Pratap Sriram Sundar

Lean manufacturing focuses on perfection, trying to eliminate all types of Muda (waste), Mura (inconsistency), Muri (overburden), defects, injuries, and accidents through a continuous improvement process. Assembly lines are the final stages of manufacturing before the product is delivered to customers. Kata methodology provides a practical approach to achieving perfection in assembly lines, but its effectiveness is often hindered by delays in data collection, analysis, and diagnostics. In this study, we address these challenges by leveraging industrial internet of things (IIoT) solutions in an industrial setting. The research question of this paper is as follows: “Why was the full potential of traditional Kata to achieve assembly line perfection not realized, and will IIoT-integrated Kata address the limitations of the traditional Kata?” We demonstrate the integration of IIoT and Kata methodology in a factory assembling automobile heating, ventilation, and air conditioning (HVAC) systems to enhance assembly line productivity. We observe that the integration of IIoT with Kata methodology not only addresses existing limitations but drives substantial gains in assembly line performance. We validate improvements in both productivity and efficiency through quantitative and qualitative outcomes. We underscore the pivotal role of real-time data for Kata’s effectiveness, discuss the process for digital transformation, and explain the need for data monetization. We recommend the development of an IIoT-savvy workforce, traceability of 4M (men, method, materials, and machine), and present the task scorecards and dashboards for real-time monitoring and decision-making. We highlight the positive impact of IIoT-enabled traceability on overall equipment effectiveness (OEE). The company reduced its workforce from 15 to 13 operators, increased OEE from 75% to 85%, and improved average throughput from 60 to 90 assemblies per hour. The time for traceability of 4M (men, machines, material, and method) was reduced from hours to minutes. The factory eliminated 350 paper documents to achieve a paperless shop floor. This real-world case study serves as a model for companies looking to transition from traditional continuous improvement processes to IIoT-supported lean manufacturing.

Pollination is a crucial ecological process with far-reaching impacts on natural and agricultural systems. Approximately 85% of flowering plants depend on animal pollinators for successful reproduction. Over 75% of global food crops rely on pollinators, making them indispensable for sustaining human populations. Wind, water, insects, birds, bats, mammals, amphibians, and mollusks accomplish the pollination process. The design features of flowers and pollinators in angiosperms make the pollination process functionally effective and efficient. In this paper, we analyze the design aspects of the honeybee-enabled flower pollination process using the axiomatic design methodology. We tabulate functional requirements (FRs) of flower and honeybee components and map them onto nature-chosen design parameters (DPs). We apply the “independence axiom” of the axiomatic design methodology to identify couplings and to evaluate if the features of a flower and a honeybee form a good design (i.e., uncoupled design) or an underperforming design (i.e., coupled design). We also apply the axiomatic design methodology’s “information axiom” to assess the pollination process’s robustness and reliability. Through this exploration, we observed that the pollination process is not only a good design but also a robust design. This approach to assessing whether nature’s processes are good or bad designs can be valuable for biomimicry studies. This approach can also inform design considerations for bio-inspired innovations such as microrobots.

Industrial revolutions have gone through four phases: steam, electricity, electronics, and Industry 4.0. Through all these four industrial revolutions, efficiency, productivity, quality, and automation have been greatly improved. However, the manufacturing processes created by humans have had disastrous consequences on the environment leading to a gigantic “climate change” problem. To mitigate climate change, engineers, and manufacturers all over the world have stepped up the research into cradle-to-cradle designs and sustainable manufacturing practices inspired by the designs and value cycles in nature. Bio-inspired designs have been gaining momentum to create products and manufacturing methods that are eco-friendly. All manufacturing (of a fruit, an organism such as a human baby) in nature happens in microfactories such as a womb, a leaf, a flower, or a chicken oviduct whose products are eggs. The product (egg) and the manufacturing process (chicken oviduct) are both green (eco-effective), lean (built with minimal resources), and smart (sensors and Internet of Things). Using a chicken as a model, this book chapter presents a set of metrics for green, lean, and smart attributes, which engineers can use to design products and microfactories.

The design of the human ear is one of nature’s engineering marvels. This paper examines the merit of ear design using axiomatic design principles. The ear is the organ of both hearing and balance. A sensitive ear can hear frequencies ranging from 20 Hz to 20,000 Hz. The vestibular apparatus of the inner ear is responsible for the static and dynamic equilibrium of the human body. The ear is divided into the outer ear, middle ear, and inner ear, which play their respective functional roles in transforming sound energy into nerve impulses interpreted in the brain. The human ear has many modules, such as the pinna, auditory canal, eardrum, ossicles, eustachian tube, cochlea, semicircular canals, cochlear nerve, and vestibular nerve. Each of these modules has several subparts. This paper tabulates and maps the functional requirements (FRs) of these modules onto design parameters (DPs) that nature has already chosen. The “independence axiom” of the axiomatic design methodology is applied to analyze couplings and to evaluate if human ear design is a good design (i.e., uncoupled design) or a bad design (i.e., coupled design). The analysis revealed that the human ear is a perfect design because it is an uncoupled structure. It is not only a perfect design but also a low-cost design. The materials that are used to build the ear atom-by-atom are chiefly carbon, hydrogen, oxygen, calcium, and nitrogen. The material cost is very negligible, which amounts to only a few of dollars. After a person has deceased, materials in the human system are upcycled by nature. We consider space requirements, materials cost, and upcyclability as “constraints” in the axiomatic design. In terms of performance, the human ear design is very impressive and serves as an inspiration for designing products in industrial environments.