Machining with milling is a common practice in manufacturing operations. Optimum surface finish i... more Machining with milling is a common practice in manufacturing operations. Optimum surface finish in the products has always been a requirement of the manufacturer and the user. This paper is focused on identifying the optimum values of input parameters to achieve better surface finish. A series of experiments have been performed using Aluminum Alloy 7075-T 7351, as this material is used in various applications. Central Composite Design (CCD) technique in the Design Expert has been applied to carry out the analysis of experimented results. At various values of input variables the response has been measured and then optimized. The results showed that at higher cutting speeds and low feed rates, lower values of surface roughness (Ra) has been achieved with additional depth of cut (DOC). By increasing the feed and cutting speeds, smaller Ra values has been achieved at lower values of depth_of_cut. Contour plots predict the cutting parameters for minimum value of Ra. The estimation error has been computed by comparing predicted and actual experimental values of surface roughness.
This study is about the suggestion of an alternate model of medium range/aggregate production pla... more This study is about the suggestion of an alternate model of medium range/aggregate production planning (APP) for the process industry. This research is conducted according to the forecasted demand of six months of a leading Cement Industry of Pakistan. A number of methods have developed by researchers to carry out the APP. But all those methods mainly focus on the discrete type of industrial processes. A very little literature addresses the aggregate production planning regarding the process industries. Therefore this study is specifically about the APP of process industry, a case of cement plant. The existing model of aggregate production planning of the selected cement plant is mainly focused on the continuous production and the excess product after meeting the demand is stored in the inventory. Cost analysis has been conducted for the existing model which revealed that nearly half of the total cost is consisted on the inventory holding cost. Different alternatives have been discussed and a proposed model has been developed and analyzed. The results of cost analysis showed that by following the proposed model the company could save approximately 60% of its total cost. Above all, a better preventive maintenance schedule could also be implemented, which might reduce the unplanned break downs and hence the overall efficiency of the plant could also be improved by implementing the proposed model.
This study is about the effectiveness of latest
technology flexible machines in apparel
manufac... more This study is about the effectiveness of latest
technology flexible machines in apparel
manufacturing. Techniques to justify the advanced
manufacturing systems, break-even and sensitivity
analysis have been developed to analyze the
significance between the conventional as well as the
latest flexible machines. Payback Period (PP) and
Return on Investment (ROI) are renowned methods to
validate the investments. These terms are calculated for
both conventional model machines and for latest
model. The comparison is made between them. The
production rate and annual profit of each model has
been calculated and compared. The break-even
analysis showed that the profit margin is increased by
using the latest flexible machines while producing the
same quantity as with the conventional machines. It is
analyzed that the break-even is achieved earlier by
using latest flexible machines as compared to the
conventional ones. The sensitivity analysis verified the
outcomes of break-even analysis. It has been learned
that the advanced manufacturing improves the
performance of the system and is justified in the
manufacturing environment.
Keywords-Advanced Manufacturing, Break-Even,
Payback Period, Return on Investment, Sensitivity
Analysis.
Machining with milling is a common practice in manufacturing operations. Optimum surface finish i... more Machining with milling is a common practice in manufacturing operations. Optimum surface finish in the products has always been a requirement of the manufacturer and the user. This paper is focused on identifying the optimum values of input parameters to achieve better surface finish. A series of experiments have been performed using Aluminum Alloy 7075-T 7351, as this material is used in various applications. Central Composite Design (CCD) technique in the Design Expert has been applied to carry out the analysis of experimented results. At various values of input variables the response has been measured and then optimized. The results showed that at higher cutting speeds and low feed rates, lower values of surface roughness (Ra) has been achieved with additional depth of cut (DOC). By increasing the feed and cutting speeds, smaller Ra values has been achieved at lower values of depth_of_cut. Contour plots predict the cutting parameters for minimum value of Ra. The estimation error has been computed by comparing predicted and actual experimental values of surface roughness.
This study is about the suggestion of an alternate model of medium range/aggregate production pla... more This study is about the suggestion of an alternate model of medium range/aggregate production planning (APP) for the process industry. This research is conducted according to the forecasted demand of six months of a leading Cement Industry of Pakistan. A number of methods have developed by researchers to carry out the APP. But all those methods mainly focus on the discrete type of industrial processes. A very little literature addresses the aggregate production planning regarding the process industries. Therefore this study is specifically about the APP of process industry, a case of cement plant. The existing model of aggregate production planning of the selected cement plant is mainly focused on the continuous production and the excess product after meeting the demand is stored in the inventory. Cost analysis has been conducted for the existing model which revealed that nearly half of the total cost is consisted on the inventory holding cost. Different alternatives have been discussed and a proposed model has been developed and analyzed. The results of cost analysis showed that by following the proposed model the company could save approximately 60% of its total cost. Above all, a better preventive maintenance schedule could also be implemented, which might reduce the unplanned break downs and hence the overall efficiency of the plant could also be improved by implementing the proposed model.
This study is about the effectiveness of latest
technology flexible machines in apparel
manufac... more This study is about the effectiveness of latest
technology flexible machines in apparel
manufacturing. Techniques to justify the advanced
manufacturing systems, break-even and sensitivity
analysis have been developed to analyze the
significance between the conventional as well as the
latest flexible machines. Payback Period (PP) and
Return on Investment (ROI) are renowned methods to
validate the investments. These terms are calculated for
both conventional model machines and for latest
model. The comparison is made between them. The
production rate and annual profit of each model has
been calculated and compared. The break-even
analysis showed that the profit margin is increased by
using the latest flexible machines while producing the
same quantity as with the conventional machines. It is
analyzed that the break-even is achieved earlier by
using latest flexible machines as compared to the
conventional ones. The sensitivity analysis verified the
outcomes of break-even analysis. It has been learned
that the advanced manufacturing improves the
performance of the system and is justified in the
manufacturing environment.
Keywords-Advanced Manufacturing, Break-Even,
Payback Period, Return on Investment, Sensitivity
Analysis.
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Papers by Ghulam Asghar
technology flexible machines in apparel
manufacturing. Techniques to justify the advanced
manufacturing systems, break-even and sensitivity
analysis have been developed to analyze the
significance between the conventional as well as the
latest flexible machines. Payback Period (PP) and
Return on Investment (ROI) are renowned methods to
validate the investments. These terms are calculated for
both conventional model machines and for latest
model. The comparison is made between them. The
production rate and annual profit of each model has
been calculated and compared. The break-even
analysis showed that the profit margin is increased by
using the latest flexible machines while producing the
same quantity as with the conventional machines. It is
analyzed that the break-even is achieved earlier by
using latest flexible machines as compared to the
conventional ones. The sensitivity analysis verified the
outcomes of break-even analysis. It has been learned
that the advanced manufacturing improves the
performance of the system and is justified in the
manufacturing environment.
Keywords-Advanced Manufacturing, Break-Even,
Payback Period, Return on Investment, Sensitivity
Analysis.
technology flexible machines in apparel
manufacturing. Techniques to justify the advanced
manufacturing systems, break-even and sensitivity
analysis have been developed to analyze the
significance between the conventional as well as the
latest flexible machines. Payback Period (PP) and
Return on Investment (ROI) are renowned methods to
validate the investments. These terms are calculated for
both conventional model machines and for latest
model. The comparison is made between them. The
production rate and annual profit of each model has
been calculated and compared. The break-even
analysis showed that the profit margin is increased by
using the latest flexible machines while producing the
same quantity as with the conventional machines. It is
analyzed that the break-even is achieved earlier by
using latest flexible machines as compared to the
conventional ones. The sensitivity analysis verified the
outcomes of break-even analysis. It has been learned
that the advanced manufacturing improves the
performance of the system and is justified in the
manufacturing environment.
Keywords-Advanced Manufacturing, Break-Even,
Payback Period, Return on Investment, Sensitivity
Analysis.