Costs cycle times

Investment Ceramic (solid or Any, including Intricate shapes and fine Cost, cycle time to build Intricate parts,... 

Sensitivity analyses are greatly facilitated by process simulation tools as well. The objective of such studies is to evaluate the impact of critical parameters on various key performance indicators (KPIs), such as production cost, cycle times, and plant throughput. If there is uncertainty for certain input parameters, sensitivity analysis can be supplemented with Monte Carlo simulation to quantify the impact of uncertainty. 

Shapes Quantity Tooling Costs Cycle Time Complexity Size Cost... 

Shapes Complexity Machine Cost Cycle Time mm/s in/s km/h miles/h Useful for... 

The batch cycle time has been reduced from 2.6 to 1.3 hours. This means that a greater number of batches can be processed, and hence, if there are two reactors each with the original capacity, the process capacity has increased. However, the increase in capacity has been achieved at the expense of increased capital cost for the second reactor. An economic assessment is required before we can judge whether the tradeoff is justified. 

Shorter cycle times produce smaller bed sizes. The minimum cycle time is usually dictated by the minimum regeneration time required to heat and cool the bed. Systems of greater than two beds provide some flexibiUty in regeneration time but add to investment costs. 

Both thermoplastics and thermosets can be formed by compression moulding (Fig. 24.5). The polymer, or mixture of resin and hardener, is heated and compressed between dies. The method is well suited to the forming of thermosets (casings for appliances, for instance) and of composites with a thermosetting matrix (car bumpers, for example). Since a thermoset can be removed while it is still hot, the cycle time is as short as 10 seconds for small components, 10 minutes for large tliick-walled mouldings. Pressures are lower than for injection mouldings, so the capital cost of the equipment is much less. 

Improperly set tolerances and uncontrolled variation are one of the greatest causes of defects, scrap, rework, warranty returns, increased product development cycle time, work flow disruption and the need for inspection (Gerth and Hancock, 1995). If manufacturing processes did not exhibit variation, quality problems would not arise, therefore reducing the effects of variability at the design stage, in a cost-effective way, improves product quality (Bergman, 1992 Kehoe, 1996). 

Wall sections in foam moulding are thicker than in solid material. Longer cycle times can therefore be expected due to both the wall thickness and the low thermal conductivity of the cellular material. In contrast, however, the injection pressures in foam moulding are low when compared with conventional injection moulding. This means that less clamping force is needed per unit area of moulding and mould costs are less because lower strength mould materials may be used. 

Most adsorbers operate on a fixed drying cycle time and, frequently, the cycle lime is set for the worst conditions. However, the adsorbent capacity is not a fixed value it declines with usage. For the first few months of operation, a new desiccant has a very high capacity for water removal. If a moisture analyzer is used on the effluent gas, a much longer initial drying cycle can be achieved. As the desiccant ages, the cycle time will be automatically shortened. This will save regeneration fuel costs and improve the desiccant life. 

For instance, in 1996, 3M company announced a breakthrough in the process for making medical adhesive tapes, a process that reduces energy consumption by 77 percent. The new process also cuts solvent use by 2.4 million pounds, lowers manufacturing costs, and cuts mannfacturing cycle time by 25 percent. The proprietary process took researchers nine years from conception through final implementation. 

To date, with the exception of vehicle tires, TPEs have been replacing TS rubbers in virtually all applications. Unlike natural TS rubbers, most TPEs can be reground and reused, thereby reducing overall cost. There are types where the need to vulcanize them is eliminated, reducing cycle times, and products can be molded to tighter tolerances. Most TPEs can be colored, whereas natural rubber is available only in black. TPEs also weigh 10 to 40% less than natural rubber (166). 

Is a multiple-cavity tooling approach possible to reduce piece costs Yes Yes. Depends on size and configuration, although rapid cycle time may eliminate the need. Not necessarily. Secondary operations may be too costly and material flow too difficult... 

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