is carried out to for the improvement of these factors. These key factors are 1) efficiency 2) waiting time 3) lead time 4) work in process 5) defects 6) transportation. When these KPI's are identified the data regarding them is collected. The current state map is being drawn and non-value added activities are being identified and are eliminated for the purpose of improvement. Lean principles are applied, solutions are presented and future sate map is drawn which shows all the improvements made in the current state map. All the plans made are then implemented to achieve the future state map. Results are quantified and compared with the current state map. By the implementing of this technique the non value added activities are eliminated and effective use of the resources and removal of the wastes is done so that the value added activities are done effectively. This report also emphasizes the VSM's important role in the paper production.
School examination management system
(University of Management and Technology, 2014) Zahra Naz
We are moving very fast day by day towards the digital world. As we know the needs of human’s beings are increasing due to fast and new technologies have been introduced. Especially the different industries and offices need fast and better technology for their good performance. The electronic examination system method is of cheap cost as compare to paper work. Electronic and computerized system made great progress in different fields specially in industrial areas and offices, like apart of B.I.S.E Lahore management system, use internet to alter students about their exams updates, different schools and education institutions used new technological management system or any latest event. In fact there is no sphere of human Endeavour that has been not been affected by computer system revolution, Not only it is affordable for any kind of organization it is the fast way to convey their message to students. So B.I.S.E Lahore will use the advantage and manage their services of organizations. Our System software will basically sending information to one or many Group of students, sending different information about the exams, roll no. slips, date sheet, print gazette etc. Basically, a management system is the framework of processes and procedures use to ensure that an organization can fulfill all tasks required to achieve its objectives.
Tool enhancement by PVD coating drills it s effects and analysis
(University of Management and Technology Lahore, 2014) Adeel Abbas; Shahum bin Sarfraz
In this project we use drills, milling cutter and turning insert with PVD coating. We used coated and uncoated tools to see the difference among them. This will show us which tool life is better than the other. This will also show us which tool is more efficient and effective than the other. Like in drilling tool coated with (TiAlN) Titanium Aluminum nitride hast better efficiency than the others same like in milling TiAlN has better efficiency than the other coated and uncoated tools. But in turning insert coated with (TiN) Titanium nitride is better than the others because insert coated with TiAlN is hard and ductile it breaks but insert coated with TiN do not breaks. The purpose of doing this to find out which tool coating can be the better option for us to use.
School examination management system
(University of Management and Technology Lahore, 2014) Zahra Naz
A management system is the framework of processes and procedures used to ensure that an organization can fulfill all tasks required to achieve its objectives. So, school examination management system will required following tasks to be performed efficiently: • Keep record of all students of board classes o Name, father name o Subjects and group (Science, Arts) o Marks in previous board class if any • Submit admission form via web page • Admin can edit the student record if there’s any mistake i.e. in name, father name etc. • Search complete record of each students all exams taken • View results and print • Export results to certain file formats: o Excel o pdf o etc. • General stats about exams; for example: o No. of students appeared o Passing ration o Gender wise classification Introduction to the Document: We are moving very fast day by day towards the digital world. As we know the needs of human’s beings are increasing due to fast and new technologies have been introduced. Especially the different industries and offices need fast and better technology for their good performance. The electronic examination system method is of cheap cost as compare to paper work. Electronic and computerized system made great progress in different fields specially in industrial areas and offices, like apart of B.I.S.E Lahore management system, use internet to alter students about their exams updates, different schools and education institutions used new technological management system or any latest event. In fact there is no sphere of human Endeavour that has been not been affected by computer system revolution, Not only it is affordable for any kind of organization it is the fast way to convey their message to students. So B.I.S.E Lahore will use the advantage and manage their services of organizations. Our System software will basically sending information to one or many Group of students, sending different information about the exams, roll no. slips, date sheet, print gazette etc. Basically, a management system is the framework of processes and procedures use to ensure that an organization can fulfill all tasks required to achieve its objectives.
Efficiency improvement of combustion engine
(University of Management and Technology Lahore, 2014) Muhammad Ammar Hussain
The purpose of doing this project was to increase the efficiency of engines.Various experiments were done to find optimum amount of hydrogen gas.Different materials were used as electrodes to find out which material is more efficient,longer life and less harmful for the environment.While doing experiments different kinds of problems occured i.e burning of electrodes,burning of rubber,non-suitablity of materials and much more.
To reduce overall lead time of PC bottle production line by takt time & line balancing approach at SPEL Pvt. Ltd. To cope up with increasing demand & by using simulation modellize it with future prospect
(University of Management and Technology, 2014) Armaghan Rauf; Saad Ullah Sheikh, Muhammad
SPEL Pvt. Ltd wants to improve the layout design to reduce their lead time to maximize their production in order to fulfill their customer’s increasing demand. They want to reduce worker involvement to minimize the part rejection in the production line. They want to increase the efficiency of production line at optimum level. Customer demands for PC Bottle on average are 1500 units per day. Company pays the worker overtime to meet it daily demand target as their daily production on average is 1440 units with in shift hours. So they want to improve the efficiency of production line to meets it increasing demand targets. We did time study of all operations from the manufacturing of PC bottle to the dispatching daily order to customer & proposed a method due to which they can produce up to 1600 units daily. This can be achieved by improving current printing mechanism. We used takt time & line balancing techniques to improve productivity by reducing their lead time. At the end of the study we used simulation software Arena (Version: 14.50) to compute the efficiency of the proposed method for comparing results.
Implementation of work and method study in PEL industry
(University of Management and Technology, 2014) Saif Shafiq; Tayeeb Hassan
This World is now all about competition and with competition it becomes impossible for an organization to earn profits without increasing production rate, giving better quality and reducing the rejection rate of the manufactured products. All these things plays a very important role for customer satisfaction and financial conditions of any company. Company not doing these things is on low profits and it decreases the quality of a product Finally when all work is done a production run was made in order to make sure that the improvements being made does actually work or not and are they actually increase the production rate and providing the desired results. Due to lack of process performance in deep freezer assembly line we choose our project on work and method study. Firstly, we observe the layout of shop floor which is highly product type. We suggested them to combine different task in a station which were perform separately. In this we combine only those activities which are highly linked. In this way, process performance increased as cycle time of the process reduced. We suggested them to use automated U-type conveyor which reduce the labor and production time. We also suggested automated roller conveyor in pre heated chamber. In safety standard we suggested use of gloves, glasses, face mask, ear muffs and helmet.
Eliminating the unnecessary operation in the production line to change the die design of under shock cover of CD-70
(University of Management and Technology, 2014) Naseer Ahmed; Zia Ur Rehman
Deep drawing process is a sheet metal forming process where a punch is utilized to force a flat sheet metal (blank) to flow into the gap between the punch and die surfaces. As a result, the blank can be formed into the various shapes. A sheet metal may be drawn into simple cylindrical-, conic- and boxed-shaped part and also complicated parts which normally require redrawing processes using progressive dies. Deep drawing is a popular selection due to its rapid press cycle times. Its capability of producing complicated axisymmetric geometries and several non-axisymmetric geometries in few operations with low technical labors requirement is also an advantage in manufacturing applications. Examples of deep drawing applications include containers of all shapes, sinks, beverage cans, automotive body and structural parts and aircraft panels. The important variables which affect the formability and outcomes of deep drawing can be grouped into two categories: Material and friction factors; and tooling and equipment factors. Proper selection of these variables is crucial in deep drawing to maximize the formability of the sheet metal while reducing undesirable outcomes which includes earing and defects such as wrinkling.
Industrial optimization by using hydrogen gas and gasoline Oil as a fuel to produce electricity in soraj fertilizer
(UNIVERSITY OF MANAGEMENT AND TECHNOLOGY, 2014) Saleem, Zeeshan; Hussain, Yasir; Murtaza, Sohaib; Ashraf, Umair
Purpose of this report is to inform about the lean tool value steam mapping. It itself is not a strategy but imply different strategies in this tool for the improvement. It is used to differentiate non-value added activities from the value added activities. It creates an image about the material flow and information flow in products and services. Many other organizations are using this method because by using this method they come to know about their problems and improves the processes by several techniques. It includes information flow from top management to workers and from the suppliers to the customers. As lean has been developed it is being implied in different industries for the improvement of the material and service flow. In this report value stream mapping is implemented in an paper industry located near kasoor named as maqsood faisal paper and board mill. For this purpose firstly the six key performance factors are identified and their performance is identified and secondly different process are carried out to for the improvement of these factors. These key factors are 1) efficiency 2) waiting time 3) lead time 4) work in process 5) defects 6) transportation. When these KPI's are identified the data regarding them is collected. The current state map is being drawn and non-value added activities are being identified and are eliminated for the purpose of improvement. Lean principles are applied, solutions are presented and future sate map is drawn which shows all the improvements made in the current state map. All the plans made are then implemented to achieve the future state map. Results are quantified and compared with the current state map. By the implementing of this technique the non value added activities are eliminated and effective use of the resources and removal of the wastes is done so that the value added activities are done effectively. This report also emphasizes the VSM’s important role in the paper production. ACKNOWLEDGMENT First
Assembly line efficiency improvement using value stream mapping
(University of Management and Technology, 2014) Abbas Amin, Muhammad; Umair Bari, Muhammad
Our report wishes to present a strategy used to create an image about the informational and material flows of products and services. In this report, value stream mapping (VSM) is applied in textile unit i.e Stylers International (Pvt) Ltd. located in Lahore. This factory deals with Denim. Value stream mapping is applied by identifying Key Performance Indicators (KPI). Six KPIs are identified and then all work is carried out in identifying them and in second phase efforts are applied in improving these KPIs. KPIs identified are 1) Transportation 2) Lead Time 3) Waiting Time 4) Work in process 5) Defects 6) Efficiency. After identifying these KPIs, Value Stream Map of current scenario of factory is developed based on data collected regarding these KPIs. By drawing the value stream maps of Basic Jean assembly line non-value added (NVA) operations were determined and then they were eliminated in the improved case. Lean principles are applied in determining loop holes and solutions are presented. Proposed best solutions of all KPIs are reproduced according to the Lean approach. Results are quantified in comparison with current state data. After all KPIs are reproduced and reset then again Value Stream Map is drawn that map is termed as Proposed Future State Map. It is shown that efforts on effective use of resources with prevention of waste in their source increase value added (VA) operations and also efficiency. This study also emphasizes the VSM’s important role in the textile sectors’ assembly line.
Time study, bottleneck analysis and most analysis, improving production efficiency using time study
(University of Management and Technology Lahore, 2014) Muhammad Naeem Khan; Slaman Fazal; Shahroz Mushtaq
The purpose of this project is to create awareness about the value of time in industries. This project is implied on PEL (PakistanElektron Limited).The main aim of the company is to generate maximum out put in a least possible time .The main focus of our study is to define the standard time to do an operation. For this reason we conducted time study for every operation. After calculating the time we set the standard to produce maximum out put in a shift. The daily output of the company was around 800 units. There were some operations whom operating time was higher than other operation in the department which lead them to bottle neck .So to overcome this we analyzed the whole department and utilized the work force and enhanced the production of those operation by adding more work stations to keep them at level. There was also extra transportation of the worker so because of that it took more time to operate. So for that reason we change the lay out and eliminated extra motion of the worker and re calculated the standard time with respect to motion by using MOST (Maynard Operation Sequence Technique). From all these calculation we enhanced the production output around 2200 units. In the end we hope that this project will be helpful for the company.
TPM (total productive maintenance) OEE (overall equipment effectivenss) at Pak Eleckron Limited (PEL) Pvt Ltd
(University of Management and Technology, 2014) Atta ul Waheed; Shahzaib Saleem; Rabeet Sajid, Muhammad; Numan Saherazi
Pak Elektron Limited (PEL) is the national bearer of the Saigol Group. Items made by PEL have dependably been inseparably joined with the name " Pel'is quality and an abnormal state all through Pakistan. Since its beginning, the organization needs to know for the advancement and improvement of designing work in Pakistan -How. The organization has delivered several designers, gifted specialists and professionals through its apprenticeship and preparing projects. The organization comprises of two specialties units; Machines Division: This division of PEL comprises of machines fridges especially fabricating. Power Division: PEL Power Division is a leading supplier of electrical gear and WAPDA KESC. The organization produces transformers, vitality meters, switches, smaller stations.
Energy audit of master molty foam head office
(UNIVERSITY OF MANAGEMENT AND TECHNOLOGY, 2015) Umer Aftab; Omer Ashraf; Abubakar Saddique; Muhammad Mubashar
In this project we studied energy being utilized in Master Molty Foam Head Office (M.M.Alam Road Lahore). We studied every single device and appliance being used there. We also studied the frequencies of utilization of devices that consumes electricity and incur cost.
To reduce production lead time by eliminating non-value added activitiesusing work studyin nishat mills limited
(University of Management and Technology, 2015) Zain Abdul Hafeez; Talha Arshad; Hassan Butt; Jamal Nasir
This thesis contains process flow of product and the methods used in Nishat Mills Ltd. Nishat Mills Ltd is a leading textile company in these days and it is equipped with latest machinery, highly qualified management and skilled labor. The organization is making many products at same time, Dream is one of them. Dream is a costly and time taking product in sewing unit because it takes much labor and resources than other products. Major causes were identified by analyzing the complete process using method study.

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