1Dr. A.S.M. Mukter-Uz-Zaman (Team Leader)1Prof. DR. IR. Wong Hin Yong2AIRUL AZHA ABD RAHMAN

1Faculty of Engineering , Multimedia University2IMEN,Universiti Kebangsaan Malaysia (UKM)

MyTRIZ Competition 2013

NoboGreen

Part 1

Email for corresponding: mukter@mmu.edu.myRegistration No: MTZ8251

Problem To Solve (As given)In a factory, there is a metal mesh conveyor belt which moves semi-processed material through a 5 meter long furnace. Although material is properly aligned at furnace input, material emerges at the output in a misaligned manner. Since it is difficult to see the inside of the furnace as it is totally encased and extremely hot, nobody knows what happened inside. Provide potential solutions which have no productivity impact.

Summarize Problem Statement:During moving semi-processed Materials misaligned in a conveyor belt inside an encased extremely hot furnace.

Whatever we can predict from the given problem

What Semi-processed materials misaligned When During moving through furnaceWhere On metal mesh conveyor inside furnaceWho Semi-processed materials Why Due to mechanical movement How Uneven surface cause uneven force

Analysis of the Problem

Benefit /Impact of solving the problem– Faster Materials will remain aligned for next process step – Cheaper By eliminating human involvement. – Safer Removing human intervention for alignment – Better reliability Uniform heat treatment on entire materials

Functionality Aligned Movement of the materials

Reason for the Changes: Furnace has extremely hot environment inside. It is encased hence not possible to manually monitoring inside.

Figure: Photograph of a hot furnace in working condition [1]

Note: 1. Used photograph is for illustration purpose only.

Define Solve

Perceived Problem

EvaluateIdeas

SolutionIdeas

Brainstorm

Resources

Investigate

Ideal Final Result IFR

Space Time Interface

FunctionAttribute Analysis

Su-Field Analysis

Trends of Evolution

Contra-dictions

Problem Statement

TRIZ Methodology used to Solve the Problem

Figure: Used TRIZ methodology to solve the given problem

Functional Attribute Analysis

1. Identifying components of the system

Key components of the system: Furnace, Conveyer belt, Metal mesh, Heat, Mechanical movement, Alignment, enclose, semi process materials.

FurnaceConveyer

Belt

Heat

Enclose

Metal Mesh

AlignmentMechanical Movement

Semi-process material

Functional Attribute Analysis

2. Identify and Characterize Function of the Components based on the given problem.

Operating Principle: Semi-process materials moves as the conveyer belt moves

Semi-process materials

Alignment

Chain

Mis- Alignment

Metal meshconveyer

EncloseMechanical Movement

EnvironmentDifferent Functions.

Uniform

Output

Input

Unknown

Rotation

Force

Power

Un-uniform

Vibration

move

• Missing functions

• Excessive functions

• Insufficient functions

• Harmful functions

• Useful functions

M• Main Useful function

M

Disappear• Missing

functions

• Excessive functions

• Insufficient functions

• Harmful functions

• Useful functions

M• Main Useful function

Different Functions.

Super system

System

Sub-System

Past Present Future

Hyper system

Industrial conveyer Belt

with metal mesh

Mechanical movement of the

conveyer belt

Commercially available Furnace

Enclose furnace chamber with

manual movement

Enclose furnace chamber with

automated movement

Transfer chamber with automated

movementpills/sensors.

Heat generate and aligner

Mechanical movement, with

heat

Automated movement

with infra red

Vacuum chamber with infra red heat

Space Time Interface: Misaligned materials

CurrentSituation i f

r

Ideality =Benefits

Costs + HarmIdeality =

Benefits

0 + 0

Misalign due to

movement

Reduction Of

Misalign Alignment Periodical

AlignmentNo

Misalign

The Ideal Final Result (IFR)

Identification and defined the problem.

Uncontrolled movement of the semi-processed Materials in conveyer belt caused misalignment while coming out from the furnace.

Technical Contradictions

Improving Parameter

DegradedParameters

Parameter Numbers

Principles used

Area of moving object

5 1,17,13,16

Automation 38 1,34, 12,3

Detecting 37 all

Manufacturing precision

29 35,10,25

Productivity 39 15,1,28

Recommendations

Principle Frequency

1 3

3 1

10 1

13, 15,16,17 1

25,28,34,35 1

All 1

Formulate problem in MATRIX Contradictions :Improve Gets worse or Stands in the way

33. Ease of operation, (Materials will come out in aligned way)

, Productivity (39)

Characteristic to improve: Easy of operationsCharacteristic becoming worseOr standing in the way: Productivity

Solution Ideas from Define stage:

From Function Attribute Analysis Conveyer belt can be sub-divide into few groups Intermediate alignment check and location correction

From 9-Windows Speed of the conveyer belt can be reduce Size of the system can be reduce

From IFR Segmentation of the system and implementation of

internal aligner Automotive process implementation for alignment

detection and thereby automated location correction

Solution Ideas from Solve stage:

From Problem DefinitionMechanism for alignment should be automated with the system

From ContradictionsSegmentationParameter can be changeInert AtmospherePeriodic actionIntermediate alignment

From TrendsHigh condensed electrolytes can be used since micro harvester.

Solution Evaluation Criteria:

Criteria Comparison with known Solution

1.The solution removes the primary tradeoffs and contradictions.

Yes since the material will be aligned on the conveyer belt inside the furnace at a periodic interval it will come out in an aligned fashion at the during the output time.

2. Do the harmful features disappear? Yes, periodic alignment

3. a) Are the useful features retained? b) Will new benefits appear?

No

4. Will new harmful features/ Contradictions appear?

No

5. Does the solution make system become Simpler? No Change? More complex?

No change.

6. Are idle, easily available, or underutilized resources used? Is the solution new?

Yes

7. Implementation: Easy, Moderate , Difficult(also: safety, security, compatibility, regulatory)

Easy.

Solution Evaluation

Solution to Pursue.

Solution 1: (Segmentation) Externally divide the conveyer belt into some segment and implement some sorts of alignment in each segment.

Solution 2: (Periodic action) Placement of external electro -magnetic structure outside the conveyer belt containing furnace so that it can convert to magnet by applying electric power on the external structure. By providing this electro-magnetic energy in a periodic manner in each segment of the system, the materials can be aligned periodically before they reach to the output end.

Conceptual structure of the system improved by Implementation of TRIZ for problem solving

Implementation of solution:

Electro-magnetic components as shown (by a) In the figure below will be attached in each segment of the external casing of the furnace.

This components will turn on periodically and it will allow to restrict the movement until they are aligned in a desire manner.

a

Figure: Photograph of a hot furnace with periodic electro-magnetic components

Conclusions• In this presentation TRIZ is used to solve the given problem that

arise during the movement of semi-processed materials through conveyer belt inside the furnace.

• It is found that TRIZ is the fastest way to come out with different innovative solution for a problem. And from the solutions best innovative idea is taken using brainstorming among the team members..

• On the solution a simple electro-magnetic structure is proposed to add periodically with the outer structure of the furnace to provide periodic alignment of the materials inside the segment in a periodic manner.

• TRIZ helps to think out of box and thereby provides unique solution that can make the system cheap in a faster way and can help to add new functionality.