The extensive global competition between companies and the development of new industrial technologies have greatly contributed to the current competitive conditions Like industrial companies, customers demand high quality products, low prices and better performance. This fierce competition has led to concerns about improved product design. This development is based on GQFD. Model of this developed Water pump is employed by CAD solid model (version 7). In order to achieve competition and high quality and high performance in the Iraqi market. GQFD demonstrates the balance between product development and environmental protection. Used a water pump for a home air cooler as a case study. Data is collected and distributed using personal interview methods and questionnaire forms to indicate customer requirements. The data is then analyzed using Pareto chart and AHP to prioritize customer needs. These priorities are then placed in house of quality and matrix of relationships between customer requirements and technical characteristics is established. The product has been developed from electrical to mechanical, in addition to using accumulated, stored and recycled materials; it also saves 20% of energy, thereby combining energy reduction with the use of damaged materials and their re-entry into work. As a result, the cost of pump manufacturing will decrease
Lean is a powerful process improvement strategy that is widely used to improve different processes. In this Paper, lean manufacturing as process improvement strategy is employed throughout relative tools and techniques as VSM, 5S, and standard work. These tools and techniques are employed to identify measure and evaluate processes. Job shop production of General Company for hydraulic industries, with focus on Damper and Tasks Factory (DTF) is tested as a case study for the two most customer demanded rear dampers of Samaned and Nissan. Data analysis shows different issues Work-In-Process (WIP) issues causing under/ over and production discrepancy. Improvements are introduced throughout WIP developments and 5S techniques. Results show that these developments may result in reduction of 65% WIP waiting time for Nissan and 58% of Samaned rear dampers. An increase in Overall Work Efficiency (OWE) could result in by 10% for Nissan, and 2% for Samaned dampers While 5S may result in improvements by 50% production processes and 43% assembly processes for Set in order , and by 33% in both production and assembly processes for standardize. Data where analyzed and further results are generated using software's are; Minitab Version 17, Quality Companion Version 3, and Edraw-Max Version 7.
ORE addresses various kinds of losses associated with manufacturing system which can be targeted for initiating improvements. Evaluating ORE will is helpful to the decision maker(s) for further analysis and continually improves the performance of the resources. Overall Resource Effectiveness (ORE) encompasses seven factors are; performance, quality rate, readiness, changeover efficiency, availability of material and availability of manpower. In this research Job shop production of General Company for hydraulic industries, with focus on Damper and Tasks Factory (DTF)is tested as a case study for two of the most customer demand rear dampers (Samaned and Nissan). Data are collected and analyzed for years 2016-2017 to evaluate of ORE values. Results show that process performance factor among other seven factors have the less value causing the highest loss in ORE decrease. Where the highest ORE value is (58.6%) for Nissan and (69.3) for Samaned rare production. Also, time loss due to set up time is detected where it ranges from 3% to about 13% per month for the above mentioned two tested dampers. Results are generated employing Minitab Version 17, Quality Companion Version 3 soft wares. It is recommended to introduce SMED (Single Minute Exchange of Dies) concept that could decrease losses in set up time .Also improvements in maintenance programs are vital, and above all improving process performance values is essential by employing lean manufacturing that result in fast outcomes ,and TQM process improvement strategy for long term outcomes these two process performance strategies may enhance ORE values therefore, decrease losses, and consequently increase quality and productivity.