Indian Juggad Technology (FRUGAL ENGINEERING)

Achieving more with Fewer ResourcesS.J.A. Rizvi

Assistant ProfessorDepartment of Petroleum Studies

Aligarh Muslim University, Aligarhjavedrizvi1976@gmail.com

What is Frugal Engineering?

The term "Frugal engineering" introduced by Carlos , the joint chief of Renault and Nissan.

He said , "frugal engineering is achieving more with fewer resources."

Engineering

Frugal is an engineering philosophy

Stream Philosophy

Gandhian Engineering

Philosophies of Gandhian engineering;-Ahinsa-Swadeshi- Acting in a selfless, compassionate, but unconventional manner to create a better world for all, not just a few.

Judggad Engineering

“I would prize every invention of science made for the benefit of all.”—Mahatma Gandhi

Derived from Sanskrit word YUKTI JUGGAT JUGGAD

Juggad term is applied to a creative or innovative idea providing a quick, alternative way of solving or fixing a problem.

Juggad Engineering: In its crude form

Juggad Engineering: In its Refined form

Somaiya College students have designed a vehicle they claim can run 300 kmpl.

What is Essential for Frugal Engineering?

1. Common Sense2. Common Sense3. Common Sense

Thanks to Almighty

Unique to Humans

1.Humour2.Appreciation of beauty3.Awareness of death4.Understanding time5. Meaning of life6.Desire for worship7.Creativity

Use your brain

What % of brain do most of intelligent humans use?

Answer is 0.67 – 1.5%.Einstein was the only person who could use his 2.28% of brain.

 if we are able to use even 4% ;- Faster than supercomputers.-Can predict the future.-And now about our previous life which is stored in the subconscious part of our mind.

Source : http://wiki.answers.com

Practicing Frugal Engineering

The Philosophy

It Is Easier To Want What You Get, Than To Get What You want. 

1. Accept that you can be

creative

2. Question traditional

assumptions

3. Expand your problem-solving

styles

4. Employ creativity techniques

5. Practice thinking in new ways

6. Search for Alternate

Explore Your SurroundingScan Your Mind for any better Alternate use

Learn from a child

They are BIGGEST EXPLORER

The frugal way

Challenge the ObviousRe-examine the traditional approach

Helios was a prototype high-altitude, long-duration unmanned solar-powered aerial vehicle. In 2001, Helios reached an altitude of 96,863 feet, breaking an official world

record altitude for a non-rocket-powered aircraft. 

Believe in yourself,

Keep patience

Don't get emotionally

attached to your innovation,

One day you or somebody else will

change it.

Every act of creation is

first of all,

An act of destruction

Pablo Picasso

Analysis Paralysis

Action without Vision

Avoid

Theory vs. Practice  

In theory, there is no difference between theory

and practice. But in practice there is.

Perfection vs. Optimization  Tank Battle : World War-II

German TIGER tank vs Russian T-34  

Counts=5,000Counts=2,500

Germans Tanks were highly precise in hitting their targets .

But Production with very tight tolerance limit slow down the production of tank during II-WW

Russian T-34 were not that accurate . Close machining tolerances were maintained only where it was a must.

Therefore Russian were able to deploy the double strength of tanks.In the first day 60 Tiger and 328

Russian T-34 were lost. Tiger emerged as better tank BUT Germans lost the battle.

SET YOU FINAL GOAL ACCURATEL

Y

Obstacles to Workplace Creativity

1. Internal politics 2. Harsh criticism of new

ideas3. Destructive internal

competition4. Avoidance of risk and

overemphasis on the status quo.

5. Extreme Work timing 6. Unrealistic expectations7. Distractions

Frugal InnovationsSix Sigma Certified Dibbawalla of Mumbai

Collection Transportation Distribution

Coding Supply Chain

•Started in : 1880•Avg. Literacy : 8th std.•Total Employee: 5000•Coverage = 60 kms•Number of Tiffin’s : 2,00,000

•Error rate = 1 in 16 Millions•6 sigma performance: 99.99%•Cost of Service : Rs.300/ pm

•Recipient of : ISO 9001-2000•World record in Best Time Management.•Name in Guinness Book of World Record. •Stood high along with MNC’s like GE, Motorola etc.

Frugal InnovationsGoogle Incorporation: Income from

Advertisements

Larry Page and Sergey Brin

•Google began in January 1996, by Larry Page and Sergey Brin, PhD students at Stanford University.

•Google search engine was different from conventional search engines because it was based on relevance and importance of page to user rather than counting how many times the search terms appeared on the page.

•Because of this new search approach , “PageRank Algorithm”, results were much refined and related to user. Very soon Google was favourite search engine world wide.

•But still earning revenue was a million dollar question for Google Team.

• They decided to incorporate user related advertisement along with search results.

•Now Google is officially bigger than Microsoft Inc according to NASDAQ.

Some of my work

Tester for Electricians

Advantages;

1. Extremely simple2. Low cost3. Easy to carry 4. Reliable result Drawbacks;

1. Difficulty in continuity testing.

Alternate design

Additional

1. Two pin Plug (male/female assembly)

Parallel Testing

Continuity Testing

Servo motor Torque Estimation

Calculation Result = 18 N.m Servo motor Cost = 2.5 lakhs

Torque Estimation: The Frugal way

Calculation Result = 9.1 N.m

Servo motor Cost = 1.45 lakhs

It is working perfectly

Microcellular Compression Moulding Machine from Universal Testing Machine (UTM)

Results of Microcellular Compression Moulding Machine

SEM Micrographs

Conversion of Microcellular Injection Moulding Machine in a Capillary Remoter

Microcellular Injection Moulding Machine

Capillary Rheometer

Rheology of Polymer/ gas Solution

Development of Injection Molding Rheometer (IMR)

Basic Assumption

Equations

Calibration of Injection Molding Rheometer

Viscometric Plots for Polystyrene at 220°C.

y = 5E-10x3 - 4E-06x2 + 0.0104x + 3.078

R2 = 0.9988

0.002.004.006.008.00

10.0012.0014.0016.0018.0020.00

0.0 1000.0 2000.0 3000.0 4000.0 5000.0

Shear rate (per sec)

Vis

cosity r

atio

cos _ IMR

CR

Vis ity ratio

y = 5E-10x3 - 4E-06x2 + 0.0104x + 3.078

R2 = 0.9988

0.002.004.006.008.00

10.0012.0014.0016.0018.0020.00

0.0 1000.0 2000.0 3000.0 4000.0 5000.0

Shear rate (per sec)

Vis

cosity r

atio

Viscosity Model for polystyrene/ N2 Solution at 220°C

Truncated Power Law

Model

Bird-Carreau Model

n1

n2

Supercritical gas Injector

Complete Setup

Disadvantage of Sintered Metal Injector

N2 @ 200bar, RT

Plastic Melt at 50 bar, 250 °C

Metallic Barrel

Sintered Metal Restrictor (Mott Corp)

Pore size < 20 micron

Gas Injector

Melt Pressure

Gas Pressure

Sintered Metal SCF injector gets

Chocked with plastic melt .

It causes complete blockage of SCF delivery port.

The Frugal Engineering Approach

SCF Injector Assembly

• NASA command came out with extraordinary solution to construct a new CO2 absorber out of;

• Plastic Bag, a hose, cardboard and Tape etc.

320,000 kilometres (200,000 miles) from home ....... ...... and we need a CO2 absorber!

It Is Easier To Want What You Get, Than To Get What You want. 

Frugal Engineering in Space

About Author

• SJA Rizvi is assistant professor in the department of Petroleum Studies at AMU – Aligarh.

• He is Polymer Technologist/ Material Engineer by Profession. He has completed B.Tech. From HBTI Kanpur and M.Tech. , Ph.D. (ongoing) from IIT-Delhi.

• He is compiler of “A glimpse of Indian Jugaad Technology”. He is practicing Jugaad Technologist or Frugal Engineer.

• Many of his Jugaad innovations have surprised the world on the front of cost saving.

• He is an industrial consultant on Frugal Engineering.

• He has presented key note talk on Frugal Engineering in many reputed organizations such as Steel Authority of India Ltd. Rourkela Steel Plant, National Institute of Technology, RLK.

• Presently involved with many Jugaad innovation for common people.

Visit his Home Page

Visit his Laboratory Home Page

Jai Hind

Thank you Very Much

javedrizvi1976@gmail.com