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Joseph Bickson CEO/Chairman Industrial Engineering, Senior [email protected] eLearning Pack ID: IE673-Spring-2014-10-03 This is MY work nobody helped or advised About Bickson Technology Bickson Technology is maintenance firm whose plan is to use various modern technology in other maintain pipes and valves in the gas and oil field. We work with a multiple companies in the related field to improve our services. We are located in Newark, New Jersey. Our business is focus on environmental disaster prevention, safety, and efficient use of resources. Our business goal is to completely dominate the gas and oil maintenance industries. We provide services for major oil and Gas Companies around the world and also the small oil offshore oil rig. Our system provides great quality of maintenance at a competitive cost. We are working with brand name suppliers and reputable consulting firms in the business. That way we can assure quality services to our clients. We want to make sure that our equipment is reliable and performs to specifications. Since our work is done in harsh environment we also want our equipment to be durable and serviceable since we are in the maintenance business. We want our services to spell quality and safety because our clients depend on those attributes. Our processes are innovative, attractive, and exiting. Since we are dealing with various governments control agencies our processes and services do conform to their standard. Our edge lies in the fact that we offer a more reliable preventive maintenance technology. We also automate some of our processes and to futuristic way of maintain their assets with trained professionals and the use of ubiquitous unmanned air and ground vehicle. Bickson technology focuses on sustainable green practices. It is part of our core philosophy that we preach to our employees and practice on a daily. The company short term and long term is based on a sustainable green model that allows us to have no significant footprint on the environment. Our equipment uses biodegradable fluids to maintain them. The hydraulics in our robotics system is made of bio-friendly components. It is important that Bickson Technology does a good job maintaining the pipes since of good percentage of those pipelines and valves is under water; to be more precise in the ocean. It is priority of for us as a company to not pollute the ocean. We cannot harm our eco system under any circumstances because there is lot at stakes. Please do take a look at the following links that will remind our clients and also reminds ourselves that must be accountable for the betterment of the environment. Here is a video of a pink black fish https://www.youtube.com/watch?v=qzuuPZ4hYt0., the Palau’s manta ray https://www.youtube.com/watch?v=sqmAbeUYoTI , the blue corner sharks https://www.youtube.com/watch?v=Z4n4ogdpqiM , the this majestic place https://www.youtube.com/watch?v=f9BDj7BK6qk, the corals https://www.youtube.com/watch?v=LequyTSSxVM, an amazing octopus https://www.youtube.com/watch?v=H1Pdaf9cys8 . Our clients transport very harmful chemicals in those pipelines. It is our job at Bickson Technologies to maintain those pipelines; unlike any other company the quality of work that we provide affect directly our environments. The pipelines and valve system that we maintain are located in remote location. We cannot afford the luxury of reacting to human errors and mishaps. It is imperative that we think of every scenario that can occurs and prevent them from coming reality. That philosophy combines with preventative maintenance services, and maritime and areal drone technology. We also advise our client on designing pipes and pipes components that can withstand the wave and current dynamics, along with other nefarious geo-hazards that can be disaster to the environment. Bickson Technologies intend to maintain the international standard organization (ISO) standard principle. We want to address all of the eight principles in order to satisfy our TQM philosophy. Our Dimensions of Quality
ISO TQM standard principle 1 Our services are focus on the needs and specifications of our customers. We design and improve our servicing packages with their constant feedback. We worked with and for our customers. We are part of their long and short term plan. ISO TQM standard principle 2 As a company, our philosophy is to stress from the highest to the lowest level employees of the company. Everybody in our company must believe in our product and our philosophy of sustainable green services and products. The company maintains a transparent method of management that is opened to be challenged by anyone. The company also has an open to all access when it comes to information about any project projects. Communication is constant and ubiquitous in all levels of our company. ISO TQM standard principle 3 We encourage our employees creative and innovative. Their daily input is crucial to our growth. We share our stock with our employees giving the feeling of equal ownership. We want to them to be willing to work with a high level of enthusiasm. Every Friday, there is a company meeting where the employees give their feedback and propose future plans or raise complaints that can be addressed. ISO TQM standard principle 4 Our company promotes lean services. We want our employee to make the most out the resources that they have. We want them to keep analyzing the processes as team and come up with various ways of making better plans to improve and control those processes. Later, the whole company gets to vote on what is best and implements those plans. This process is done on a monthly basis ISO TQM standard principle 5 The management team monthly task is not only to identify but evaluate to evaluate interrelated processes that necessary for our company to be lean. That’s the reason even though we do not manufacture the pipes ourselves our input on the type of pipes our customers use is significant. We are not going to maintain pipes that can pass our stress analysis. ISO TQM standard principle 6 It is important for Bickson Technologies to keep on improving on our processes. The eco-system depends on it. We are transporting hazardous materials across land and oceans. We cannot afford to be complacent any point of time. We have to better each and every. We have to keep our employees motivated. We set new goals every day. We make it a company priority to achieve them ISO TQM standard principle 7 Bickson Technologies relies on accurate information system and information delivery system in order to perform better than our competitors. Our data is collected by the best in the business. We consult with the top data analyst in the country and cross reference with the result of our own data analyst in order to make create an atmosphere of debate and also to make sure that our data is reliable. Our data is readily accessible to our employees. We establish a network of data sharing with our partners. This is how we make the best decision for our primarily for our customers and eventually our company. ISO TQM standard principle 8 One of company core values is to build a strong and mutually beneficial relationship not only with our customers but also with our suppliers. We want to optimize the use of our resources. We want to keep cost as low as possible and increase our profit margin as big as big as possible. We have joint meeting between our engineering team and our suppliers on a monthly basis in order to improve constantly the quality the materials and the equipment that we use. Summary of Videos ChemEng-Proc-Siemens-Part1 This video shows a demo system for a chemical plant that using smart instrumentation and safety rated equipment. Safety rated means that the equipment system will work 99.99 percent of the time, which is perfect for shutting down a system in dangerous situation. The system relies on those input that is coming from smart instrumentation to shut down the plant in case in an unsafe condition. The idea is to protect people in dangerous processes. The instrument is also monitored all the time. They have transducers and on board computing capabilities that help the system to identify and react in dangerous situations. Some valves only shut under dangerous, partial shutdown test must be done to prove that those equipment works. Those valves can be controlled and tested remotely. The other reason a partial test is done is to show in can be close on demand make valve respond to command. The control cabinet that contains the program logic controller or plc has optical fibers not only to prevent low losses but also to prevent sparks that can occur in normal wires of an electrical system. Their system is completely sealed and can go in explosive area. The control panel is pressurized and sealed to prevent dust has to keep equipment clean to increase durability. Batch controls is done by integrated safety system using profibus instruments, they monitor the centrifugal pump cavitation and wear. The model is run inside the controller, object oriented system that can be program into these boxes. You can run dynamic simulation into the software. There is a library to build the objects. People can build graphical objects, color configuration; real world is mapped by the objects. Values can be control by seeing real trend analysis. There is an automated intervention if pressure is going up do a shutdown. Comments: The TQM lessons that can be draw from this video is safety. There are various systems that check constantly the process. Those systems are being monitored themselves. Those systems can be check and monitored remotely; that is another dimension of quality; the fact that the system is easy to maintain. Bickson Technologies can apply those remote checks and preventive maintenance technologies in order to assure safety. ElGalleon-AllanJohnNash This video is about an eco-friendly diving resort where they can also certified divers. The owner of the resort bought after there was a fire on the island, his friend Dave and he lost everything even their passport and money. They took ownership of shop in May of 1987 with the money that the owner had saved up in Hong Kong. That’s how Asia divers started. Later on they added another partner. All three of them own the company. They purchased ElGalleon resort later on. They practice an eco-friendly way of doing business. They equipped the place with solar water system. They do not use plastic cups in their restaurant in order keep an environmentally sound resort. Their intention is to blend in with the green surroundings. They present outside of the building with a native feel while accommodating the inside to the customers taste. The menu looks good and consistent. They maintain a proper kitchen system meaning that whatever they use can go in the ground safely. They have healthy dishes. The entertainment is native. The resort has its own dance team that performs in different costume with flares. They provide quality services with entertain to match for customers. They have a regimented system for divers. There is a procedure for every dive cl ass in order to keep things flowing. They want to keep the process simple. They have nitrox analyzer at every station to assist divers in order to maintain a safe environment. They have simple preparation steps. The resort is made of 30 dives site that extremely close to each other. The divers can cover a lot of range in short distance. The divers don’t to spend all day visiting all those dive sites. They give customers a manageable schedule; if you want miss a dive you can; you can go back to the resort and go on the following dive they try to accommodate the customers preference; they make it easy for customer. They have fantastic restaurant on the water front. The famous “the point bar” facilitates management to talk with guest in order to gather feedback. They try constantly to improve customers’ experience. It is a great place for photographer because of the scenery that is close to immaculate; Wi-Fi is included in the resort. Comments: The lesson that can be drawn from this beautiful resort is that the company has business model that is design to improve and sustain customer satisfaction. They are very conscious about the environment. The company maintains discipline in their training regiments. Bickson Technologies will have similar business model when it comes to improving and sustaining customer satisfaction. Flow Water Jet Cutting This video is about the ultra-abrasive water jet. It is highly effective system for cutting simultaneously multiple materials the system cuts materials without mechanical stress or heat effect. It cuts materials with great precision. It is versatile. The machine is affordable. The machine has multiple functions. It has as setting for pure cutting or none abrasive but it also has an abrasive setting. The pure water jet function is to cut soft materials. It can be used for different applications like cutting candy bars. One of the advantages of having the ultra-abrasive water jet is that the operator doesn’t need different tooling. It optimizes the use of time and resources because the operator won’t need to dispose of worn out bits. It is cost effective for trimming parts in motor industries, different program. The system is capable of three dimensional cutting. It provides flexibility for the operator. This high fast cutting system compare to other technology like laser or the milling machines or EDM the ultra-abrasive water jet is better, because the other system has materials requirements meaning that, the materials must have right thermal properties, the water jet uses erosion process the materials don’t similar requirements. Unlike the EDM system has critical conductive material requirements; the water jet does not. It has flexibility of movement. The supersonic erosion eliminates waste compare to others. Overall it is lean and flexible. Comments: The ultra-abrasive water jet is multifunctional tool. Its application for industrial use is virtually limitless. The product is durable. It performs to standards. It eliminates waste by not have the need to tools between tasks but it also reduces time for the overall cycle. Bickson Technologies Ford Synus concept car This video depicts an interview with exterior designer working for Ford Motors. Before they start to design, they begin with market research. They look at social economic trends in the urban areas. From those data they designed the concept car. They are targeting a specific group living an urban environment. The car has an aesthetically tough exterior and warm and inviting homely interior. The analysis chose to gather data from a cultural point of view. Their market research is driven by data, and from those data they can extract what they need to design the car. They primarily look what the people in their targeted market are doing. The spent time collecting attributes from those market research and turn into a design experience. There is lot of branding involved. They want to build more than a car they want to make it a story goes beyond styling and engineering. It is a story that is turning into a design. The concept car is becomes like a metaphor for the urban environment. They took inspiration from bank vault to design a key lock; drawing an emotional connection. They amplified details. They attached a feature that provides privacy and protect the window. They design the interior with modern apartment feeling. The skin tone fabric emphasizing space; nothing appears bulking. The concept car itself provides humor. They design the car with simple control while making features that allows running multiple types of gadgets for the end user. They were no waste in their design. Comments: The lesson that can be drawn from this video is customer focus design. The designer really did their homework about the type of customer they wanted to target. The product does create excitement. They tried hard to create an emotional connection with the end user. Their design is heavily data driven that’s is aspect that should incorporated in Bickson Technologies. I beam This video is about a product that is badly design because that the company wanted to reduce cost. It is probably manufactured oversea where there is little if any when it comes to manufacture the product. The “I beam” is the product. Its application is to attach two rollers that can roll back and forth. However; some of the rollers don’t roll it was bas design for. The roller does not perform. The end user would expect the roller to roll. That’s one of the few dimensions of quality this product is missing. There is a huge variation in design. It is poor quantity design. It is cheap design. They heat it to hard now the roller is stuck. The manual comes in a dirty bag. The manual itself is also dirty. That’s the second dimension of quality this product is missing. It does not look good to the eyes. The drawing is not big enough; and to make matters worse, there is no safety precaution on the manual. Since it is made in oversea, it is hard for a customer to provide feed in order to facilitate improvement. If the item is return then the customer will get a similar item to replace the old one. It is a low cost design made by accountants instead of engineers Comments: The lesson that can be drawn from watching this video is that lowering cost must be done by engineers instead of accountants. The quality of the product is very poor. The product does not perform to expectation. The manual is not very helpful. The presentation of the product is frankly appalling. Bickson Technologies can only learn from the errors that is committed by the manufacturer of the product. . Marc Bauman Marc Bauman director of sales and marketing for Sams tour. The owners believe in sustainable practice in restaurants, bars, retails and everything that they do. Since the business is located on a remote island they are challenges. It takes a lot of planning to keep their business working efficiently. They do not want to disturb too much the ecosystem. That is why they reusable lunch containers, water bottle instead of cups; solar power system; solar heated water. They are making equal commitment to customers and also the environment. Maintenance is a challenge because they cannot call on a technician or expert that be there promptly because of global position. Sustainable practices are even bigger challenges. However; Palauan government has passed tough laws to protect the environment compare to other islands in the region. Funding is not easy for an eco-tour company. The margin for the company is not great. They teach people about conservation and the local culture. They have solar light. The people in Palau are open to eco- friendly project and new tech but the funding makes it very difficult. Eco tourism fastest growing segment in travel, they teach and entertain. The instructors are well qualified. It is a constant classroom. The island is very diverse and the project is funded by different parties Eastern and Western entities; They try to meet the expectation of both Eastern and Western clients. Sams deals win the minority western. Sams tour choose to partner with vendors and suppliers that believe and sustainable and environmentally conscious project. MINI Quality This video shows a behind the scenes look at how the mini-cooper is design and also manufactured. They use a robotic probe to get measurement. Those measurements are transferred into a computer from those data; they can do all kind of quality analysis. The measurement by the probe taken must be absolutely accurate. The quality of the data is very significant. There is an operator who is working alongside the probe who is taking measurements. The environment that the operator is taking the measurement from is as quiet as possible in order to have best quality measurement that is possible. That way they can cross check those measurements and catch errors even before they occur. You can make all shapes from the same structure of the auto body. They provide a stable environment in which measurements can be taken. They can have a consistency in product. Not Green Generator Challenge This video is about a generator that is stored in the generator room. The generator is very loud. The generator is also very dirty. There is no ventilation system in the room. Generators produces a lot heat because energy losses. They let the door open which could be hazardous for children. The generator can subject of theft or people just tampering with it. The PVC pipes that shield the electrical wires are exposed meaning that they are not buried. Some of are suspended in way if somebody steps on them they are likely to break. It is not a safe way to design a wiring installation. There is wire outside of the main building that is also exposed. The product is not presentable. It does not look pleasing to the eye. There is wiring that causing concern. The generator is lacking dimensions of quality. The features are of the generator are not so great. When compare to the generators; there are quieter generators out there. Nobody wants to go to vacation and hears noises. The generator was put too close to the main buildings. The entire resort as product did conform to standards. There are also concerns for loose bricks and loose shingles on the roof. Comments: The lesson to be drawn from this video is the resort presents a quality product. Their building looks unsafe. The place does not look exciting. It is run down. The buildings do no look good. They are in bad shape they are electrical wires that are hanging outside the building. Bickson Technologies can only learn from those mistakes. Okuma Lean cells This video is about an aluminum wheel manufacturing cell for Okuma USA. They way that they produce aluminum wheel is form a long casting. The first step of step of the process is the turning operation where they turning the inboard and the outboard side of the wheel. The second part of the process is where they drill the hole for the lug nuts. The third step of the process is where putting the wheel into another turning machine where they turn the street side and the tire mounting area of the wheel. The fourth is where they put the final finish for the wheel. The process of making the wheel is done by using a conveyor and also robotic arm. The production time is 40 wheels per hour. The environment is clean and control. The process is done behind class which eliminates dust and other debris contaminating the process. They enclose where the robot is pivoting the wheel to avoid somebody from being while the robot is pivoting. The data is behind share among the machines. The operator does not have to keep updating the information among the machines. During the process there are several measuring cycle that is carried out by the machines in order to assure quality. The specs of each machine are written on the outside of the machines respectively. CNC machines are also used to assure absolute precision. Comments: Those wheels are made with extreme precision. The floor is clean and the environment is safe. The machines are sharing data without the need of a operator. Bickson Techonologies can use similar technology. We want our computers to communicate and share information. Smart Sensors This video is about National Instruments present their product at national manufacturing week. The product that they are presenting is plug and play transducer. Transducers are first step toward making smart sensors. Those are easy to use sensors that require little installation. Those smart transducers do not need processing or networking. The process is used to make better measurement or add value to the sensor. The connectivity of those sensors is very high. Those smart sensors can integrate quickly and also more they are more reliable. They can also work with analog system. Transducer Electronic Data Sheet or (TEDS) is an onboard memory that is embedded in the sensors that gathers information from the analog inputs. Those data are necessary for the sensors to make meaningful measurement. The location of those sensors can be found by programing them. They are made to be dynamic intelligent barcode also they are capable of networking. Those sensors are easily adaptable. They are easy to replace in the overall configuration of a system. TEDS systems can be adapted into the analog sensors, therefore making them smart sensors. That way those analog sensors or dumb sensors will not be thrown away. That would have a waste. Those analog sensors can now be recycled which is great for environment. Comments: The lesson can be draw the smart transducers is the fact that it can work with old system that would be otherwise obsolete. It displays a good process approach meaning accountability and responsibility. It display systematic approach because good results depends on the instruments. Bickson Technologies can use that tool to measure temperature in pipes and pressure in our valves. RFID This video is about a demo of an RFID system. There are no batteries in the system. The system is powered by the RFID field. The RFID system behaves like a radio sending signal and information to the user. The RFID has different type of memories. Those memories are non-volatile. Those tags can be used for production control and also quality control and traceability. Those tags come in different size and shape. Some tags looks piece of paper that sticks to the side of bottle or some looks a thumb drive. It all depends on the application. There is an RFID reader has an antenna that is attached to a controller. The whole system is simple and modular. There different type of antenna depends on the application. They are all interchangeable with the system. The readers are automatic. Once they are given a task by the operator they are pretty much autonomous. The readers and antennas can be operated in low power. They are only turned whenever the operator is looking for an object. The system is not wasteful when it comes to the use of resources. The biggest advantage of the RFID system the operator does need to physically see the tag for the reader to read it unlike other system like the barcode. The RFID can provide a complete documentation of an industrial process. It provides quality control, traceability, and data mining capabilities. The system can be easily programmed. It is also relatively cheap. It also provides a good return on investment. They are robust and reliable. Comments: That product spells total quality control. It displays a good process approach meaning it can reduce cost and effectively controlled the use of resources. It establishes accountability and responsibility. Bickson Technologies can use that tool and implement that in the equipment that we use. This way can track our heavy or small equipment that is used around the world. Sekisui This video is shows a demo of Sekisui different type of glass. One glass is normal laminated glass box which is good for safety there is also another laminated glass box that noise and heat reduction capability. This particular glass has multiple layers that are made of acoustic materials and also heat insulating materials which is perfect for a vehicle or building. In summer time, buildings and cars don’t have to spend lot money of energy in order to cool down because that special glass can trap heat. It is great for a building especially if the building is located in an urban environment. The glass has noise reduction capabilities; it will allow the workers to operate quietly therefore making them more productive or create a productive environment. In the video, the curator shows the difference in sound reduction between the two glasses. He also shows difference in heat reduction between the two windows as well. There is another demo about special brand of acrylic tape by also be Sekisui made for HVAC applications. Volatile organic compound are being minimized by using those tape; they don’t have to use harmful to attach the components in the HVAC unit. The auto industries want to eliminate those compounds. The adhesive has low amount of harmful agents. The tapes are also flame retardants. They do not release harmful components to the atmosphere. There is another demo about foams that be used for different applications like gasket or seals. Comments: The lesson that can be drawn from those products is that those products are customer focus. The glass will allow the end user to be productive and make the end used spend less on energy. The products are environmental conscious. That is the way that Bickson Technologies should be. Toyota-Honda Floor mat This video shows first floor mat in a Toyota Venza and then a floor mat of Honda Odyssey. Upon initial inspection of the Toyota Venza, it shows that the fabric of the mat is of poor quality because it started to shed. Even the mat does not restrict the range of motion of the pedals; however when it is lifted, it interferes with the brake pedal. It cannot be removed without hitting the brake pedal. The pedals will not stick to it though. However; there are spikes on the bottom of mat in order to keep it from moving back and forth. That is great feature because the mats with no spikes on the other sides tend to bunch up when the drivers feet is moving back and forth. However; the mat still can be bunch up. It can be a safety hazard. If the mat is bunch up against the brake pedal; it could have devastating result if someone is trying to brake so that they don’t hit a child that chasing a ball down the road. The second mat if from the Honda Odyssey. When it is lifted, it does touch the brake pedal. In addition to spikes on the other side; there is a metal pin that goes through a metal ring that is attached to the mat. The mat in the Hondo does restrict air vent on the floor. It does not bunch up like the mat in the Toyota. Comments: The fact of the matter is not continuous improvement was not made for this mat. It is obvious that the Honda design tried to implement some safety measure with spikes. However; it did not work. They did gather data from customer feedback. Honda did a lean and spacious design. It was thin and slick. References Ranky P.G. PhD, IE 673 Total Quality Management Spring 2014 eLearning Packet 2014-63-26 Ranky, P.G.: A Case-based Introduction to Total Quality Management and the International Quality Standards, |